EP2004022B1 - A corner block for a mattress, and a mattress and method of manufacuture relating thereto - Google Patents
A corner block for a mattress, and a mattress and method of manufacuture relating thereto Download PDFInfo
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- EP2004022B1 EP2004022B1 EP07754191A EP07754191A EP2004022B1 EP 2004022 B1 EP2004022 B1 EP 2004022B1 EP 07754191 A EP07754191 A EP 07754191A EP 07754191 A EP07754191 A EP 07754191A EP 2004022 B1 EP2004022 B1 EP 2004022B1
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- European Patent Office
- Prior art keywords
- mattress
- corner
- corner block
- legs
- inches
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
- A47C27/066—Edge stiffeners
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
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- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Bedding Items (AREA)
- Details Of Garments (AREA)
- Buffer Packaging (AREA)
Abstract
Description
- The invention relates generally to mattresses. More particularly, in various embodiments, the invention relates to a corner block for providing a reinforced square corner on a mattress, mattresses made with such corner blocks, and methods of manufacturing mattresses employing such corner blocks.
- Conventionally, mattresses generally have unreinforced, rounded corners. When installed into a crib frame, conventional mattress corners make it possible for an infant to injure him/herself by lodging an extremity, such as an arm or leg, between the crib frame and the corner of the crib mattress,
- Various prior art approaches have been employed to reduce the likelihood of this occurring. In some instances, crib bumpers are employed. Typically, crib bumpers are affixed along the periphery of a crib mattress and extend upward and between the mattress and the crib sides. A disadvantage to bumpers is that they often pull away from the corners of the mattress and leave a gap between a mattress corner and a corner of the crib frame. Another prior art approach employs mattresses that extend upward along their periphery to provide an integrated bumper. However, such mattresses can be significantly more complicated to manufacture.
US 4,539,723 discloses a corner block comprising first and second legs, each having inner and outer terminal ends, the first leg extending from an inner end of the second leg at an angle to the second leg, both legs including inner and outer surfaces, the inner surfaces of the first and second legs intersecting at a transition section, and the outer surfaces of the first and second legs intersecting at a vertex of an angle. Accordingly, there is a need for an improved structure for a crib mattress, - The present invention provides a corner block according to the characterising portion of claim 1. The invention addresses the deficiencies in the prior art by, in various embodiments, providing a corner block for squaring a corner of a mattress. In other embodiments, the invention provides mattresses employing the corner block of the invention and methods of manufacturing such mattresses. In some embodiments, a mattress of the invention may be employed as a crib mattress. An advantage of such crib mattresses is that they better fit within the corners of a crib frame to inhibit an infant from lodging an extremity between a corner of the mattress and a corner of the crib frame.
- According to one embodiment, the invention provides a corner block formed from a shape resilient polymer material, such as, polyurethane foam, visco-elastic foam, latex, polyethylene foam, polystyrene, or from cardboard, wood, metal, wire, plastic molded part, polypropylene, and acrylonitrile butadiene styrene (ABS). In one implementation, the polymer material has a density of about 23 kilograms/meter3, In other implementations, the polymer material has a density of between about 18 kilograms/ meter3 and about 28 kilograms/meter3. In other implementations, the polymer material has a density of between about 20 kilograms/ meter3. and about 26 kilograms meter3. In other embodiments, the corner block of the invention may be formed from any suitable material depending on the desired application.
- The corner block includes first and second legs, which extend from a vertex at an angle to each other. Each leg includes an inner (e.g., frame contacting) surface and an outer surface. In one configuration, the outer surfaces of the first and second legs intersect at a substantially right angle. In one embodiment, each leg is about 4½ inches (11.4cm) long, as measured from the intersection of the outer surfaces of the first and second legs to terminal ends of each respective leg, According to a further embodiment, the first and second legs are about 4½ inches (11.4cm) high. According to an alternative embodiment, each leg is about 5 inches (12.7cm) high. In other configurations, the legs of the corner block are between about 4 inches (10.2cm) and about 10 inches (25.4cm) long and between about 4 inches (10.2cm) and about 10 inches (25.4cm) high, In alternate configurations, the legs of the corner block are between about 4 inches (10.2cm) and about 6 inches (15.2cm) long. In further configurations, the legs of the corner block are between about 4 inches (10.2cm) and about 6 inches (15.2cm) high.
- According to another feature, the legs are between about ¼ inch (0.6cm) and about 1½ inches (3.8cm) thick as measured from the inner surface to the outer surface. In some embodiments, the outer surfaces of the first and second legs each include first and second sections. The first section of each leg extends from the vertex at approximately a right angle to each other, and the second section of each leg extends from a terminal end of a respective first section of each leg along an axis angled inward relative to a respective axis of the respective first section.
- According to some configurations, the inner surfaces of the first and second legs intersect at a transition section. According to one feature, the transition section is sized and shaped to interfit around a corner of a coil spring mattress frame. According to another feature, the transition section may be curved to further facilitate such interfitting, In one embodiment, the distance between the vertex of the angle of intersection of the outer surfaces and the apex of the curve of the transition section is between about ¾ inch (1.9cm) and about 1½ inches (3.8cm).
- In some embodiments, a portion of the inner surfaces of the first and second legs may be carved out to receive a corner of a coil spring mattress frame. According to one feature of these embodiments, the carve out may be sized and shaped such that upper and lower parts of the legs may overlap upper and lower sides of a mattress frame, when interfitted onto a corner of the frame to facilitate attaching the corner block to the frame.
- According to another aspect, the invention is directed to a mattress employing a corner block of the invention. In one embodiment, the mattress includes a coil spring frame, in which the coil springs may or may not be pocketed. The corner blocks are attached to each corner of the frame, either prior or subsequent to attachment of polymer foam material to short ends of the frame. The mattress of the invention may then be further assembled by any suitable approach. According various constructions, the mattress may be of any size, including without limitation, single, double, full, queen, king, California king, or crib size.
- According to a further embodiment, subsequent to attachment of a fire retardant material, the mattress is placed in a compression bag, With the mattress so placed, the compression bag is evacuated to compress it, including compressing the coil springs of the mattress frame. With the mattress so compressed, it is inserted into a final mattress cover. The cover may then be closed by any suitable mechanism, Optionally, the compression bag may be removed prior to closing the mattress cover. In some instances, the compression bag may be made from a water resistant polymer and left on the mattress to shield inner portions of the mattress from inadvertent exposure to fluids during use.
- Other features and advantages of the invention are described below with regard to various illustrative embodiments.
- The invention may be better understood with reference to the appended illustrative drawings in which like reference designations refer to like parts, the various views may not be drawn to scale; and in which:
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Figure 1A is a top view of a corner block for providing a reinforced square corner on a mattress according to an illustrative embodiment of the invention; -
Figure 1B is an outside perspective view of the corner block ofFigure 1A ; -
Figure 1C is an inside perspective view of the corner block ofFigure 1A ; -
Figure 1D is an inside perspective view of the corner block ofFigure 1A including an optional cutout according to another illustrative embodiment of the invention; -
Figures 2A-2H depict an illustrative process for making a mattress that includes a corner block of the invention; -
Figure 3 depicts an alternative embodiment of the invention; and -
Figure 4 depicts a further alternative embodiment of the invention. - As described above in summary, the invention addresses the deficiencies in the prior art by providing, in various illustrative embodiments, devices, systems and methods relating to forming a substantially square corner on a mattress. According to various implementations, the invention provides a corner block for attaching to an otherwise curved/rounded corner of a mattress frame. One advantage of the corner blocks of the invention is that they may be applied to the corners of conventional mattress frames, without need of changing the process by which the mattress frames are made. Another advantage is that, with the exception of the outer mattress cover (which may need to be formed with square rather than rounded corners) the corner blocks of the invention can be attached to the corners of the mattress frame without need of modifying the other components that cover, surround or otherwise attach to the mattress frame. A further advantage is that the corner blocks of the invention may be attached to the mattress frame at the same time that end foam padding is attached to the short ends of the mattress frame. As mentioned above, another advantage of the invention is that it may be employed with a crib mattress to decrease the likelihood that an infant lodge an extremity between a corner of the mattress and a corner of a crib frame.
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FIGS. 1A-1D show various views ofcorner block 100 according to an illustrative embodiment of the invention, Referring to those Figures, theend block 100 includes first 102 and second 104 legs, Thefirst leg 102 has aninner end 106 and aterminal end 108. It also has aninner surface 110 and anouter surface 112. The outer surface has first 112a and second 112b sections. Similarly, thesecond leg 104 has aninner end 114 and a terminal end 116. It also has aninner surface 118 and anouter surface 120. The outer surface has first 120a and second 120b sections. - The
inner surfaces transition section 122. As depicted thetransition section 122 may be curved, but this need not be the case. As shown in further detail inFIGS. 2B and2C , thetransition section 122 is sized and shaped to interfit with and cover a rounded or otherwise non-square corner of a mattress frame. In this particular embodiment, the mattress frame is a crib mattress frame. However, suitably sized and shaped corner blocks according to the invention may also be applied to any size mattress frame, for example, including single, double, full, queen, king and California king size mattress frames. - The
outer surfaces vertex 124. According to the illustrative embodiment, theouter surfaces square corner 124. In the illustrative embodiment ofFIG. 1 , thedistance 125 between thevertex 124 and an apex 123 of thecurved transition section 122 is about 1 inch (2.5cm). However, thedistance 125 may have any suitable dimension depending on the size of the particular mattress frame corner with which it is to interfit. For example, in other illustrative embodiments, thedistance 125 ranges from about ½ inch (1.3cm) to about 2 inches (5.1cm). - As shown in
FIG. 1A , thefirst leg 102 of theillustrative corner block 100 has alength 126 of about 4 ½ inches (11.4cm), as measured along theouter surface 112 between thevertex 124 and theterminal end 108. However, in other illustrative embodiments, thelength 126 may be any suitable length for any particular mattress frame. In some illustrative embodiments, thelength 126 ranges from about 6 inches (15.2cm) to about 12 inches (30.5cm). In other illustrative embodiments, thelength 126 ranges from about 4 inches (10.2cm) to about 10 inches (25.4cm). As also shown inFIG. 1A , thefirst section 112a of theouter surface 112 extends along anaxis 128 from thevertex 124. Thefirst section 112a of the illustrativefirst leg 112 has alength 130 of about 2 inches (5.1cm). However, it may have any suitable length depending on the particular mattress frame corner with which it is sized and shaped to interfit. In one illustrative embodiment, thelength 130 is between about 1 inch (2.5cm) and about 6 inches (15.2cm). In other illustrative embodiments, thelength 130 ranges from about 1 inch (2.5cm) to about 4 inches (10.2cm). Thesecond section 112b of theouter surface 112 extends from thefirst section 112a. According to the illustrative embodiment, thesecond section 112b extends along anaxis 132 angled inward from theaxis 128 of thefirst section 112a, However, this need not be the case, According to the illustrative embodiment, thesecond section 112b has alength 134 of about 2½ inches (6,4cm). However, thesecond section 112b may be of anysuitable length 134 depending on the particular mattress frame corner with which it is sized and shaped to interfit. In one illustrative embodiment, thelength 124 ranges from about 1 inch (2.5cm) to about 6 inches (15.2). In other illustrative embodiments, thelength 124 ranges from about 1 inch (2.5cm) to about 4 inches (10.2cm). - The
first leg 102, in one implementation, has a width/thickness 136 of between about¼ inch (0.6cm) and about 4 inches (10.2cm). However, in other implementations, thewidth 136 is between about ¼ inch (0.6cm) and about 2 inches (5.1cm). According to the illustrative embodiment, the angle of theaxis 132 relative to theaxis 128 causes thewidth 136 to vary from about 1 inch (2.5cm) near theinner end 106 of theleg 102 to about ¼ inch (0.6cm) at theterminal end 108 of theleg 102. However, in other illustrative embodiments, theaxis 128 may be coaxial with theaxis 132, causing thewidth 136 of theleg 102 to be substantially uniform along its length. - As shown most clearly in
FIGS. 1B-1D , thefirst leg 102 has aheight 138 of about 5 inches (12.7cm) in the case of thecorner block 100 being sized and shaped for interfitting with a corner of an open coil mattress frame, and aheight 138 of about 4½ inches (11.4cm) in the case of thecorner block 100 being sized and shaped for interfitting with a corner of a pocketed coil mattress frame. However, as in the case of the other dimensions for thecorner block 100, theheight 138 may be of any suitable measurement, depending on the particular mattress frame corner with which thecorner block 100 is sized and shaped to interfit. For example, in other illustrative embodiments, theheight 138 is between about 3 inches (7.6cm) and about 12 inches (30.5cm). - According to the illustrative embodiment, the first 102 and second 104 legs are of similar dimensions, and may or may not be symmetrical. More particularly, the
second leg 104 of theillustrative corner block 100 has alength 140 of about 4½ inches (11.4cm), as measured along theouter surface 120 between thevertex 124 and the terminal end 116. However, in other illustrative embodiments, thelength 140 may be any suitable length for any particular mattress frame. In some illustrative embodiments, thelength 140 ranges from about 6 inches (15.2cm) to about 12 inches (30.5cm), In other illustrative embodiments, thelength 140 ranges from about 4 inches (10.2cm) to about 10 inches (25.4cm). As also shown inFIG. 1A , thefirst section 120a of theouter surface 120 extends along anaxis 142 from thevertex 124. Thefirst section 120a of the illustrativefirst leg 120 has alength 144 of about 2 inches (5.1cm). However, it may have any suitable length depending on the particular mattress frame corner with which it is sized and shaped to interfit. In one illustrative embodiment, thelength 144 is between about 1 inch (2.5cm) and about 6 inches (15.2cm). In other illustrative embodiments, thelength 144 ranges from about 1 inch (2.5cm) to about 4 inches (10.2cm). Thesecond section 120b of theouter surface 120 extends from thefirst section 120a. According to the illustrative embodiment, thesecond section 120b extends along anaxis 146 angled inward from theaxis 142 of thefirst section 120a. However, this need not be the case. According to the illustrative embodiment, thesecond section 120b has alength 148 of about 2½ inches (6.4cm). However, thesecond section 120b may be of anysuitable length 148 depending on the particular mattress frame corner with which it is sized and shaped to interfit. In one illustrative embodiment, thelength 148 ranges from about 1 inch (2.5cm) to about 6 inches (15.2cm). In other illustrative embodiments, thelength 148 ranges from about 1 inch (2.5cm) to about 4 inches (10.2cm). - The
second leg 104, in one implementation, has a width/thickness 150 of between about ¼ inch (0.6cm) and about 2 inches (5.1cm). However, in other implementations, thewidth 150 is between about inch (2.5cm) and about 2 inches (5.1cm). According to the illustrative embodiment, the angle of theaxis 146 relative to theaxis 142 causes thewidth 150 to vary from about 1 inch (2.5cm) near theinner end 114 of theleg 104 to about ¼ inch (0.6cm) at the terminal end 116 of theleg 104. - However, in other illustrative embodiments, the
axis 146 may be coaxial with theaxis 142, causing thewidth 150 of theleg 104 to be substantially uniform along its length. - As shown most clearly in
FIGS. 1B-1D , thesecond leg 104 has aheight 152 of about 5 inches (12.7cm) in the case of thecorner block 100 being sized and shaped for interfitting with a corner of an open coil mattress frame, and a height 252 of about 4½ inches (11.4cm) in the case of thecorner block 100 being sized and shaped for interfitting with a corner of a pocketed coil mattress frame. However, as in the case of the other dimensions for thecorner block 100, theheight 152 may be of any suitable measurement, depending on the particular mattress frame corner with which thecorner block 100 is sized and shaped to interfit. For example, in other illustrative embodiments, theheight 152 is between about 3 inches (7.6cm) and about 12 inches (30.5cm). - According to the illustrative embodiment, the
inner surfaces 110 and 11.8 are substantially flat. However, as shown inFIG. 1D , theinner surfaces cutout 154 to better interfit with a corner of a mattress frame. More particularly, thecutout 154 provides anoverhang 156 for extending over a top side of a corner of a mattress frame and anoverhang 158 for extending over a bottom side of a corner of a mattress frame. Theoverhangs corner block 100 to the mattress frame. - According to one illustrative embodiment, the corner block is formed from a polymer foam core. In one implementation, it has a density of about 23 kilograms/m3, and a cell size of between about ¾ millimeter and about 1¼ millimeters. However, the
corner block 100 may be made from any material, including, without limitation, any suitable polymer plastic, having sufficient rigidity to maintain the squareness of theintersection 124 of theouter surfaces corner block 100 is also that it has sufficient shape resiliency to return to its substantially square configuration if compressed or otherwise deformed, for example, during packaging and/or shipping. - In some embodiments, the
corner block 100 is formed out of a single piece of material. However, in other embodiments, thelegs - According to another illustrative embodiment, the invention provides a mattress employing one or more corner blocks of the invention to provide substantially square corners. In other illustrative embodiments, the invention provides a method of manufacturing a mattress employing one or more corner blocks of the invention. Although an illustrative mattress and method of manufacture is described below with respect to
Figures 2A-2I in terms of a mattress and a mattress frame, it should be noted that thecorner block 100 of the invention may be sized and shaped for use with any suitable mattress and mattress frame. - Referring to
Figure 2A anend foam 200a is attached to ashort end 202a of a coilspring mattress frame 204. In accordance with conventional practices, the attachment is by way of hog rings. As shown inFigure 2B , acorner block 100a of the invention is then interfitted with thecorner 206a of thecoil spring frame 204, with thefirst leg 102 overlapping the end foam 200 and thesecond leg 104 extending along a portion of along edge 208a of theframe 204. Thecorner block 100 is then hog ringed in place along the top 102a and bottom 102b of thefirst leg 102 and along the top 104a and bottom 104b of thesecond leg 104. As shown inFigure 2C , the same approach is used to attachcorner blocks 100b-100d to each of the remainingcorners 206b-206d and theend foam 200b to the othershort end 202b. As also shown inFigure 2C , themattress frame 204 with the end foam and corner blocks attached is then placed onto a conventionalsynthetic fiber pad 210. As shown inFigure 2D , themattress frame 204 is then wrapped in thefiber pad 210 leaving the end foams 200a and 200b exposed. Thefiber pad 210 is secured using a conventional hog ring approach. As shown inFigure 2E , the mattress is then covered on atop surface 212 and bothshort ends conventional upholstery 214, also secured with hog rings; leaving thelong sides upholstery 214. As shown inFigure 2F , the mattress is then wrapped in a conventionalfire retardant material 216, also secured with hog rings, leaving theupholstery 214 exposed at bothshort ends - As shown in
Figure 2G , the mattress is then inserted into apolymer bag 218, which is substantially evacuated to compress the mattress. As shown inFigure 2H , the mattress is then inserted into anouter cover 220 while in a compressed state. The compressed state enables the mattress to be easily inserted into thecover 220, without risk of ripping or otherwise damaging thecover 220. Themattress cover 220 is then closed using any suitable technique, such as stitching and/or gluing. - The
evacuation bag 218 may be unsealed subsequent to inserting the mattress into thecover 220. In some embodiments, thebag 218 is unsealed and removed prior to closing thecover 220. In other embodiments, thebag 218 is unsealed prior to closing thecover 220, but left inside the cover to provide added protection for core components of the mattress, for example, against inadvertent exposure to bodily fluids during use. In further embodiments, thebag 218 is left sealed while thecover 220 is being closed and is either unsealed subsequent to closure or left to slowly inflate over time due, for example, to porosity of thebag 218 material/construction. - Turning now to
Figure 3 , an alternative embodiment of the invention is depicted wherein a side piece, typically a header or footer piece, is provided that includes two corner block elements. In particular,Figure 3 depicts acorner block 300 that includes twocorner blocks bridge 308 that connects the twocorner blocks corner block curved surface 312 and aside arm piece 310. In the embodiment depicted inFigure 3 thecorner block assembly 300 may be slide over a side of the mattress, thereby providing a corner block at two of the mattress corners. The dimensions of thecorner block assembly 300 may vary according to the application, and in one embodiment thecorner block assembly 300 may have dimensions suitable for allowing thecorner block assembly 300 to slide over the head or foot of a mattress. However, in alternate embodiments, thecorner block assembly 300 may have dimensions suitable for allowing thecorner block assembly 300 to slide over the side of a mattress thereby providing a corner block at the head and the foot of the mattress. Thecorner block assembly 300 may be made of materials such as those used with the corner block assembly embodiments depicted inFigures 1 and2 . Similarly, the wall thickness and height of the corner blocks 302 and 304 may be similar to the wall thickness and height of the corner block depicted in views 1A and 1B. Optionally, the corner blocks 302 and 304, as well as thearm 308 and theside arms 310 may include a lip, similar to the lip depicted inFigure 1D . This optional lip allows for thecorner block assembly 300 to engage the upper and lower surfaces of the mattress. - Once engaged against the mattress, the mattress may be assembled as depicted in
Figures 2A-2F and optionally be compressed as also shown in the figures. - Turning to
Figure 4 , a further alternative embodiment of the corner block is depicted. In particular, acorner block assembly 320 is shown inFigure 4 having fourcorner block elements bridge arms interior cavity 332 into which a mattress may be inserted. In this embodiment, thecorner bock assembly 320 provides four corner blocks that may be attached by asingle assembly 320 to the mattress. Once attached, the mattress may be assembled as depicted inFigures 2A-2D . As described above, the corner block assemblies as well as thesidewalls corner block assembly 320 may be made of the materials described above with reference to the corner block assembly shown inFigures 1A andB and the wall thickness and height of the corner block assembly may be similar to the wall thickness and height of the corner block illustrated inFigures 1A and1B . Thesidewalls - It should be noted that additional modifications can be made to the illustrative embodiments without departing from the subject invention as defined by the following claims. By way of example, the corner block of the invention may be made in any suitable dimensions, from any suitable materials. Additionally, mattresses of the invention may also be of any suitable dimensions and employ any suitable mattress frame, coil spring or not, pocketed or not. Further the methods of manufacture may employ any steps including the step of locating at least one corner block of the invention in a corner of a mattress, regardless of at what point in the fabrication process the corner block is included and regardless of whether the corner block is located directly next to the mattress frame, on top of an intervening layer between the corner block and the mattress frame, covered by a subsequent layer/material or located in an exposed fashion on an outer surface of a mattress corner. Also, the corner block of the invention may or may not be affixed to the corner of the mattress or mattress frame.
Claims (15)
- A corner block (100) comprising:first (102) and second (104) legs each having inner (106, 114) and outer terminal (108, 116) ends, the first leg (102) extending from an inner end (114) of the second leg (104) at an angle to the second leg, both legs including inner (110,118) and outer surfaces (112, 120), the inner surfaces (110, 118) of the first and second legs intersecting at a transition section (122), the outer surfaces (110, 118) of the first and second legs intersecting at a vertex (124) of an angle,characterised in that
the corner block is for squaring a corner of a mattress;
the transition section (122) is curved to interfit around a corner of a mattress frame; and
the first (102) and second legs (104) each have a height of between 4 inches (10cm) and 10 inches (25cm), and a length of between 4 inches (10cm) and 10 inches (25cm) measured from the vertex (124) to the terminal end (108, 116) of a respective leg along the outer surface of the respective leg. - The corner block of claim 1, wherein the corner block (100) is formed from a shape resilient polymer material.
- The corner block of claim 1, wherein the angle is about 90 degrees.
- The corner block of claim 1, wherein one or both of the length or height is between 4 inches (10cm) and 6 inches (15cm).
- The corner block of claim 2, wherein the polymer material has a density of between about 18 kilograms/meter3 and about 28 kilograms/meter3.
- The corner block of claim 1, wherein the first (102) and second (104) legs are formed integrally with each other.
- The corner block of claim 1 having a distance from a vertex of the angle where the outer surfaces (112, 120) of the first (102) and second (104) legs intersect and an apex of the curved transition section (122) being between 1/2 inch (12.5mm) and 2 inches (5cm) and preferably between 1 inch (25mm) and 2 inches (5cm).
- The corner block of claim 1, wherein the first (102) and second (104) legs have a thickness of between 1/4 inch (6.25mm) and 2 inches (5cm) and preferably between 1/2 inch (12.5mm) and 1 inch (25mm).
- The corner block of claim 1, wherein the first (102) and second (104) legs have a thickness that decreases from the inner end (106, 114) of each of the legs to the terminal end (108, 116) of each of the legs.
- The corner block or claim 1, wherein the outer surfaces (112, 120) of the first and second legs (102, 104) each include first (112a, 120a) and second (112b, 120b) sections, the first section (112a, 120a) of each leg extends from the vertex (124) at approximately a right angle to each other, and the second section (112b, 120b) of each leg extends from a terminal end of a respective first section (112a, 120a) of each leg along an axis angled inward relative to a respective axis of the respective first section.
- The corner block of claim 1, wherein the inner surfaces (110, 118) of the first and second legs (102, 104) include a carved out portion sized and shaped to interfit over a corner of a mattress frame.
- The corner block of claim 1, wherein the block (100) comprises a material selected from the group consisting of polyurethane, polystyrene, polymer, wood, metal, polyurethane foam, visco-elastic foam, latex, polyethylene foam, polystyrene, cardboard, cellulose, wood, wire, plastic molded part, polypropylene, and acrylonitrile butadiene styrene (ABS).
- A mattress comprising:a mattress frame; andat least one corner block (100) according to any previous claim.
- A method of manufacturing a mattress according to claim 13 comprising:attaching a corner block (100) to a curved corner of a mattress frame, andcovering the mattress including the corner block (100) with a mattress upholstery,characterised by
the corner block being curved to interfit around the curved corner and for transforming the curved corner into a substantially square corner. - The mattress of claim 13 comprising a mattress upholstery for covering the mattress.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/391,493 US20070220680A1 (en) | 2006-03-27 | 2006-03-27 | Systems and methods relating to a corner block for a mattress |
PCT/US2007/007634 WO2007120446A1 (en) | 2006-03-27 | 2007-03-27 | A corner block for a mattress, and a mattress and method of manufacuture relating thereto |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2004022A1 EP2004022A1 (en) | 2008-12-24 |
EP2004022B1 true EP2004022B1 (en) | 2010-12-15 |
Family
ID=38335520
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP07754191A Not-in-force EP2004022B1 (en) | 2006-03-27 | 2007-03-27 | A corner block for a mattress, and a mattress and method of manufacuture relating thereto |
Country Status (12)
Country | Link |
---|---|
US (1) | US20070220680A1 (en) |
EP (1) | EP2004022B1 (en) |
JP (1) | JP2009531144A (en) |
KR (1) | KR20090006116A (en) |
CN (1) | CN101448435A (en) |
AT (1) | ATE491374T1 (en) |
AU (1) | AU2007239025A1 (en) |
CA (1) | CA2647695A1 (en) |
CL (1) | CL2007000799A1 (en) |
DE (1) | DE602007011235D1 (en) |
MX (1) | MX2008012590A (en) |
WO (1) | WO2007120446A1 (en) |
Families Citing this family (14)
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US20090193591A1 (en) * | 2008-02-05 | 2009-08-06 | Demoss Larry K | Variable coil density anisotropic innersprings |
US8584277B1 (en) | 2008-05-13 | 2013-11-19 | Thomas A. Roberts | Mattress foundation corner connector and bed frame assembly |
US8028362B1 (en) * | 2010-11-15 | 2011-10-04 | Fred Barreau | Toe protecting bed frame accessory |
US8302229B1 (en) * | 2011-06-28 | 2012-11-06 | L&P Property Management Company | Furniture cushion |
US8671483B2 (en) * | 2011-06-28 | 2014-03-18 | L&P Property Management Company | Furniture cushion having at least one edge guard |
US8667630B2 (en) * | 2011-06-28 | 2014-03-11 | L&P Property Management Company | Furniture cushion |
USD731881S1 (en) | 2013-12-27 | 2015-06-16 | Thomas A. Roberts | Multi-lap connector for a supported structure |
US11076705B2 (en) | 2014-05-30 | 2021-08-03 | Sealy Technology, Llc | Spring core with integrated cushioning layer |
CA3008818C (en) | 2015-12-17 | 2023-02-28 | Sealy Technology, Llc | Coil-in-coil spring with variable loading response and mattresses including the same |
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US10598242B2 (en) | 2016-05-20 | 2020-03-24 | Sealy Technology, Llc | Coil springs with non-linear loading responses and mattresses including the same |
USD837572S1 (en) | 2016-06-21 | 2019-01-08 | Oddello Industries, Llc | Click lock corner |
KR102115083B1 (en) | 2018-06-04 | 2020-05-26 | (주)보화산업 | Method and apparatus for manufacturing corner spring block of bed mattress |
KR102448081B1 (en) | 2022-02-18 | 2022-09-27 | 에버에스티 주식회사 | Apparatus for connecting of wood deck |
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US2201361A (en) * | 1937-03-22 | 1940-05-21 | Ralph W Tyler | Casing for mattresses and the like |
JPS4614509Y1 (en) * | 1965-09-08 | 1971-05-21 | ||
JPS557168Y2 (en) * | 1971-01-30 | 1980-02-18 | ||
JPS4720514U (en) * | 1971-01-30 | 1972-11-08 | ||
JPS5253825U (en) * | 1975-10-14 | 1977-04-18 | ||
US4539723A (en) * | 1984-05-29 | 1985-09-10 | Hillsberry Jerl D | Auxiliary mattress corners |
JPS6275747U (en) * | 1985-10-31 | 1987-05-15 | ||
US5077847A (en) * | 1990-03-08 | 1992-01-07 | Dennis Boyd | Waterbed mattress corner and method of making same |
US20020116884A1 (en) * | 1996-09-18 | 2002-08-29 | Smythe Timothy D. | Drywall finishing system |
US5884385A (en) * | 1997-05-12 | 1999-03-23 | Ohio Mattress Company Licensing And Components Group | Method of manufacture and formation of metal mattress foundation corner guards |
US5878455A (en) * | 1998-01-21 | 1999-03-09 | Chattam & Wells | Corner guard for mattress |
US6568014B1 (en) * | 2002-03-28 | 2003-05-27 | Serta, Inc. | Edge support on a mattress |
FR2865120B1 (en) * | 2004-01-20 | 2006-10-13 | Emmanuel Severi | AIR-MATTRESS BAMBOO ROD |
-
2006
- 2006-03-27 US US11/391,493 patent/US20070220680A1/en not_active Abandoned
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2007
- 2007-03-26 CL CL2007000799A patent/CL2007000799A1/en unknown
- 2007-03-27 KR KR1020087025951A patent/KR20090006116A/en not_active Application Discontinuation
- 2007-03-27 CA CA002647695A patent/CA2647695A1/en not_active Abandoned
- 2007-03-27 AT AT07754191T patent/ATE491374T1/en not_active IP Right Cessation
- 2007-03-27 MX MX2008012590A patent/MX2008012590A/en not_active Application Discontinuation
- 2007-03-27 DE DE602007011235T patent/DE602007011235D1/en active Active
- 2007-03-27 AU AU2007239025A patent/AU2007239025A1/en not_active Abandoned
- 2007-03-27 WO PCT/US2007/007634 patent/WO2007120446A1/en active Application Filing
- 2007-03-27 CN CNA200780018422XA patent/CN101448435A/en active Pending
- 2007-03-27 JP JP2009502965A patent/JP2009531144A/en active Pending
- 2007-03-27 EP EP07754191A patent/EP2004022B1/en not_active Not-in-force
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AU2007239025A1 (en) | 2007-10-25 |
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EP2004022A1 (en) | 2008-12-24 |
CL2007000799A1 (en) | 2008-01-25 |
US20070220680A1 (en) | 2007-09-27 |
CN101448435A (en) | 2009-06-03 |
JP2009531144A (en) | 2009-09-03 |
CA2647695A1 (en) | 2007-10-25 |
KR20090006116A (en) | 2009-01-14 |
WO2007120446A1 (en) | 2007-10-25 |
ATE491374T1 (en) | 2011-01-15 |
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