IL96778A - Mattress and method of making it - Google Patents

Description

MATTRESS AND METHOD OF MAKING IT GENERALE FRANCAISE DE LITERIE C: 11899 11899tra.ns H-l 8/11/91 MATTRESS AND METHOD FOR MANUFACTURE THEREOF The invention relates to a mattress and the method of manufacture thereof.

There are already known various mattresses, particularly foam mattresses of the general type that includes a plurality of modular elements which are elastically deformable in an axial direction, which are juxtaposed on common support means such that the modular elements are rigidly associated with each other in lines and columns.

The state of the art is illustrated particularly by the following documents: DE-3303625 , FR-2592779 and FR-2047088.

The purpose of the invention is to provide a mattress of the aforementioned type which is at the same time adaptable specifically to its user, as the result of its characteristic modular element construction, and manufacturable in a simple and efficient manner.

To this end, the invention proposes a mattress of the type including a plurality of modular elements of differing elasticity which are deformable in an axial direction and a common support means for all of the modular elements, which are associated therewith in a rigid manner by gluing using adhesive means onto a support means constituted by a cloth which is elastically deformable, particularly in the axial direction.

A method for construction of such a mattress is such that successively one places on a work surface a mold corresponding to the exterior contour of the mattress constructed; one 096778/2 organizes on the work surface interior of the mold the modular elements according to their desired juxtaposition; one places the adhesive on the base of the support cloth, and/or the bottom faces of the modular elements; one applies the support cloth over the modular elements, with the support surface on the bottom faces, the contour of the support cloth corresponding to that of the mold; one ensures that the adhesive has held and one removes the mattress, thus constructed, from the mold.

Additional characteristics and advantages of the invention follow from the description which follows with reference to the attached drawings in which: Fig. 1 is a bottom view of one possible construction of the mattress according to the invention; Fig. 2 is a side view (longitudinal side) of the mattress of Fig. 1; Fig. 3 is a view of the same type as Fig. 2, taken in section along an axial transverse plane of another variation, illustrating the adaptation of the mattress to its user; Figs. 4A, 4B, and 4C are three schematic bottom views illustrating the successive steps of the method of manufacture of a mattress according to the present invention; Fig. 5 is a sectional schematic view taken in a vertical plane also illustrating the method of the present invention; Fig. 6 is a sectional schematic view taken in a vertical plane illustrating a variation of the technique according to the present invention. 096778/2 The invention relates to a mattress 1 including a plurality of different modular elements 2 which are elastically deformable, particularly in an axial direction and support means 3 common to the plurality of modular elements 2 and with which the modular elements 2 are rigidly associated being juxtaposed preferably but not necessarily in vovis 4 and columns 5.

The modular elements 2 are, according to the invention, rigidly associated by gluing to a cover means 6 to support means 3, constituted by an elastically deformable cloth which is deformable particularly in the axial direction.

In the usual preferred case, the mattress 1 is limited, in elevation vis a vis the exterior, by a rectangular or pseudo rectangular border which is defined within a rectangular envelope. This defines for the mattress 1 a longitudinal edge 7 and a lateral edge 8, which respectively constitute the long side and the short side of mattress 1. It will be appreciated that other edge contours may be envisaged.

The mattress 1 may be limited at the top or the bottom in accordance with its normal position of use, by large planar faces or by a planar or generally planar envelope (this latter expression indicates that it may have limited local reliefs) ' or the large planar faces may be limited by curved cloths according to the function under the conditions in which the mattress 1 is intended to be used.

References 9 and 10 respectively indicate the lower and upper faces of mattress 1, that is, the planes or cloths which form an envelope below and above the mattress 1. Similarly, reference 11 designates the axis perpendicular to 096778/2 faces 9 and 10, axis 11 being generally vertical. This axis 11 defines the axial sense in which the mattress 1 presents a certain deformability .

The mattress 1 presents a deformability both local and combined, particularly parallel to axis 11.

The modular elements 2 can by themselves be in various forms and configurations. They can be, for a given mattress 1, of the same general type or alternatively of different types. They can be, for a given type, identical or different. For example, the modular elements can be formed of blocks of foam of plastic material or by soft conformal envelope filled with balls, or by soft conformal envelopes filled with air.

A modular element 2 includes a base surface 12 which is to be attached and adhered to a surface 13 of support means 3, at its engagement surface.

The base surface 12 of one modular element 2 can have a contour which is square or pseudo square, rectangular or pseudo rectangular, circular or pseudo circular, elliptical or pseudo elliptical, polygonal or pseudo polygonal or otherwise. The modular elements 2 touch each other or alternatively are spaced one from the other, over the totality or only along a portion of their periphery. They may be, for example, mutually tangential.

The mattress 1 may include in its configuration of rows and columns represented by the drawings, a single line and multiple columns or alternatively, multiple rows and a single column. It includes, in its generality, multiple rows and multiple columns. The base surfaces 12 of different modular elements 2 preferably cover the totality of the surface of 096778/2 surface 13. Alternatively they only cover a part of the surface. In one possible embodiment, which is purely representative, the modular element 2 s limited by a base surface 12, an exterior surface 14, defined or limited by upper surface 10 and a lateral surface 15. For example, the modular element 2 has a generally pyramidical form wherein the small base is the exterior surface 14 and the large base is the base surface 12. In the embodiment here considered, the lines and the columns are essentially rectilinear. However, alternatively, they may be curved ( in a plane or otherwise), closed upon themselves or otherwise (for example: a line or column of circular or elliptical or a similar form).

In the present case, the modular elements 2 are more or less overlapping and/or rigidly associated one with the other. The mattress 1 is preferably specially adapted for a user by virtue of conforming the structure provided in the modular elements 2. This adaptation is illustrated, for example by Fig. 3 where it is shown that certain modular elements 2 have a height (in an axial sense) greater than that of others and that the density of the foam constituting the modular elements 2 provides a support which comports to the body of the user. One will appreciate that the best result is obtained. with a "matrix" (corresponding to lines and columns 4, 5) including the maximum number of elements. Also, specifically, the construction of a mattress according to the invention permits, without prejudice, to have a mattress including a large number of modular elements 2 without either the mattress or its method of manufacture becoming substantially more complex. 096778/2 The support means 3 is limited by a surface 13 and by an exterior surface which corresponds to the lower surface 9 and Nnnlly by th exterior mi fnoert I r> which def ine edg s 7 and 8. In the present case, the modular elements 2 adjacent edges 7 and 8 present a contour adapted by their lateral surfaces 15, so as to extend surfaces 16 as seen in Fig. 2. In order to permit efficient gluing of the modular elements 2 on the support means J^^using adhesive 6, the surfaces that are to be glued 12, 13 are arranged accordingly particularly and for example so as to present a configuration which is smooth overall to permit ready positioning of the modular elements 2 on the support means 3. Furthermore, the glue can be effectively disposed on one or more surfaces 12 and 13. The construction of faces 12 and 13 includes honeycomb colls, such to be constructed of plastic foam, and such that it is compatible with mutual adhesion of the modular elements 2 and of the support means 3. Also, while permitting adhesion, the modular elements 2 have base surfaces intended for contact with or adhesion to the support surface 13 of support means 3 substantially identical to the aforesaid support surface 13. In other terms, the modular elements 2, arranged in rows 4 and columns 5, must define at their base surfaces 12 a surface complementary to the support surface 13. As already indicated, the modular elements 2 should have characteristics of elastic deformabil ity along axis 11, particularly adapted to the morphology of the user. It follows that the mattress thus realized is personalized and modular.

Equally, as already mentioned, the support surface is preferably substantially planar. In an alternative embodiment 096778/2 (not shown) the mattress includes additionally a second cloth applied under and/or rigidly associated - preferably glued - to modular elements 2 by their exterior faces, such that modular elements 2 are sandwiched between the second cloth and the cloth of the support means 3. This second cloth can have, particularly, the same characteristics or general characteristics of the same type of the cloth support 3.

The invention also relates to a method of manufacture of such a mattress. In this method, successively, one places on the work surface 17, particularly horizontal such as a table, a mold 18 which defines a central hollow space 19, limited by walls 20 which are located vertically on the work surface 17. For example, the mold 18 includes walls 20 having a rectangular facing configuration limited by two longitudinal walls 21 and two lateral walls 22 which are intended respectively to define the longitudinal and lateral limits 7 and 8 of the mattress 1. One accordingly appreciates that the mold 18 has a contour corresponding to the contour of the mattress to be manufactured.

The mold 18 is preferably detachable in a manner such that it can be placed and removed from the work surface 17. In the present case, detachable clamping apparatus is envisioned for mold 18 on the work surface 17. This stage of the technique is represented schematically in Fig. 4A.

Reference is now made to Fig. 4B which illustrates schematically the step in which one places and organizes on the work surface 17 and in the central space 19 of the mold 18 the modular elements 2 appropriately along rows 4 and columns 5.

This arrangement is carried out in a manner such that the configuration of the matrix of modular elements 2 corresponds to the that of the mattress to be manufactured. For example, with reference to Fig. 4B, a mattress having three different modular elements 2, which are referenced A, B and C is envisioned. The modular elements A are those at the periphery of the mattress. The modular elements B are those along the central line adjacent the periphery of the mattress. Finally the modular elements C are those at the center of the mattress. This form of construction is given for the purpose of example. One accordingly envisions that the operator, at this stage of proceeding, would take the modular elements 2 of each of the homogeneous stocks of modular elements for placing them in a convenient manner at the interior of the mold 18.

Then in a final step, one places adhesive 6 on the base surfaces of the modular elements 2 and/or the support surfaces and/or the support surface 13 of the support means 3. The application of adhesive is carried out by impregnation, pulverization or soaking. It is continuous or discontinuous. The adhesive is naturally compatible with the material or materials forming the modular elements 2 and the support means 3. Fig. 4C schematically represents the deposit of adhesive 6 on the surfaces of base 12 of the modular elements 2 using a roller 23 of the type used by painters. Preferably, one places the adhesive 6 on the base surfaces and then in the final step one places the support material including the support means 3 on the modular elements 2 by applying the support surface 13 on the base surfaces 12, the walls 16 of the support means 3 corresponding to walls 20 of mold 18. In this manner, eventually, the height of mold 18 is that which permits at least partially placement therein of the support means 3. It must be noted that the form of construction which is envisaged, permits the manipulation in this step only of the support means 3 while the modular elements 2 are fixed and maintained by the work surface 17 and the mold 18.

In the final steps of the method, one ensures that the adhesive 6 has held such that the modular elements 2 and the support means 3 cannot be readily detached from each other. Finally, once this has been done, one removes the mattress, thus manufactured, from the mold 18.

Thus, in accordance with one possible characteristic of the technique described above, for applying the support means 3 in the form of cloths onto the modular elements 2, one maintains the modular elements 2 substantially fixed and one reverses thereover the support means 3.

Preferably, in accordance with another characteristic of the technique, one employs means for identification 24 of the type in which each modular element 2 must be placed in the mold 18 in a manner to represent at each placement location of a modular element, which type of modular element is to be placed thereat. One may refer for this purpose to Fig. 4B which illustrates such a means for identification 24 in the form of a sheet placed on the work surface 17 inside the mold 18. On this sheet appear indications such as A, B, C or any other suitable means of identification, permitting the indication of the position of each modular element 2.

According to another characteristic of the invention wherein, for example, the modular elements 2 are not all of the same height along axis 11, one places in the mold 18 an appropriate wedge or brace 25 on which the modular element 2 is to rest on the base surface 12.

In the case wherein a second cloth is envisioned, it is placed initially in the mold prior to placement of the modular elements 2.

Claims (8)

1. 096778/2 C L A I M S 1- A method of construction of a mattress of the type including a plurality of different modular elements (2) , which are elastically deformable particularly in the axial sense and common support means (3) with which the modular elements (2) are associated in a rigid manner, being arranged in a juxtaposed arrangement, particularly in rows and columns (4, 5), characterized in that it comprises successively placing on a work surface (17) a mold (18) corresponding to the exterior contour of the mattress (1) to be manufactured; one places and organizes on the work surface (17) and at the interior of the mold (18) the modular elements (2) conveniently and preferably in rows and columns (4, 5); one places adhesive (6) on the support faces (13) of the support means (3) chosen in the form of a cloth which is elastically deformable particularly in an axial sense and/or the base surfaces (12) of the modular elements (2) ; one applies the cloth support (3) on the modular elements (2) in applying the support surface (13) to the base surfaces (12) , the contour of the cloth support (3) corresponding to that of the mold (18) ; one ensures that the adhesive has adhered and one removes the mattress thus realized from the mold (18) .

2. A method according to claim 1 characterized by the fact that for applying the cloth support (3) onto the modular elements (2) , one maintains them substantially fixed and one reverses the cloth support (3) thereover.

3. A method according to either of claims 1 and 2, and characterized in that it employs means for identification (24) of the type of each modular element (2) such as to indicate for each location at which a modular element (2) is to be located, which type of modular element is to be placed there.

4. A method according to any of claims 1 - 3 and characterized by the fact that one places in the mold (18) and on the work surface (17) one or more wedges or braces (25) on which the modular elements (2) rest.

5. A mattress obtained by the method of manufacture of claims 1 - 4, characterized in that the modular elements (2) are rigidly associated by adhesive with a support means (3) constituted by a cloth which is elastically deformable, particularly in an axial sense.

6. A mattress according to claim 5, characterized in that the modular elements (2) have substantially identical base surfaces intended for contact and adhesion to the cloth support (3).

7. A mattress according to any one of claims 5 and 6, characterized by the fact that the modular elements (2) have different characteristics of form, dimensions, elastic deform-ability which are adapted to the morphology of the user.

8. A mattress according to any one of claims 5 - 7, characterized by the fact that it includes a second cloth, the modu- lar elements (2) being placed in a sandwich between the cloth and the second cloth. For the Applicant, Sanford T. Colb & Co. Advocates and Patent Attorneys C: 11899 H-1