A CORNER BLOCK FOR A MATTRESS, AND A METHOD TO MANUFACTURE WHAT REFERS TO IT
FIELD OF THE INVENTION The invention relates generally to mattresses. More particularly, in various embodiments, the invention relates to a corner block for providing a reinforced square corner in a mattress, to mattresses made with said corner blocks, and to mattress manufacturing methods employing said corner blocks. BACKGROUND OF THE INVENTION Conventionally, mattresses in general have reinforced rounded corners. When installed in a crib frame, the corners of conventional mattresses can cause a baby to be injured by receiving a limb, such as an arm or a leg, between the frame of the crib and the corner of the mattress. same Various prior art approaches have been employed to reduce the possibility of this happening. In some cases shock absorbers are used for cradle. Typically, shock absorbers for cradle are fixed along the periphery of a crib mattress and extend up between the mattress and the sides of the crib. A disadvantage of shock absorbers is that they often come out at the corners of the mattress and leave a gap between the corner of the mattress and a corner of the frame of the mattress.
cradle. Another prior art approach employs mattresses that extend upwards along its periphery to provide an integrated damper. However, such mattresses can be significantly more complicated to manufacture. Accordingly, there is a need for an improved structure for a crib mattress. BRIEF DESCRIPTION OF THE INVENTION In various embodiments, the invention solves deficiencies of the prior art by providing a corner block to square the corner of a mattress. In other embodiments, the invention provides mattresses employing the corner block of the invention and manufacturing methods for said mattresses. In some embodiments, a mattress of the invention can be used as a crib mattress. An advantage of such crib mattresses is that they fit better within the corners of a crib to prevent a baby from lodging a limb between a corner of the mattress and a corner of the frame of the crib. According to one aspect, the invention provides a corner block formed from an elastically shaped polymer material, such as polyurethane foam, viscoelastic foam, latex, polyethylene foam, polystyrene or cardboard, wood, metal, wire, molded part of plastic, polypropylene and acrylonitrile butadiene styrene (ABS). In one implementation, the polymer material has a density of approximately 26 kilograms / meter3. In other implementations, the polymer material
It has a density between approximately 1 8 kilograms / meter3 and approximately 28 kilograms / meter3. In other embodiments, the polymer material has a density between about 20 kilograms / meter3 and about 26 kilograms / meter3. In other embodiments, the corner block of the invention can be formed from any suitable material, depending on the desired application. The corner block includes first and second legs, which extend from one vertex, and at an angle to each other. Each for includes an interior surface (for example, that comes into contact with the frame) and an exterior surface. In one configuration, the outer surfaces of the first and second legs intersect at a substantially straight angle. In one embodiment, each leg is approximately 1 1 .43 cm (4.5 inches) long, 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 approximately 1 1 .43 cm (4.5 inches) in height. According to an alternative embodiment, each leg is approximately 1 2.7 cm (5 inches) in height. In other configurations, the legs of the corner block are between about 1 0.1 6 cm (4 inches) and about 25.4 cm (1 0 inches) long, and about 1 0.1 6 cm (4 inches) and about 25.4 cm ( 1 0 inches) tall. In alternate configurations, the legs of the corner block are
they are between about 10.16 cm (4 inches) and about 1 5.24 cm (6 inches) long. In other configurations, the legs of the corner block are between approximately 6.1 6 cm (4 inches) and approximately 1 524 cm (6 inches) high. According to another feature, the legs are between about 0.635 cm (0.25 inches) and about 3.81 cm (1.5 inches), measured from the inner surface to the outer surface. In some embodiments, the exterior surfaces of the first and second legs each include first and second sections. The first section of each leg extends from the apex 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 at an angle toward in relation to a respective axis of the respective first section. According to some configurations, the inner surfaces of the first and second legs intersect in a transaction section. According to one feature, the transition section has the size and shape to fit around the corner of a spring mattress frame. According to another feature, the transition section can be curved to further facilitate said adjustment. In one embodiment, the distance between the vertex of the angle of intersection of the outer surfaces of the apex of the curve of the section of
transition is between approximately 1.905 cm (0.75 inches) and 3.81 cm (1.5 inches). In some embodiments, a portion of the interior surfaces of the first and second legs can be recessed to receive a corner of a spring mattress frame. According to one feature of these embodiments, the cupping can be of such size and shape that the upper and lower parts of the legs can be spliced on the upper and lower side of the mattress frame, when they fit into a corner of the frame to facilitate the attachment of the corner block to the frame. According to another aspect, the invention is directed to a mattress that employs a corner block of the invention. In one embodiment, the mattress includes a spring frame, in which said springs may or may not be covered. The corner blocks are attached to each corner of the frame, either before or after the clamping of the polymer foam material to the short ends of the frame. The mattress of the invention can then be assembled using any suitable approach. According to various constructions, the mattress can be of any size, including without limitation simple, double, matrimonial, queen, king, California king or crib size. According to another embodiment, after placing a fire retardant material, the mattress is placed inside a compression bag. With the mattress placed like this, the compression bag is evacuated to compress it, including the compression of
the springs of the mattress frame. With the mattress compressed in this way, it is inserted into a final mattress cover. The cover can then be closed by any suitable mechanism. Optionally, the compression bag can be removed before closing the mattress cover. In some cases, the compression bag can be made of a water resistant polymer, and left on the mattress to protect the internal parts thereof from unexpected exposure to fluids during use. Other advantages and features of the invention are described below in relation to various illustrative modalities. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be better understood with reference to the accompanying illustrative drawings, in which like reference designations refer to equal parts, the various views may not be drawn to scale, and where: Figure 1 A is a top view of a corner block for providing a square corner reinforced in a mattress according to an illustrative embodiment of the invention; Figure 1 B is an external perspective view of the corner block of Figure 1 A; Figure 1 C is an interior perspective view of the corner block of Figure 1 A; Figure 1 D is an interior perspective view of the corner block of Figure 1 A, including an optional cutout according to another illustrative embodiment of the invention;
Figures 2A-2H show an illustrative process for making a mattress including a corner block of the invention; Figure 3 illustrates an alternative embodiment of the invention; Y
Figure 4 illustrates another alternative embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION As described above in the abstract, the invention solves the deficiencies of the prior art by providing, in various illustrative embodiments, devices, systems and methods related to forming a substantially square corner in a mattress. According to various implementations, the invention provides a corner block for securing it to a curved or rounded corner of a mattress frame. An advantage of the corner blocks of the invention is that they can be applied to the corners of conventional mattress frames, without the need to change the process by which the mattress frames are manufactured. Another advantage is that, with the exception of the outer mattress cover (which may need to be formed with square corners instead of round ones) the corner blocks of the invention can be attached to the corners of the mattress frame without the need to modify the other components of the mattress. cover, surround the mattress frame or attach to it in some other way. Another advantage is that the corner blocks of the invention can be attached to the mattress frame at the same time that the final foam pad is attached to the short ends of the mattress frame. As already mentioned, another advantage of the invention is that it can be used with
a crib mattress to reduce the possibility of a baby lodging a limb between a corner of the mattress and a corner of the crib frame. Figures 1A to 1D show various views of a corner block (100) according to an illustrative embodiment of the invention. Referring to those figures, end block (100) includes first and second legs (102), (104). The first leg (102) has an inner end (106) and a terminal end (108). It also has an interior surface (110) and an exterior surface (112). The outer surface has first and second sections (112a), (112b). Similarly, the second leg (104) has an inner end (114) and a terminal end (116). It also has an interior surface (118) and an exterior surface (120). The outer surface has first and second sections (120a), (120b). The inner surfaces (110) and (118) of the first and second legs (102) and (104), respectively, intersect in a transition section (122). As illustrated, the transition section 122 can be bent, but it is not a requirement in this case. As shown in greater detail in Figures 2B and 2C, the transition section (122) has the size and shape to fit a round or non-square corner of a mattress frame, or cover said corner. In this specific modality, the mattress frame is a crib mattress frame. However, corner blocks of suitable size according to the present invention can also be applied to any mattress frame size, by
example, including single, double, matrimonial, queen, king and California king. The outer surfaces (112) and (120) of the first leg (102) and of the second leg (104), respectively, intersect at an angle to each other at a corner / vertex (124). According to an illustrative embodiment, the outer surfaces (112) and (120) of the first leg (102) and of the second leg (104), respectively, intersect at a substantially straight angle (i.e., 90 degrees) to forming a substantially square corner (124). In the illustrative embodiment of Figure 1, the distance (125) between the apex (124) and an apex (123) of the curved transition section (122) is approximately 2.54 cm (1 inch). However, the distance (125) can have any suitable dimension depending on the size of the particular mattress frame corner with which it fits. For example, in other illustrative embodiments, the distance (125) ranges from approximately 1.27 cm (0.5 inches) to 5.08 cm (2 inches). As shown in Figure 1A, the first leg (102) of the illustrative corner block (100) has a length (126) of approximately 11.43 cm (4.5 inches), measured along the exterior surface (112) between the vertex (124) and the terminal end (108). However, in other illustrative embodiments, the length (126) can be any suitable length for any particular mattress frame. In some illustrative embodiments, the distance (126) ranges from approximately 15.24 cm (6 inches) to
approximately 30.48 cm (12 inches). In other illustrative embodiments, the distance (126) ranges from about 10.16 cm (4 inches) to about 25.40 cm (10 inches). As also shown in Figure 1A, the first section (112a) of the outer surface (112) extends along an axis (128) from the apex (124). The first section (112a) of the first illustrative leg (112) has a length (130) of approximately 5.08 cm (2 inches). However, it could have any suitable length depending on the size and shape of the particular mattress frame corner with which it fits. In an illustrative embodiment, the distance (130) ranges from approximately 2.54 cm (1 inch) to approximately 15.24 cm (6 inches). In other illustrative embodiments, the distance (130) ranges from approximately 2.54 cm (1 inch) to approximately 10.16 cm (4 inches). The second section (112b) of the outer surface (122) extends from the first section (112a). According to an illustrative embodiment, the second section (112b) extends along the axis (132), angled inwardly from the axis (128) of the first section (112a). However, it is not a requirement in this case. According to the illustrative embodiment, the second section (112b) has a length (134) of approximately 6.35 cm (2.5 inches). However, the second section (112b) could have any suitable length (134) depending on the size and shape of the particular mattress frame corner with which it fits. In an illustrative embodiment, the distance (124) is approximately 2.54 cm (1
inches) to approximately 15.24 cm (6 inches). In other illustrative embodiments, the distance (124) ranges from approximately 2.54 cm (1 inch) to approximately 10.16 cm (4 inches). The first leg (102), in one implementation, has a width / thickness (136) of between about 0.635 cm (0.25 inches) and about 10.16 cm (4 inches). However, in other implementations, the width (136) is between approximately 0.635 cm (0.25 inches) and approximately 5.08 cm (2 inches) According to an illustrative embodiment, the angle of axis (132) relative to the axis (128 ) causes width (136) to vary from about 2.54 cm (1 inch) near the inner end (106) of the leg (102) to about 0.635 cm (0.25 inches) at the terminal end (108) of the leg (102). ). However, in other illustrative embodiments, the shaft (128) may be coaxial with the shafts (132), causing the width (136) of the leg (102) to be substantially uniform over its entire length. As shown more clearly in Figures 1B to 1D, the first leg (102) has a height (138) of about 12.7 cm (5 inches) in case the corner block (100) has the size and shape to fit with a corner of a spring mattress frame, and a height (138) of approximately 11.43 cm (4.5 inches) in case the corner block (100) has the size and shape to fit with a corner frame mattress springs lined. However, in the case of other dimensions for the corner block (100), the height (138) may
be of any suitable measure. For example, in other illustrative embodiments, the height (138) ranges from approximately 7.62 cm (3 inches) to approximately 30.48 cm (12 inches). 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 the illustrative corner block (100) has a length (140) of approximately 11.43 cm (4.5 inches), measured along the outer surface (120) between the apex (124) and the terminal end (116). However, in other illustrative embodiments, the length (140) can be any suitable length for any particular mattress frame. In some illustrative modalities, the distance (140) ranges from approximately 15.24 cm (6 inches) to approximately 30.48 cm (12 inches). In other illustrative embodiments, the distance (140) ranges from about 10.16 cm (4 inches) to about 25.40 cm (10 inches). As also shown in Figure 1A, the first section (120a) of the outer surface (120) extends along an axis (142) from the apex (124). The first section (120a) of the first illustrative leg (120) has a length (144) of approximately 5.08 cm (2 inches). However, it could have any suitable length depending on the size and shape of the particular mattress frame corner with which it fits. In an illustrative embodiment, the distance (144) ranges from approximately 2.54 cm (1 inch) to approximately 15.24 cm (6 inches). In other modalities
illustrative, the distance (144) ranges from approximately 2.54 cm (1 inch) to approximately 10.16 cm (4 inches). The second section (120b) of the outer surface (120) extends from the first section (120a). According to an illustrative embodiment, the second section (120b) extends along an axis (146), angled inward from the axis (142) of the first section (120a); however, this is not a requirement. According to the illustrative embodiment, the second section (120b) has a length (148) of approximately 6.35 cm (2.5 inches). However, the second section (120b) could have any suitable length (148) depending on the size and shape of the particular mattress frame corner with which it fits. In an illustrative embodiment, the distance (148) ranges from approximately 2.54 cm (1 inch) to approximately 10.16 cm (6 inches). In other illustrative embodiments, the distance (148) ranges from approximately 2.54 cm (1 inch) to approximately 10.16 cm (4 inches).
The second leg (104), in one implementation, has a width / thickness (150) of between about 0.635 cm (0.25 inches) and about 5.08 cm (2 inches). However, in other implementations, the width (150) is between approximately 0.635 cm (0.25 inches) and approximately 5.08 cm (2 inches) In accordance with the illustrative embodiment, the axis angle (146) in relation to the axis (142). ) causes the width (150) to vary from approximately 2.54 cm (1 inch) near the inner end (114) of the leg (104) to approximately 0.635 cm (0.25 cm).
inches) at the terminal end (116) of the leg (104). However, in other illustrative embodiments, the shaft (146) may be coaxial with the shafts (142), causing the width (150) of the leg (104) to be substantially uniform over its entire length. As shown more clearly in Figures 1B to 1D, the second leg (104) has a height (152) of about 12.7 cm (5 inches) in case the corner block (100) has the size and shape to fit with a corner of a spring mattress frame, and a height (252) of approximately 11.43 cm (4.5 inches) in case the corner block (100) has the size and shape to fit with a frame corner mattress springs lined. However, in the case of other dimensions for the corner block (100), the height (152) can be of any suitable size, depending on the size and shape of the corner of the specific mattress to which the corner block fits ( 100). For example, in other illustrative embodiments, the height (152) ranges from approximately 7.62 cm (3 inches) to approximately 30.48 cm (12 inches). According to an illustrative embodiment, the internal surfaces (110) and (118) are substantially planar. However, as shown in Figure 1D, the interior surfaces (110) and (118) may include a cutout (154) to better fit a corner of a mattress frame. More particularly, the cutout (154) provides a projection (156) to extend over an upper side of a corner of a mattress frame and a
protruding (1 58) to extend it over a lower side of a corner of a mattress frame. The projections (1 56), (1 58) make it easier to fasten (for example, by means of "C" rings) the upper part and the lower part of the corner block (1 00) to the mattress frame. According to an illustrative embodiment, the corner block is formed of a core of polymer foam. In one implementation, it has a density of about 23 kilograms / m3, and a cell size of between about 0.75 millimeters and about 1.25 millimeters. However, the corner block (1 00) can be made of any material, including without limitation any polymer plastic having sufficient stiffness to maintain the squaring of the intersection (1 24) of the outer surfaces (1 1 2) and (1 20). A desirable feature of the corner block material (100) is also that it has sufficient shape elasticity to return to its substantially square configuration, compressed or deformed, for example, during packaging and / or packaging. In some embodiments, the corner block (1 00) is formed of a single piece of material. However, in other embodiments, the legs (102) and (104) can be held together by any suitable mechanism. According to another illustrative embodiment, the invention provides a mattress that employs one or more corner blocks of the invention to provide corners substantially
square In other illustrative embodiments, the invention provides a manufacturing method for a mattress employing one or more corner blocks of the invention. Although a mattress and illustrative manufacturing method are described below with respect to Figures 2A to 21 in terms of a mattress and a mattress frame, it should be noted that the corner block (1 00) of the invention can have the size and the shape to use with any mattress and mattress frame. Referring to Figure 2A, a finishing foam (200a) is attached to a short end (202a) of a spring mattress frame (204). According to conventional practices, the fastening is done by means of "C" rings. As shown in Figure 2B, a corner block (1 00a) of the invention fits with the corner (206a) of the spring frame (204), with the first leg (1 02) spliced to the finishing foam ( 200) and the second leg (1 04) extends along a portion of a long edge (208a) of the frame (204). The corner block (1 00) is often held with curved cord rings along the top (1 02a) and bottom (102b) of the first leg (1 02) and along the top (1 04a) and the lower part (1 04b) of the second leg (1 04). As shown in Figure 2C, the same approach is used to attach the corner blocks (100b-100d) to each of the remaining corners (206b) - (206d) and the finishing foam (200b) to the other short end (202b). As also shown in Figure 2C, the mattress frame (204) with the finishing foam and
the subject corner blocks are then placed on a conventional synthetic fiber pad (210). As shown in Figure 2D, the mattress frame (204) is then wrapped in the fiber pad (21 0), leaving the finishing foams (200a) and (200b) exposed. The fiber pad 210 is secured using a conventional curved bead ring approach. As shown in Figure 2E, the mattresses are covered on an upper surface (21 2) and both short ends (202a) and (202b) with a conventional upholstery (21 4), also secured with curved cord rings; leaving the long sides (208a) and (208b) and the lower part of the mattress not covered by the upholstery (21 4). As shown in Figure 2F, the mattress is then wrapped in a conventional fire retardant material (21 6), also secured with curved cord rings, leaving the upholstery (214) exposed to both short ends (202a) and (202b) ). As shown in Figure 2G, the mattresses are inserted into a polymer bag (21 8), which is evacuated substantially to compress the mattress. As shown in Figure 2H, the mattress is inserted into an outer cover (220) in a compressed state. The compressed state allows the mattress to be easily inserted into the cover (220), without risk of tearing or damaging the cover (220). The mattress cover (220) is closed using any suitable technique, such as stitching or gluing it with adhesive. It is possible to break the seal of the evacuation bag (218)
after introducing the mattress inside the cover (220). In some embodiments, the bag (218) is not sealed and is removed before closing the cover (220). In other embodiments, the bag (218) is not sealed prior to closing the cover (220), but is left inside the cover to provide added protection for core components of the mattress, eg, against inadvertent exposure to body fluids during the use. In other embodiments, the bag (218) was left sealed while the cover (220) is closed, and sealed after closing or allowed to slowly inflate over time, due for example to the porosity of the material / construction of the bag (218) Turning now to Figure 3, there is illustrated an alternative embodiment of the present invention that provides a side piece, typically a head piece or lower part, which includes two corner block elements. In particular, Figure 3 illustrates a corner block (300) including two corner blocks (302) and (304). The corner blocks (302), (304) are joined by a bridge (308) connecting the two corner blocks (302), (304). Each corner block (302) and (304) includes an inner curved surface (312) and a side arm piece (310). In the embodiment illustrated in Figure 3, the corner block assembly (300) can slide on one side of the mattress, thereby providing a corner block at two of the corners of the mattress. The dimensions of the corner block assembly (300) may vary according to the request, and in one embodiment, the
The corner block assembly (300) may have suitable dimensions to allow the corner block assembly (300) to slide over the head or feet of a mattress. However, in alternative embodiments, the corner block assembly (300) may have suitable dimensions to allow the corner block assembly (300) to slide over the side of a mattress, thus providing a corner block in the head and the mattress feet. The corner block assembly (300) can be made of materials such as those used in the corner block assembly embodiments illustrated in Figures 1 and 2. Similarly, the thickness and height of the wall of the blocks of corner (302) and (304) may be similar to the thickness of the wall and the height of the corner block in views 1 A and 1 B. Optionally, the corner blocks (302) and (304), as well as the arm (308) and the side arms (310) may include a lip, similar to the lip illustrated in Figure 1 D. This optional lip allows the assembly of corner block (300) engages the upper and lower surfaces of the mattress. Once it is hooked against the mattress, the mattress can be assembled as illustrated in Figures 2A-2F and optionally compressed as shown also in the Figures.
Turning to Figure 4, another alternative embodiment of the corner block is illustrated. In particular, Figure 4 shows a corner block assembly (320) having four corner block elements (322), (324), (328) and (330). The blocking elements of
corner are joined by the arms (334), (338), (340) and (342) of the bridge. The corner blocks and bridge arms form a peripheral side wall having an interior amount (332) into which a mattress can be inserted. In this embodiment, the corner block assembly (320) provides four corner blocks that can be secured by means of a single assembly (320) to the mattress. Once it is clamped, the mattress can be assembled as illustrated in Figures 2A to 2D. As described above, the corner block assemblies as well as the side walls (334), (338), (340) and (342) may include lip elements abutting the upper surface and the lower surface of the mattress, and which optionally are hooked by means of friction. The corner block assembly (320) can be made of the materials described above, with reference to the corner block assembly shown in Figures 1 A and B, and the wall thickness and height of the corner block assembly can be be similar to the thickness and height of the corner block, illustrated in Figures 1 A and 1 B. The side walls (334), (338), (340) and (342) can be made of any suitable material and can have cutouts optional (not shown) inside the side wall to control the stiffness of the side walls and reduce the cost of the materials. Note that further modifications can be made to illustrate embodiments without departing from the subject matter of the invention, as defined by the following claims. As an example, the
The corner block of the invention can be made in any suitable dimension of any suitable material. Additionally, the mattresses of the invention can also be of any dimension and employ any suitable mattress frame, whether of springs, lined or not. Moreover, the manufacturing methods can employ any step, including the step of placing at least one corner block of the invention in a corner of a mattress, no matter where in the manufacturing process it is included, and regardless of whether the 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 material / layer or located in an exposed form on an outer surface of a corner of the mattress. mattress. In addition, the corner block of the invention may or may not be fixed to the corner of the mattress or the frame thereof.