US2301596A - Mattress or the like - Google Patents

Description

Nov. 1o, 1942. H E, WELLS 2,301,596

MATTRESS ORY THE LIKE Filed DeC. 14, 1959 mattress or related padded Patented Nov. 10, 1942 2,301,596 MAITRESS ORTHE LIKE nai-ry E. wens, Detroit, Mich.,

Warren-Wells Co., ot Michigan o to" assign r Detroit, Mich., a corporation Application December 14, 1939', sensi-N0. 309,181'

1 claim.

period of time withoutbecoming permanently packed.

While for the purpose tion herein reference the use of the with mattre^ses, it will be understood that the present invention is applicable to any padded article in which the padding is made up of cotton or other similarly loosely associated bers including, for instance, pads or padding of various kinds and descriptions, upholstery units for mattresses, automobile seat cushions or the like, and in its broader use the term mattress is to be considered, both in the specication and claims hereof, as including such other articles.

Mattresses, whether they be of the so-called inner spring type or of the solid tionally constructed, are made clude cotton bers usually in the form-of bats. These cotton bers become compacted or compressed under the application of a constant weight as, for instance, the Weight oi a person resting upon the same, with the result that in time and usually altogether too quickly the mattress loses its softness and becomes permanently hard and uncomfortable to the average person.

Objects of the present invention include the provision of a mattress or the like including a mass of cotton or other bers which mass is so constructed and arranged as to largely eliminate permanent compression or packing of the same; the provision of a mattress or padding for the same or related objects including a mass of fibrous material with readily compressible means cooperating therewith materially more resistive to permanent packing than the bers themselves, and operating to relieve the bers of a packing e'ect thereon upon relieving of the weight tending to cause such packing; the provision of a element including a mass of bers in which readily compressible means more resistant to packing than the bers is interspersed uniformly or otherwise through the mass o1' bers whereby to be subjected to compression simultaneously with compression of the bers, but acting after the` compressive force has been relieved to return to its normal size and, therefore, aid in returning the mass of fibers to its original size and condition;

will be made primarily to of simplicity of descrip-v presentinvention in connection visionvof a method of type as convenup from or inloosening fof the of a mattress or related padded lelerrient includ'- ing a mass of bers in which readily compressible means particularly resistant to becoming set un-` der deformation is associated with the bers in a. predetermined manner whereby to effect a stress thereon tending. to cause the bers" to becomel packed; `the provision of Va, mattress or related paddedele'ment includinga mass of loosely associated Vfibers inU vWinch particles of rubber, and preferably sponge rubber, are cooperatively associated with the brous mass -in such a manner. to aid the lbrousniassA in resisting a packing effect upon it upon being relieved of a packing force; and the provision ofl a mattress or related padded tively loose action or other bers having a plurality of relatively small particles'of sponge rubber uniformly or otherwise :dispersed through the massof bers.

vOther objects of the invention include the prorelated padded element,v including a 4 mass of lfibrous material whereby to condition the mass of fibrous material against packing. inservice; andthe method of manufacturinga mattrerqs or other related padded article including a mass of brous material so as to provideA such mass of fibrous material with relatively small particles of sponge rubber arrangedl therein in a predetermined manner. l

'Ihe above being among the objects of the present invention, the same consistsin certain novel features of construction, combination of parts, and steps of operation to be hereinafter described with reference to the accompanying drawing, and

' then claimed, having the above and other objects in view.

In the accompanying drawing which illustrates suitable embodiments of the present invention and in` which like numerals refer to like parts throughout the several different views,

Fig. `1 is a perspective view of a mattress constructed in laccordance with. the present invention;

Fig. 2 is an enlarged fragmentarysectional view, taken on the line 2 2 `of Fig. 1; the same being. a partial section through the mattress shOWninFig. 1;

Fig. 3 is an enlarged fragment of a portion o1' the padding employed in the construction shown in Fig. 2; c

Fig. 4 is a more or less diagrammatic view illustrating the manner in which the padding the provision illustrated in Fig. 3 may be manufactured;

bers upon-relieving of any element v'incluciinijg a mass of relamaking a mattress or other Fig. 5 is a perspective view of a different form of mattress constructed in accordance with the present invention;

Fig. 6 is an enlarged fragmentary sectional view taken transversely through the mattress shown in Fig. 5 as on the line 6-6 thereof;

Fig. 7 is an enlarged fragment of the view showninFlg. 6; Y

Figs. 8 and 9 are views similar to Fig. 7, but illustrating modified forms of construction;

Eig. 10 is a transverse sectional view taken longitudinally through a mattress of the same general type as shown in Fig. 5, but constructed in a modified manner and illustrating its action in response to the eiects of the weight of a person lying upon the same.

The public generally demands that a padded article be relatively soft to the touch. The padding of such article is generally constructed from relatively loose cotton or other iibers, but cotton is almost universally used because of its relative cheapness and unlimited supply. While such cotton, usually in the form of a bat, :may be originally arranged in the padding so as to'impart to it the desired softness to touch, its characteristics are such that under` a prolonged compressive stress, as under the weight of a person, it is compacted or compressed and gradually takes a set in its compressed state, which destroys its softness to touch and therefore its desirability. This is true even though suich padding is associated with an upholstery or other spring units designed to enhance the yieldability of the structure as a whole. for in cases where a mattress, automobile seat cushion, or other upholstery unit, or the like, including such spring units, is designed to support the weight of a person, the springs must necessarily be of such strength and therefore rigidity as to form a sufcient support for the weight of a person, and such rigidity is too great to particularly enhance the softness of the structure to the touch. The padding in such cases is employed to give the necessary softness of touch to the structure and, accordingly, in constructions as heretofore produced, is subject to the same disadvantageous effects of permanent packing or set as in the structures formed solidly from such libres.

It is the principal object of the present invention to so construct the padding of the type described as to substantially prevent any permanent packing or set of the same from occurring, thereby enabling such padding to be provided which will substantially retain its original softness to the touch throughout its life. This is accomplished by enclosing within the mass of fibers of the packing, interspersing throughout the mass of bers of the packing, or otherwise distributing or arranging in the mass of fibers a mass of material preferably having a degree of yieldability approaching that of the mass 0f fibers as originally presented, but of a character such that it is particularly resistant to 'becoming set even under a prolonged compressive stress. Being included in the mass of fibrous.` material and therefore being subject -to compression simultaneously with it, it will be appreciated that upon relieving ol' the compressive stress. it will return to its originally uncompressed condition andindoingso willservetoloosenup'theflbers of the mass and aid them to return to their originally uncompressed condition or to a condition closely approaching the same.

Preferably, such readily compressible material resistant to permanent deformation or set comprises a mass of relatively small particles of soft rubber and, in the broader aspects of the invention, uniformly or otherwise dispersed through the mass of fibrous material. Preferably, such mass of relatively small particles is composed of what is commercially known as sponge rubber (that is a rubber material having a multitude of small gas bubbles entrapped therein), preferably in a macerated or shredded condition exposing on the various surfaces thereof the interstioes in the sponge rubber at the boundary layer thereof, and which therefore imbues such particles witha particular ailinity to the various individual iibers of the mass, which thereby act to hold and retain such particles in a predetermined or otherwise distributed condition in the mass of iibers. It will be appreciated that when a mass of cotton or other bers having a mass of relatively small particles of sponge rubber interspersed therethrough is employedas a padding, such padding will have a softness of touch closely approaching the original softness of touch of a padding made up of a loosely associated mass of the fibers alone. It will have this difference, however, that when any force which has compressed the padding is relieved, the particles of sponge rubber will instantly tend to expand to their originally free condition and in doing so` will act to separate the various bers of the mass and return lt t0 its originally loose condition. Thus, a padding may be constructed in accordance with the present invention that will have the characteristic of having a softness of touch that will be retained in substantially unvaried condition throughout its life under ordinary usage.

In order to more clearly understand the present invention, reference may be had to the accompanying drawing and particularly to the construction illustrated in Figs. 1 to 4 thereof. The mattress, indicated generally at I I in Fig. l, is of conventional appearance and, except for the particular construction of the padding hereinafter more clearly described, may be of any suitable or conventional construction. For instance, referring to Fig. 2, it will be noted that the mattress II is of the so-called inner-spring type, in which a spring assembly, indicated generally at I2, is positioned interiorly of the mattress and forms a core upon which the padding or covering elements are built up. A padding element, indicatedv generally at I4, overlies both the top and bottom surfaces of the spring unit I2 and the marginal edge portions of such padding are preferably turned around the marginal edge portions of the spring unit I2, as indicated at I6, and suitably secured thereto. A covering I8 envelopes the whole and is preferably provided with welts or beads 2li around the outer margins of the top and bottom panels of the covering. This covering is also preferably provided with openings such as 22 in the side portions thereof between the layers of padding Il so as to permit relatively free circulation of air through the central portion of the mattress not only to permit any moisture that may be absorbed by the padding to be readily dispersed, but also to better maintain the mattress inV a sanitary condition by permitting a more or less constant `airing of the same.

In the particular construction illustrated in Figs. 1 to 4, inclusive, it is the particular construction of the padding I4 with which the present invention is concerned. Referring now to Fig. 3 it will be noted that the padding Il comprises two main layers 24 and 2i, respectively,

the layer 24 being positioned outwardly of the layer 26, but in actual practice it will be understood that both layers 24 and 26 combine to form a single layer I4. In the construction illustrated in Fig. 3 the outer layer 24, which may be made of any suitable loosely associated fibers but will ordinarily be formed of cotton in the form of bats, is entirely free of any foreign inclusion. The layer 26, however, which may be and usually will be formed of the same kind of fibers as the layer 24, has interspersed therethroughl a plurality of relatively small particles 28 of a material that is readily yieldable but particularly resistant to taking a permanent set under prolonged compressive stresses. While in the broader aspect of the present invention these particles 28` may be formed of any suitable material having a resiliency preferably approaching that of a cotton bat in which the fibers are in a relatively free state, and materially more resistant to becoming set under prolonged compressive stresses than the cotton bat itself, such particles are preferably formed from soft rubber or compounds thereof, lbut in accordance with a more limited phase of the present invention these particles are formed from sponge rubber.

In the broader aspects of the invention these particles 28 may be interspersed throughout the mass of fibers in the layer 26 uniformly or otherwise and by any desired method. However, it will ordinarily be found most convenient to introduce the particles 28 into the layer 26 by interposing such particles between the various layers of a cotton bat as illustrated more or less diagrammatically in Fig. 4. This introduction of the particles 28 between the various layers of a bat may be accomplished after the bat has been formed and even cut to size by separating the `various layers thereof or combinations of layers thereof and simply sprinkling or otherwise distributing the particles 28 over the surfacecf such layer or combination of layers. On the other hand these particles 28 may be introduced into the bat during the process of building it up out of relatively thin individual layers in accordance with conventional practice in a garnetting machine.

In the construction illustrated in Figs. lfto 4,

l from the ability of the inclusive, the particles 28 are not provided in the v layer 24for the reason that luider some conditions the particles 28 may create a certain amount of unevenness to the surface of the bat containing them and, accordingly, the layer 24 is provided for the exterior surface of the padding I4 so as to eliminate the possibility of such unevenness and to enhance the appearance of the mattress. The layer 26 of the padding I4, however, is relied upon for maintaining the softness of the padding I4 to the touch. l

As previously mentioned, the particles 28 are preferably formed from sponge rubberrand preferably formed by mascerating or otherwise separating alarger piece of sponge rubber into relatively small particles. By following out this procedure, it Will be appreciated that substantially all of the exposed surfaces of such particles present a multitude of relatively small openings or lnterstices therein, formed by the air bubbles trapped within the rubber during its process of manufacture. vItfhas been found that when a particle of sponge rubber of the character described is introduced into a loose mass ,of cotton or similar fibers, the ends of a great number of such fibers find their way into a great many of the small openings in the surface of the particles struction is illustrated.

throughout the mass.

and tend to hold themselves therein. Thus such particles have a peculiar affinity to the fibers which, without `the aid of any other means, serve to adhere one to the other and thus serve to maintain the position of the individual particles Thus once the particles are Vdistributed through the mass of fibers they invariably retain the relative position in the mass without material displacement.

It will be understood that when a person rests upon the mattress illustrated in Figs. 1 to 4, inclusive, the padding layer I4 is compressed by the weight of such person over the area through which the weight of the person is transmitted to the mattress to a degree depending upon the distribution of the weight of such person. The layers 24 and 26 are both compressed under the application of such weight and both the particles 28 and the mass of fibers in the layer 26 are compressed. As soon as such person arises from the mattress and the mattress is therefore relieved of the persons weight, the fibers of the layers 24 and 26 will, of course, tend to return to their origina-l condition, as will be particles 28. However, because 'of the inherent characteristics of such fibers and particularly cotton fibers as conventionally employed in such instances, constant recurrence or prolonged application of such compressive stresses tends to cause a permanent set in the condition of the fibers which, unless corrected, would finally cause the padding to be permanently packed or set and thus rendered less soft to the touch. However, the particles 28 being materially more resistant to taking a permanent set under such conditions, tend to immediately return to their original free condition and in doing so separates the various fibers and layers of fibers in the layer `26 and thus bring the various fibers thereof to their original condition of looseness, This action on the part of the particles 28 in returning the fibers to their original condition of looseness obviously eliminates the possibility of the fibers taking a permanent set and maintains such mass of bers substantially in its original loose state and thereby prevents a loss of the softness to touch thereof. It may be noted that the inclusion of the rubber particles in the manner described does not detract padding to allow air to seep or circulate through it, and consequently its characteristics in this respect are not impaired.

In Figs. 5, 6 and v'7, amodified form of con- The mattress indicated generally at 30 in these figures is also conventional in appearance and, as in the previously described case, except for the construction of the padding material itself, is built in a conventional manner. For instance, as best illustrated in Figs. 6 and 7, an external covering indi-cated at 32 is provided and preferably with beads orwelts 34 at the margin-al edges thereof corresponding to the beads of welts 20 previously described. In this case, however, no inner spring is used. Instead,

`transversely extending wallsor webs 36 of a height equal to the desired thickness of the mattress, are interposed between and connected to the top and bottom panels of the cover at more or less regular intervals over the length of the mattress and preferably extend the full width thereof. In each orf the pockets thus formed between the top and bottom. panels of the covering 32 and between each adjacent pair of walls 36, and between the end walls 36 and the corresponding end walls of the covering, a mass of padding indicated generally at 88 is insex'ted. While such mass may be in the form of simple superposed layers of cotton or other brous material in bat or other form, ormay be formed by rolling up a bat of such material, the latter is shown by way v of illustration and accordingly, each mass 38 is made up by taking a suitable length and width of cotton bat and simply rolling it up. However, in accordance with the present invention the 'bats from vwhich the rolls 38 are formed are interspersed with small particles I8 of material corresponding in all respects to the particles 28 jpreviously described, and which may be inserted in or distributed through the bat'in exactly the same manner as previously described.

It will be appreciated that the type of mattress illustrated in Figs. 5, 6 and 'l is considerably more susceptible to losing its overall softness or resiliency over a protracted period of use inasmuch as the inner springs employed in the first described construction will retain their resiliency in substantially unaltered condition throughoutits life regardless of the fact that the padding I4 may lose its softness to touch. Accordingly, it is much more important in connection with a mattress or other padding of the general type lllustrated in Figs. 5, 6 and 7 that some means be provided to prevent the fibrous material from taking a permanent set under compression and it will also be appreciated that the means provided in accordance with the present invention will effectively accomplish this purpose and that Whenever a compressive force on the mattress illustrated in Figs. 5, 6 and 7 is relieved, the particles 48 in tending to instantly expand and reassume their originally free condition, will tend to loosen up and separate the various fibers in the rolls 38 and thus return the bers. to their originally loose condition.

It is not essential that the particles 28 or I0, as the case may be, to be uniformly dispersed through their corresponding layer or mass of bers as illustrated in Figs. 1 to '1, inclusive, as it-will ber apparent that under some conditions a variation in the concentration of such particles may be desirable and may readily be provided. For instance, referring to Fig. 8 which illustrates a construction of the same general character as illustrated in Figs. 5, 6 and 7, and in which equivalent parts are illustrated by the same numerals except that such numerals bear a prime mark, the particles IB' are provided in a condition of greater concentrationfin the central portion of the roll 38' than in the outer portion thereof, the concentration gradually becoming less from the center outwardly. This may be accomplished by application of the particles 48' to one end portion only of the bat before it is rolled up into roll form and in such case it will be appreciated that a condition similar to that provided in the padding layer I4 in the construction illustrated in Figs. 1 to 4, inclusive, will result.

On the other hand, and as illustrated in Fig. 9 which also shows a construction similar to that shown in Fig. 'Z and in which, accordingly, equivaient parts are indicated by the same numerals except that such numerals bear a double prime mark, no particular attempt is made to intersperse the particles I8" throughout the bers of the roll. Instead, such particles are concentrated in the central portion of the roll 38" substantially to the exclusion of the remaining portion ofthe roll 38". This type of construction. may be readily obtained by simply applying the entire a,so1,59o

roll 88" to that end of the bat at which the rolling is initiated in rolling `up the bat to form the roll Il. Itwlll also be appreciated that in the construction illustrated in Fig. 9 the relative size of the particles Il" does not bear the same importance as in the previously described constructions but in this case may be substantially larger.

In accordance with a further phase of the present invention, the type of construction illustrated generally inFlgs. 5 to 9, inclusive, may be employed to obtain still other characteristics in a mattress or other padding of the type under discussion. For instance, referring to Fig. 10, a

mattress of the general type illustrated in the preceding gures is shown in longitudinal section and with a person resting upon the same. The individual rolls of such mattress corresponding with the rolls 38 and/or 48 previously described are illustrated at 58 to 59, inclusive. 'Ihe mattress-which is indicated generally at 60 in Fig. 10 is shown as resting upon a conventional spring unit 62 in a conventional manner. Now the weight of a persons body is generally concentrated to a greater extent in the area of his hips and to a lesser extent in the area of the shoulders and, accordingly, the rolls 54 and 55 which re- ,ceive the hips are compressed to the greatest extent by the weight of the person, the rolls 51 and 58 supporting the shoulders to a lesser extent, and the remaining rolls a still lesser extent. The brous materials composing the rolls 54 and 55 will thus be subjected to a greater tendency toward taking a permanent set than the rest of prising a spring unit and padding overlying thel mass of rubber particles to be included in the Y the rolls, and the material of the rolls 51 and 58 than the remaining rolls. Accordingly, in order to render-'such mattress 68 more or less equally responsive throughout its length in its tendency to mset any permanent packing effects thereon, the concentration of the rubber particles in the rolls 5I and 55 is illustrated as being greater than the concentration of such particles in the rolls 51 and 58, and the concentration of these particles in the latter rolls as being greater than in the remaining rolls, and in some cases it may be 4desirable to even entirely eliminate such particles from the end rolls and 59 which seldom, if ever, are subjected to any great compressive stresses. Cbviously, this variation in the concentration of the rubber particles in the rolls or layers of the brous material may be varied throughout any layer of padding, whether made up of rolls or otherwise to obtain any desired condition or effect.

Other specific' 'adaptations of the principles of the present invention will, of course, be apparent to those skilled in the art once the teachings of the present invention are made known to them, and accordingly it will be understood that formal changes may be made in the specic embodiment of tha present invention described without departing from the spirit and substance of the broad invention, the scope Vof which is'commensurate with the appended claim.

' What is claimed is: V

A mattress or other upholstered device comface of said imt and including a layer of relatively loose bers, a plurality of relatively small particles of sponge rubber interspersed through that portion ot said layer nearest said spring unit, and that portion of said layer most remote from said spring unit being substantially devoid of material ammmts of said sponge rubber.

' HARRY E. WELLS.

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