US20080078026A1

US20080078026A1 - Integrated Mattress and Foundation

Info

Publication number: US20080078026A1
Application number: US11/536,397
Authority: US
Inventors: Lawrence M. Thomas
Original assignee: Grand Packaging LLC
Current assignee: Grand Packaging LLC
Priority date: 2006-09-28
Filing date: 2006-09-28
Publication date: 2008-04-03

Abstract

An integrated mattress and foundation according to the invention comprises a frame and resilient webbing support that forms a foundation and a spring-less padding element and a casing that forms a mattress. The casing covers that padding element and is mounted to the frame to integrate the mattress and the foundation. The integrated mattress and foundation preferably has a low profile.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
This invention relates generally to mattress, and more specifically to a mattress that is combined with a foundation.
2. Description of the Related Art
Conventional mattresses and foundations for beds are provided separately. Mattresses usually consist of a quilted case, usually of heavy cloth, that contains padding, foam rubber, and a framework of springs, which is referred to as an inner spring. A common foundation is a box spring, usually consisting of a cloth covered frame containing rows of coil springs.
While the separate mattress and foundation is convenient in the home environment, in certain environments, a separate mattress and foundation are not practical because of space and weight limitations. For example, in the recreational vehicle (RV) industry, it has been the practice to provide slimmer foam-only mattresses without an inner spring and which is built up on a wooden sheet, such a plywood or particle board, to form a single integrated unit of a mattress and foundation. The foam functions as the mattress and the wooden sheet as the foundation.
While functional as a bed, this integrated structure does not have the comfort of a traditional mattress with inner spring being supported by a box spring. Another disadvantage is up to 50% of mattress life is lost when putting a mattress on a hard surface like plywood.
A mattress is needed that can offer the comfort of a traditional mattress and box spring in a compact and lightweight form.

SUMMARY OF THE INVENTION

An integrated mattress and foundation according to the invention comprises a frame defining an interior area, a resilient webbing support attached to the frame and spanning at least a portion of the interior area, a spring-less padding element overlying the resilient webbing support and a casing covering the padding element and mounted to the frame, wherein the frame and resilient webbing form a foundation and the casing and spring-less padding element form a mattress, with the casing integrating the foundation and the mattress.
The frame can be rectangular and can comprise a first pair of spaced sides joined by a second pair of spaced sides, and the resilient webbing support is attached to the sides. The first pair of spaced sides of the frame can be connected to the second pair of spaced sides at their respective ends. The sides of the frame can comprise wood and can be connected to one another by mechanical fasteners.
The resilient webbing support can comprise a sheet. The resilient webbing support can comprise a plurality of strips. The strips can form a matrix of spaced longitudinal strips that are crossed by spaced traverse strips. The frame can be rectangular and comprise a first pair of spaced sides joined by a second pair of spaced sides, with the longitudinal strips attached between the first pair of spaced sides and the traverse strips attached between the second pair of spaced sides.
The casing can completely encloses the padding element relative to the frame. The frame can define a periphery and the casing can be affixed about the periphery. The frame can comprise a bottom surface and a sheet of ticking can cover the bottom surface.
The spring-less padding element can comprise multiple layers. The multiple layers can comprise an upper layer that is less dense than a lower layer. The multiple layers can comprise an upper layer that is less firm than a lower layer.
The spring-less padding can be non-inflatable. The spring-less padding can comprise foam. The casing can comprise a quilted material.
The integrated mattress and foundation can have a low profile. The thickness of the integrated mattress and foundation can equal 8 inches or less. The spring-less padding element can have a thickness ranging from 2 to 7 inches.
According to another aspect of the invention, an integrated mattress and foundation comprises a rectangular frame comprising a first pair of spaced sides joined by a second pair of spaced sides and defining an interior area, a resilient webbing support comprising a plurality of spaced longitudinal strips that are crossed by a plurality of spaced traverse strips, with the strips attached to the frame and spanning at least a portion of the interior area, a foam padding element overlying the resilient webbing support, and a casing covering the padding element and mounted to the frame, wherein the frame and resilient webbing form a foundation and the casing and spring-less padding element form a mattress, with the casing integrating the foundation and the mattress.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a broken perspective view of an integrated mattress and foundation according to the present invention.

FIG. 2 is a schematic view of the integrated mattress and foundation from FIG. 1 in a recreational vehicle (RV).

FIG. 3 is an exploded view of the integrated mattress and foundation from FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the FIG. 1, an integrated mattress and foundation according to the invention is illustrated. The integrated mattress and foundation 10 generally comprises a mattress component 12 and a resilient foundation component 14 that are unitarily constructed. The mattress component 12 provides a comfortable surface on which a user can rest. The resilient foundation component 14 resiliently supports the mattress component to further enhance the comfort to the user. The integrated mattress and foundation 10 provides almost the same level of comfort as the traditional mattress with inner spring supported by a box spring without the extra weight and size of the inner spring and box spring.
The integrated mattress and foundation 10 has a low profile and reduced weight as compared to a traditional mattress and box springs that makes it especially suitable for such environments as the RV environment, although the application of the present invention is not so limited. As used herein, the term “low profile”, in the context of describing mattress and foundation structures means that the integrated mattress and foundation 10 has a thickness T that is less than the combined thickness of a separate mattress and foundation. The thickness T of the integrated mattress and foundation 10 can vary, but should be appropriate for low profile applications. Preferably, the low profile integrated mattress and foundation 10 has a thickness T that is equal to or less than 8 inches.
In an RV environment, the 8 inch limitation is important because the structure on which the integrated mattress and foundation 10 is placed normally performs the dual function of a bed frame and a storage device, with a door being provided and the mattress resting on the door. Referring to FIG. 2, the integrated mattress and foundation 10 is shown within an RV. The integrated mattress and foundation 10 is placed on a hinged platform or door 52 that covers a storage space 54. The user normally lifts the door 52, which typically pivots about a hinge, without removing the integrated mattress and foundation 10. The height of the integrated mattress and foundation 10 limits the amount that the door 52 can be pivoted before contacting some other structure of the RV 50, which is directly related to the degree of accessibility to the storage space 54 in the structure. The integrated mattress and foundation 10 may also be placed on a bunk 56, and thus the integrated mattress and foundation 10 is also subject to height restrictions due to the close proximity of the ceiling of the RV.
Referring to FIGS. 1 and 3, more specifically, the integrated mattress and foundation 10 comprises a frame 16, a resilient webbing support 18, a spring-less padding element 20, and a casing 22. The webbing support 18 is attached to and spans the frame 16. The padding element 20 overlies or rests directly on the webbing support 18. The casing 22 covers the padding element 20 and is mounted to the frame. The padding element 20 and the casing 22 form the mattress component 12 and the frame 16 and the webbing support form the foundation, with the casing 22 uniting or integrating the mattress component 12 and the foundation component 14.
The frame 16 defines an interior area 24 and the webbing support 18 spans the interior area 24. The frame 16 can be configured to be fit onto a bedstead or other support structures, or may be placed on a floor surface. As illustrated, the frame 16 comprises four slats 26 that are attached at their respective ends to form a generally rectangular structure. The frame 16 can be quickly constructed during assembly by using mechanical fasteners 28 such as gang-nail or truss plates. The frame slats 26 can be constructed of wood, metal, or plastic, however, wood is preferred.
The webbing support 18 is illustrated as comprising a plurality of spaced longitudinal webbing strips 30 that are crossed by spaced traverse webbing strips 32. The webbing strips 30, 32 are preferably equidistantly spaced and cross one another at generally right angles. The webbing support 18 can have a basket-weave construction, with the webbing strips 30, 32 forming a woven matrix for supporting the padding element 20. The webbing strips 30, 32 can be attached to the frame 16 using glue, staples, nails, or any other suitable attaching means. Preferably, the webbing strips 30, 32 are attached to the frame sides 26 using staples 34 to allow for a quick, simplified assembly. The webbing support 18 can have a customized tension based on a user's specifications. The tension of the webbing strips 30, 32 can be adjusted by stretching the strips 30, 32 when attaching them to the frame 16. In an alternate embodiment (not shown) the webbing support 18 can comprise a sheet of webbing material attached to the four frame sides 26. An example of suitable resilient webbing strips 30, 32 and resilient webbing sheets are Ultra-Flex® strap webbing and sheet webbing, and is commercially available from Ultraflex Corporation (High Point, N.C.).
The spring-less padding element 20 comprises one or more layers of material that will yield or compress under a weight placed on top of the integrated mattress and foundation 10 and thus provides a comfortable resting place for a user. The padding element 20 is spring-less, in that is does not comprise an innerspring. The padding element 20 can be batting made from cotton, wool, or synthetic fibers; foam; or other suitable material. The padding element 20, including the type of material, material properties, number of layers, layer properties, and the thickness of the padding element, T_p, can be customized based on a user's specifications. In the illustrated embodiment, the padding element 20 comprises two layers of foam, 36, 38 having different material properties. The first or lower layer 36 can be more dense and/or more firm than the upper layer 38. Types of suitable foam include, but are not limited to polyurethane, latex, viscoelastic, and rubber foams. The padding element 20 does not contain any springs and preferably is non-inflatable. The thickness T_pof the padding element 20 can vary according to dimensions of the other components of the integrated mattress and foundation 10, but in either case, the thickness T_pshould be selected to provide an overall thickness T that is appropriate for low profile applications. The thickness T_pof the padding element 20 preferably ranges from 2 to 7 inches.
The casing 22 covers the top surface of the padding element 20 and preferably also covers the peripheral sides of the padding element 20 and frame 16. The casing 22 can alternately completely enclose the padding element 20 and not cover the frame 16. The casing 22 can comprise a quilted material. A sheet of ticking 40 can cover the bottom side of the frame 16 and span at least a portion of the interior area 24. The casing 22 and ticking 40 can be attached to the frame 16 using glue, staples, nails, or any other suitable attaching means. The ticking 40 can also be attached or sewn to the casing 22.
The integrated mattress and foundation 10 is suited for incorporation into static structures, such as houses, apartments, condominiums, hotels, gyms, and other buildings, and ideally suited for mobile structures, such as recreational vehicles (RVs), trailers, mobile homes, cruise ships, and houseboats. Due to its low profile and light weight structure, the integrated mattress and foundation 10 is particularity suitable for use in the RV or marine market where size and weight are a concern. Mattress life is preserved by using a resilient webbing support 18 as a major portion of the foundation component 14. The tension of the resilient webbing support 18 and the firmness of the padding element 20 can be customized to a user's specifications. By employing a webbing support 18 and a spring-less padding element 20, the overall height of the integrated mattress and foundation 10 is kept low. Furthermore, the integrated mattress and foundation 10 has a simplified construction and can be quickly assembled.
While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.

Claims

1. An integrated mattress and foundation comprising:

a frame defining an interior area;

a resilient webbing support attached to the frame and spanning at least a portion of the interior area;

a spring-less padding element overlying the resilient webbing support; and

a casing covering the padding element and mounted to the frame, wherein the frame and resilient webbing form a foundation and the casing and spring-less padding element form a mattress, with the casing integrating the foundation and the mattress.

2. The integrated mattress and foundation according to claim 1 wherein the frame is rectangular and comprises a first pair of spaced sides, a second pair of spaced sides extending between the first pair of spaced sides, and the resilient webbing support is attached to at least two of the sides.

3. The integrated mattress and foundation according to claim 2 wherein the first pair of spaced sides of the frame are connected to the second pair of spaced sides at their respective ends.

4. The integrated mattress and foundation according to claim 3 wherein the sides of the frame comprise wood and are connected to one another by mechanical fasteners.

5. The integrated mattress and foundation according to claim 1 wherein the resilient webbing support comprises a plurality of strips.

6. The integrated mattress and foundation according to claim 5 wherein the strips form a matrix of spaced longitudinal strips that are crossed by spaced traverse strips.

7. The integrated mattress and foundation according to claim 6 wherein the frame is rectangular and comprises a first pair of spaced sides joined by a second pair of spaced sides, with the longitudinal strips attached between the first pair of spaced sides and the traverse strips attached between the second pair of spaced sides.

8. The integrated mattress and foundation according to claim 7 wherein the casing completely encloses the spring-less padding element relative to the frame.

9. The integrated mattress and foundation according to claim 1 wherein the casing completely encloses the spring-less padding element relative to the frame.

10. The integrated mattress and foundation according to claim 9 wherein the frame defines a periphery and the casing is affixed about the periphery.

11. The integrated mattress and foundation according to claim 1 wherein the spring-less padding element comprises multiple layers

12. The integrated mattress and foundation according to claim 11 wherein the multiple layers vary in firmness.

13. The integrated mattress and foundation according to claim 1 wherein the spring-less padding is non-inflatable.

14. The integrated mattress and foundation according to claim 13 wherein the spring-less padding comprises foam.

15. The integrated mattress and foundation according to claim 1 wherein the casing comprises a quilted material.

16. The integrated mattress and foundation according to claim 15 wherein the frame comprises a bottom surface and a sheet of ticking covering the bottom surface.

17. The integrated mattress and foundation according to claim 1 wherein the integrated mattress and foundation has a low profile.

18. The integrated mattress and foundation according to claim 17 wherein the thickness of the integrated mattress and foundation equals 8 inches or less.

19. The integrated mattress and foundation according to claim 18 wherein the spring-less padding element has a thickness ranging from 2 to 7 inches.

20. An integrated mattress and foundation comprising:

a rectangular frame comprising a first pair of spaced sides joined by a second pair of spaced sides and defining an interior area;

a resilient webbing support comprising a plurality of spaced longitudinal strips that are crossed by a plurality of spaced traverse strips, with the strips attached to the frame and spanning at least a portion of the interior area;

a foam padding element overlying the resilient webbing support; and