US20020166175A1 - Bed mattress and method of manufacturing the same - Google Patents

Bed mattress and method of manufacturing the same Download PDF

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Publication number
US20020166175A1
US20020166175A1 US10/037,503 US3750302A US2002166175A1 US 20020166175 A1 US20020166175 A1 US 20020166175A1 US 3750302 A US3750302 A US 3750302A US 2002166175 A1 US2002166175 A1 US 2002166175A1
Authority
US
United States
Prior art keywords
mattress
spring frame
pad layers
bed
bed mattress
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/037,503
Other languages
English (en)
Inventor
Sung Ho An
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ace Bed Co Ltd
Original Assignee
Ace Bed Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ace Bed Co Ltd filed Critical Ace Bed Co Ltd
Assigned to ACE BED CO., LTD. reassignment ACE BED CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: AN, SUNG HO
Publication of US20020166175A1 publication Critical patent/US20020166175A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • 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
    • A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
    • 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
    • A47C27/045—Attachment of spring inlays to coverings; Use of stiffening sheets, lattices or grids in, on, or under spring inlays
    • A47C27/0456—Use of stiffening sheets, lattices or grids in, on, or under, spring inlays
    • 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
    • A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
    • A47C27/053—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers with only one layer of foamed material
    • 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
    • A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
    • A47C27/056—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers with different layers of foamed material

Definitions

  • the present invention relates to a bed mattress and a method of manufacturing the bed mattress. More particularly, the present invention relates to a bed mattress constructed such that a mattress body, in which a spring frame, cushion members mounted on upper and lower sides of the spring frame and the like are combined with one another, is enclosed with a foam molded layer and a method of manufacturing the same.
  • FIG. 1 shows an example of a conventional bed mattress.
  • the mattress comprises a spring frame 2 having upper and lower supporting rims 1 ′ between which springs 1 made of metal wires are disposed at regular intervals and to which upper and lower ends of the springs 1 are fixedly supported so that the springs may perform a function of absorbing external shock or vibration; pad layers 3 stacked on the top and bottom sides of the spring frame 2 ; a pair of side sheets 4 for surrounding four peripheral sides of the spring frame 2 ; a pair of first seaming sheets 5 for enveloping outer peripheral ends of the pad layers 3 and ends of the side sheets 4 which are also overlapped with the outer peripheral ends of the pad layers 3 ; a pair of cushion members 8 composed of compressed pad layers 6 stacked on respective top and bottom surfaces of the pad layers 3 and sponge sheets 7 which are thicker than the compressed pad layers 6 ; a pair of cover sheets 12 composed of non-woven fabrics 9 stacked on respective top and bottom surfaces of the sponge sheets 7 , sponge sheets 10 and cloths 11 ; and a pair of cover
  • an object of the present invention is to simplify the manufacturing process of a bed mattress, thereby improving the workability and productivity.
  • Another object of the present invention is to provide a bed mattress wherein production costs thereof can be reduced by mass-production.
  • a further object of the present invention is to provide a mattress wherein external appearance thereof is improved by enveloping the body of the mattress with only one cover.
  • a bed mattress including a spring frame having a plurality of springs, pad layers mounted to upper and lower sides of the spring frame and at least one cushion member mounted on either one or both of the upper and lower pad layers, the improvement comprising: a mattress body as a combination of the spring frame, the pad layers and at least one cushion member, and a wall member formed through a foam molding process for enclosing the perimeter of the mattress body therein, and a mattress cover which may have only one stitched portion or line.
  • a bed mattress with a firm structure resiliences of which are not so much affected by the wall member as the thickness thereof is relatively thin in comparison with the whole area of the bed mattress surface.
  • FIG. 1 is a schematic sectional view of a conventional bed mattress.
  • FIG. 2 is a partial schematic sectional view showing major parts of a bed mattress according to an embodiment of the present invention.
  • FIG. 3 is a partial cut-away perspective view of the bed mattress shown in FIG. 2.
  • FIG. 4 is a schematic view of an apparatus for manufacturing the bed mattress according to the present invention.
  • FIG. 5 is a partial perspective view of the bed mattress according to the present invention.
  • a bed mattress according to an embodiment of the present invention comprises a spring frame 50 in which springs 50 ′ made of metal wires are kept at regular intervals between upper and lower spring rims 51 such that the springs 50 ′ can perform a function of absorbing external shock or vibration; pad layers 52 of a felt fabric mounted on the respective top and bottom sides of the spring frame 50 and two cushion members 53 and 53 ′ of a sponge sheet bonded to the surface of the pad layers.
  • the pad layer and the sponge sheet are preferably to have a thickness of 15 to 25 mm and 25 to 35 mm respectively, while it is preferable that a high density sponge sheet is used on one side and a low density one is used on the other side.
  • the spring frame 50 , the pad layers 52 and the cushion member 53 are enveloped by only one mattress cover.
  • a mattress body as a combination of the spring frame, pad layers and cushion member(s) are known in the art.
  • a bed mattress comprising a spring frame 50 ; a wall member 55 which is formed through a foam molding process and coupled with the mattress body as a combination of the spring frame 50 , the pad layers 52 and 52 ′ and the cushion members 53 and 53 ′ by enveloping four peripheral sides of the mattress body therein and a mattress cover having upper and lower cover sheets 54 ′ and 54 ′′ which can hold the structural elements of the mattress therein.
  • an isolating sheet 56 preferably made of a non-woven fabric was fixed to the four peripheral sides of the spring frame 50 .
  • the pad layers 52 having a predetermined thickness were bonded to the top and bottom sides of the spring frame 50 .
  • the cushion member 53 of a low density sponge sheet was bonded to the surface of the upper pad layer 52
  • the cushion member 53 ′ of a high density sponge sheet was bonded to the surface of the lower pad layer 52 ′.
  • the mattress body A in which the pad layers 52 and 52 ′ and the cushion members 53 and 53 ′ were bonded to the top and bottom surfaces of the spring frame 50 was secured into a foaming mold 57 with the top thereof being opened. Since there was a difference in sizes between the mattress body A and the mold 57 , a space B was defined around between the peripheral sides of the mattress body A and the inner walls of the mold 57 .
  • the top of the mold 57 was covered with a cover 58 that could open and close the mold 57 , and the cover was locked and fixed to the mold. Then, a foaming material was injected into the space B defined between the mattress body A and the mold 57 through injection holes 60 formed through the cover 58 and was foamed to allow a wall member 55 to be molded in the space. As the wall member 55 was cured, it was integrally coupled with the mattress body of the spring frame 50 , the pad layers 52 and the cushion members 53 and 53 ′.
  • the isolating sheet 56 surrounding the four peripheral sides of the spring frame 50 prevented the foaming material from being introduced into the space in the spring frame 50 and adhering to the springs 50 ′.
  • the integrally molded structure obtained in such a manner was covered with the upper and lower cover sheets 54 ′ and 54 ′′.
  • the upper cover sheets 54 ′ was put on the top and four peripheral sides of the integrally molded structure, while the bottom side thereof was held by the lower cover sheet 54 ′′.
  • the rim of the upper cover sheet 54 ′ was brought into contact with the rim of the lower cover sheet 54 ′′, the overlapped portions of the two cover sheets was stitched together with a rim 61 .
  • the manufacture of the mattress was completed.
  • the spring frame, felt fabrics, sponge sheets, etc. were utilized as the structural elements of the mattress in the preferred embodiment of the present invention, some of them may not be used or may be replaced by the other materials. Further, it is apparent that the material or the structure of the cover may be modified, while the isolating sheet may not be used if the wall member is foam-molded separately for being assembled with the mattress body thereafter.
  • the perimeter or the four peripheral sides of the combined structure formed by bonding the cushion members such as sponge sheets to the top and bottom sides of the spring frame are surrounded by the foam-molded wall member. Then, the integrally molded structure obtained as such is covered with only the upper and lower cover sheets which in turn are stitched together.
  • the process of manufacturing the bed mattress is greatly simplified, and workability and productivity are enhanced.
  • the portion to be stitched can be minimized to one portion.
  • the manual works needed for making the fine appearance of the stitched portions are reduced and bed mattresses with a better appearance can be obtained.

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
US10/037,503 2001-05-10 2002-01-04 Bed mattress and method of manufacturing the same Abandoned US20020166175A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR2001-13634 2001-05-10
KR2020010013634U KR200242165Y1 (ko) 2001-05-10 2001-05-10 매트리스

Publications (1)

Publication Number Publication Date
US20020166175A1 true US20020166175A1 (en) 2002-11-14

Family

ID=19707017

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/037,503 Abandoned US20020166175A1 (en) 2001-05-10 2002-01-04 Bed mattress and method of manufacturing the same

Country Status (5)

Country Link
US (1) US20020166175A1 (ko)
EP (1) EP1262127A1 (ko)
JP (1) JP2002336086A (ko)
KR (1) KR200242165Y1 (ko)
CN (1) CN1385130A (ko)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080201859A1 (en) * 2007-02-28 2008-08-28 L&P Property Management Company Method and System of Manufacturing A Mattress and Components Thereof
US20100269743A1 (en) * 2009-04-28 2010-10-28 L & P Property Management Company Methods for manufacturing a self-forming mattress cover
US20110131724A1 (en) * 2009-04-28 2011-06-09 L & P Property Management Company Methods for manufacturing a self-forming mattress cover
CN114451743A (zh) * 2022-03-16 2022-05-10 安徽情暖家具有限公司 一种高弹性床垫用加强弹簧框架成型方法
US20220395105A1 (en) * 2021-06-09 2022-12-15 Dreamwell, Ltd. Hybrid side rail assemblies and mattresses including the same

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7185379B2 (en) * 2003-03-28 2007-03-06 Sealy Technology Llc Foam encased innerspring with internal foam components (triple case)
KR100743885B1 (ko) * 2005-09-01 2007-07-30 주식회사 에이스침대 매트리스용 스프링구조체와 쿠션재의 고정장치 및 고정방법
US7398570B2 (en) * 2006-10-02 2008-07-15 Louisville Bedding Company Mattress cover with fit enhancing composite end panels
KR200450375Y1 (ko) 2008-07-08 2010-09-29 신주호 골조와 쿠션재가 일체로 형성된 소파
JP6614613B2 (ja) * 2016-04-28 2019-12-04 株式会社弘樹 敷きパッド
AU2017351032B2 (en) * 2016-10-27 2023-09-21 Eugene Alletto Jr. Mattress assembly and method
CN108402781A (zh) * 2018-02-06 2018-08-17 佛山市南海金振阳直爽五金制品有限公司 床垫的制造工艺
KR102146235B1 (ko) * 2019-05-07 2020-08-20 주식회사 에이스침대 다양한 느낌의 쿠션력 및 완충력을 제공하는 침대매트리스
JP7282724B2 (ja) * 2020-09-16 2023-05-29 フランスベッド株式会社 マットレスおよびその製造方法

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Publication number Priority date Publication date Assignee Title
FR1601166A (en) * 1968-03-06 1970-08-10 Clothing mattress carcass with foam
GB1328222A (en) * 1970-08-10 1973-08-30 Mirabed Ag Mattresses
JPS5228067B1 (ko) * 1970-09-10 1977-07-23
JPS4739611Y1 (ko) * 1970-11-28 1972-11-30
JPS4739612Y1 (ko) * 1970-11-28 1972-11-30
JPS49120772A (ko) * 1973-03-24 1974-11-19
FR2229194A5 (en) * 1973-05-09 1974-12-06 Plasse Robert Method of forming walls of foam covered mattresses - edges are completed by foam filling tissue sealed cavity
JPS5026652A (ko) * 1973-07-10 1975-03-19
JPS5336164Y2 (ko) * 1974-10-12 1978-09-04
JPS591559Y2 (ja) * 1977-05-27 1984-01-17 アイシン精機株式会社 スプリングマツトレス
JPS5429050Y2 (ko) * 1977-06-15 1979-09-17
JPS5545818Y2 (ko) * 1977-08-22 1980-10-27
FR2563421A1 (fr) * 1984-04-27 1985-10-31 Jydor Sa Matelas Procede de fabrication d'articles a rembourrage elastique, tels que les matelas et articles ainsi realises
JP3008437U (ja) * 1994-08-31 1995-03-14 日本ベッド製造株式会社 スプリングマットレス
JPH11244098A (ja) * 1998-02-27 1999-09-14 Nippon Bed Seizo Kk ベッド用マットレス
US20020122914A1 (en) 1999-07-02 2002-09-05 Moshe Rock Double-face velour fabric articles having improved dynamic insulation performance

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080201859A1 (en) * 2007-02-28 2008-08-28 L&P Property Management Company Method and System of Manufacturing A Mattress and Components Thereof
US7644671B2 (en) * 2007-02-28 2010-01-12 L&P Property Management Company Method and system of manufacturing a mattress and components thereof
US20100089298A1 (en) * 2007-02-28 2010-04-15 L&P Property Management Company Method and System of Manufacturing A Mattress and Components Thereof
US20100269743A1 (en) * 2009-04-28 2010-10-28 L & P Property Management Company Methods for manufacturing a self-forming mattress cover
US20110131724A1 (en) * 2009-04-28 2011-06-09 L & P Property Management Company Methods for manufacturing a self-forming mattress cover
US8074313B2 (en) * 2009-04-28 2011-12-13 L & P Property Managment Company Methods for manufacturing a self-forming mattress cover
US8458837B2 (en) 2009-04-28 2013-06-11 L & P Property Management Company Methods for manufacturing a self-forming mattress cover
US20220395105A1 (en) * 2021-06-09 2022-12-15 Dreamwell, Ltd. Hybrid side rail assemblies and mattresses including the same
US11806978B2 (en) * 2021-06-09 2023-11-07 Dreamwell, Ltd. Hybrid side rail assemblies and mattresses including the same
CN114451743A (zh) * 2022-03-16 2022-05-10 安徽情暖家具有限公司 一种高弹性床垫用加强弹簧框架成型方法

Also Published As

Publication number Publication date
CN1385130A (zh) 2002-12-18
EP1262127A1 (en) 2002-12-04
KR200242165Y1 (ko) 2001-10-15
JP2002336086A (ja) 2002-11-26

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Legal Events

Date Code Title Description
AS Assignment

Owner name: ACE BED CO., LTD., KOREA, REPUBLIC OF

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:AN, SUNG HO;REEL/FRAME:012448/0154

Effective date: 20011203

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION