US2862214A - Cushion or mattress construction and method of manufacture - Google Patents

Cushion or mattress construction and method of manufacture Download PDF

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Publication number
US2862214A
US2862214A US613866A US61386656A US2862214A US 2862214 A US2862214 A US 2862214A US 613866 A US613866 A US 613866A US 61386656 A US61386656 A US 61386656A US 2862214 A US2862214 A US 2862214A
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springs
cushion
mattress construction
manufacture
fabric
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US613866A
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Lloyd W Thompson
Klein Sidney
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Marspring Corp
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Marspring Corp
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    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/06Spring inlays
    • A47C27/063Spring inlays wrapped or otherwise protected
    • A47C27/064Pocketed springs

Description

Dec. 2, 1958 L. w. THOMPSON ETAL 2,862,214

CUSHION OR MATTRESS CONSTRUCTION .AND METHOD OF MANUFACTURE Filed oct. 4, 195s INVENTORS rraeA/Ey.

United States Patent O CUSHION OR MATTRESS CONSTRUCTION AND METHOD F MANUFACTURE Lloyd W. Thompson, Inglewood, and Sidney Klein, Los Angeles, Calif., assignors to Marspring Corporation, Los Angeles, Calif., a corporation of California Application October 4, 1956, Serial No. 613,866

4 Claims. (Cl. 5-353) This invention relates to cushion or mattress construction and method of manufacture and is a continuation-in-part of a previously filed application for Cushion or Mattress Construction and Method of Manufacture filed March 26, 1956, Serial No. 573,927, now abandoned. Included in the objects of this invention are:

First, to provide a cushion or mattress construction wherein a bed or core of fabric bag-enclosed springs is completely surrounded and restrained by a covering formed of rubberized or latex-coated hair, without the use of metal fastening means between the springs or the use of metal framework bounding the core or the covering. v

Second to provide a cushion or mattress construction and method of manufacture, wherein'a box-like container is formed of cemented sections of rubberized or latexccated hair or analogous material, into which is packed a continuous string of fabric bag-enclosed springs and over which is cemented a cover also of such coated hair, the shape and form of the nished cushion or mattress being determined by the container formed of the coated hair rather than an interconnected series of coil springs.

Third, to provide a cushion or mattress construction and method of manufacture of this type wherein the fabric bag enclosures for the springs are cemented to the confronting surfaces of the container or covering of latex-coated hair so that the springs are iixed in place.

Fourth, to provide a cushion or mattress construction which combines the advantages and avoids the disadvantages inherent in conventional foam rubber cushions and mattresses and conventional coil spring cushions and mattresses. Y

With the above and other objects in view, as may appear hereinafter, reference is directed to the accompanying drawings in which:

Figure l is a perspective view of the encasing structure;

Fig. 2 is a fragmentary, sectional view thereof, taken through 2 2 of Fig. 1;

Fig. 3 is a fragmentary, plan view thereof, showing the manner in which the fabric bag-enclosing springs are installed in the box-like structure;

Fig. 4 is an enlarged, fragmentary, sectional view, taken through 4 4 of Fig. 3, showing the completed cushion or mattress.

The cushion or mattress includes a plurality of helically coiled springs 1 which are encased in compartments 2 provided in a fabric strip 3. The fabric Strip is first folded upon itself and stitched transversely to form contiguous compartments, after which the springs are inserted and the open ends are sewn closed.

The springs as encased in fabric bags may be considered conventional and are known in the trade as Marshall-type springs. Conventionally, these springs are arranged in rows and columns and clipped together at their points of tangency by metal clips, so as to form a self-supporting spring unit which may be later encased to form a mattress or cushion. In the exercise of the present invention, however, the metal clips or other 2,862,214 Patented Dec. 2, 1958 ICC fastening devices between the springs, other than the connection aiforded between the compartment of the folded fabric strip, are completely eliminated. Thus, contrary to standard construction, the springs do not form a self-supported spring unit.

In place of wrapping and sewing the conventional padding over and around the clip-connected spring units, the loose spring units are packed into a box-like structure formed of special padding material. To accomplish this, such box-like structure is formed of a rubberized or latex-coated hair or hair-like material. Such material is quite porous, yieldable, and resilient. The rubberized or latex-coating, which holds the hair-like material in place, provides a tough bond between the hair or laments so that pads of such material are easily handled and have a substantial amount of tensile strength. Still further, such pads retain to a remarkable degree their original memory or ability to return to their original shape after being deformed.

The box-like structure includes a bottom pad 4, preferably of uniform thickness. Joined to the edges of the bottom pad are side wall pads 5. This may be accomplished by use of rubber or plastic cements, as indicated by 6, which rmly and permanently join the pads together.

After the box-like structure is formed, the fabric strip 3 with the springs 1 encased therein is folded back and forth within the confines of the side wall pads 5 until the cavity formed thereby is completely lled, and the springs are held in position by mutual engagement as well as by the surrounding side wall pads. After the springs have been installed, a cover pad 7 is placed thereover. The cover pad is dimensioned to iit within the upper margins of the side wall pads 5 and is joined thereto by cement or adhesive 6.

Prior to placement of the springs, the interior of the bottom pad 4, cover pad 7, and, if desired, the side wall pads 5 are coated with an adhesive 6a. The fabric strip may, if desired, also be precoated with adhesive, either in its entirety or at the ends of the compartments 2. As a consequence, the springs are yieldably maintained in their individual positions.

The free length of the springs, that is, of the maximum length thereof as determined by the compartments 2 in which they t, is preferably somewhat greater than the distance between the bottom and cover pads so that on installing the cover the springs are compressed an optimum amount so that the springs tend to bow the bottom and cover pads from each other, as suggested in Fig. 4. Also it has been found highly desirable to bevel the upper and lower edges of the side wall pads 5, as indicated by 8.

The cushion or mattress structure thus formed may be further enclosed in various conventional coverings such as various batting materials or by foam rubber sheeting, as indicated by 9 in Fig. 4. Such foam rubber sheeting may form a complete encasement for the pads 4, 5, and 7, and may in turn be encased in suitable fabric, not shown.

While it is preferred that all of the walls of the encasing structure be formed of latex-coated hair or similar material, it should be noted that the wall which ultimately becomes `the bottom side may be a rigid member, for example, formed of plywood.

While a particular embodiment of this invention has been shown' and described, it is not intended to limit the same to the exact detail-s of the construction set forth, and it embraces such changes, modifications, and equivalents of the parts and their formation and arrangement as come within the purview of the appended claims.

What is claimed is:

l. A cushion or mattress construction, comprising: an encasing structure having a bottom wall, top wall, and

side walls defining a completely enclosed cavity, at least some of said walls being formed of panels of latex-coated hair-like material and said walls being permanently cemented together; a plurality of coil springs; an'd fabric casings for said coil springs, said springs and their casings completely filling said cavity for mutual support and constituting the sole content thereof, and yieldably restrained by the surrounding walls, said fabric casings being `cemented at their upper and lower endsto said top and bottom walls.

2. A cushion or mattress construction, comprising: an encasi'ng structure having a bottom wall, top wall, and side walls defining a completely enclosed cavity, at Ieas't some of said walls being formed of panels of latex-coated hair-like material and said walls being permanently' cemented together, a plurality of coil springs; and a continuous strip of fabric having a series of pockets therein to receive said springs, said strip with the springs in said pockets constituting the sole content of said cavity and being packed snugly between the side walls of said structure, whereby the springs mutually support each other and are restrained by said side Walls, said fabric casings being cemented at their upper and lower ends 4to said top and bottom walls.

3. A cushion or mattress construction, comprising: an encasing structure having a bottom wall, top wall, and side walls defining a completely enclosed cavity, at least some of said walls being formed with panels of latexcoated hair-like material and said walls being permanently cemented together; a plurality of coil springs; limp fabric casings for said coil springs, said springs completely filling said cavity for mutual support, said springs 4 and their casings constituting the entire contents of said cavity and yieldably restrained by the surrounding walls; and a cover completely surrounding said encasing structure, said fabric casings being cemented at their upper and lower ends to said top and bottom walls.

4. A cushion or mattress construction, comprising; an en'casing structure having a bottom wall, top wall, and side walls defining a completely enclosed cavity, at least Y said top wall comprising a panel of latexcoated hair-like material and said walls being permanently cemented t0- gether; a plurality of coil springs; and limp fabric casings for said coil springs, said springs and casings con'- stituting the sole content of and completely filling said V cavity; and an adhesive 'bond between the top and bottorn ends of said casings and said encasing structure to yieldably maintain each of said springs in position, the unrestrained length of `said springs and casings being greater than ythe normal height of said cavity whereby said top wall is crowned upwardly.

References Cited in the file of this patent UNITED STATES PATENTS

US613866A 1956-10-04 1956-10-04 Cushion or mattress construction and method of manufacture Expired - Lifetime US2862214A (en)

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Cited By (37)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3083381A (en) * 1960-03-01 1963-04-02 Theodore L Bailey Mattress construction
US3178735A (en) * 1962-05-18 1965-04-20 Prelude Corp Construction for cushion, mattress and chair
US3425068A (en) * 1967-08-07 1969-02-04 Barber Mfg Co Inc Spring-foam cushion
US3513491A (en) * 1968-03-13 1970-05-26 Donald W Gordon Athlete's landing pit with foam-block cushion units
US3869739A (en) * 1973-11-16 1975-03-11 Marspring Corp Cushion or mattress construction
EP0052389A1 (en) * 1980-11-19 1982-05-26 N.V. Bekaert S.A. Spring assembly for cushion or mattress and method and machine for making such assembly
US4566926A (en) * 1984-03-09 1986-01-28 Simmons U.S.A. Corporation Method and apparatus for manufacturing innerspring constructions
US4578834A (en) * 1984-03-09 1986-04-01 Simmons U.S.A. Corporation Innerspring construction
US5040255A (en) * 1990-06-06 1991-08-20 Barber Manufacturing Company, Inc. Cushion or mattress structure
US5438718A (en) * 1988-08-05 1995-08-08 Slumberland Holdings Limited Spring units for mattresses and the like
US5699998A (en) * 1993-02-01 1997-12-23 Zysman; Milton Manufacture of pocket spring assemblies
US6143122A (en) * 1998-09-15 2000-11-07 L&P Property Management Company Adhesive bonding of strings of pocketed coil springs
US6159319A (en) * 1996-04-29 2000-12-12 L&P Property Management Company Method and apparatus for forming pocketed coil spring mattresses
US6175997B1 (en) 1998-01-22 2001-01-23 L&P Property Management Company Pocketed coil spring mattress cores
US6176961B1 (en) 1998-09-15 2001-01-23 L&P Property Management Company Adhesive bonding of strings of pocketed coil springs
US6295673B1 (en) 1998-07-24 2001-10-02 L & P Property Management Company Reinforced pocketed spring assembly
US6315275B1 (en) 1995-09-18 2001-11-13 Furniture Row Technologies, Llc Pocket spring assembly and methods
US6367881B1 (en) 1999-10-14 2002-04-09 L & P Property Management Company Coil seating assembly
US6374442B1 (en) 2000-01-28 2002-04-23 L&P Property Management Co. Pocketed coil spring unit with combination of top and bottom sheets and inter-row bonding
US6574811B1 (en) 1998-07-24 2003-06-10 L & P Property Management Company Pocketed spring assembly and associated method
US6643876B2 (en) * 2001-11-21 2003-11-11 Denver Mattress Co., Llc No-flip mattress and methods for their construction
US6698166B2 (en) 1995-09-18 2004-03-02 Springquilt Industries Ltd. Pocket spring assembly and methods
US20040117913A1 (en) * 2000-01-13 2004-06-24 Dreamwell, Ltd. Bed construction with reduced sagging
US20040148706A1 (en) * 2001-11-21 2004-08-05 Denver Mattress Co. Llc No-flip mattress systems and methods
US20050000026A1 (en) * 2002-10-15 2005-01-06 Gladney Richard F. Tray support for a mattress
US20050081298A1 (en) * 2003-10-17 2005-04-21 Wright Richard S. Mattress assembly and manufacturing process for a mattress using adhesive patches
US20050097676A1 (en) * 2003-11-10 2005-05-12 Denver Mattress Co. Llc High comfort mattresses and methods for constructing them
WO2005065493A1 (en) * 2003-12-31 2005-07-21 Dreamwell, Ltd. Methods for manufacturing encased mattresses
US20060059631A1 (en) * 2004-09-17 2006-03-23 Denver Mattress Co., Llc Mattress systems and methods of making
US20060096032A1 (en) * 2003-11-10 2006-05-11 Denver Mattress Co. Llc High comfort mattresses having fiberballs
US7210181B1 (en) 2003-10-10 2007-05-01 Atlanta Attachment Company Spring construction
US20070204407A1 (en) * 2006-08-14 2007-09-06 Youn Jae Lee Foam Integrated Innerspring Mattress And Method of Manufacture
US20090222985A1 (en) * 2008-03-06 2009-09-10 L&P Property Management Company Stackable bedding foundation having pocketed topper
US7640611B1 (en) * 2005-01-25 2010-01-05 Kluft Earl S Mattress design
US20110047708A1 (en) * 2009-09-02 2011-03-03 Denver Mattress Co. Llc Mattresses with heat dissipation
US20110173757A1 (en) * 2009-09-02 2011-07-21 Denver Mattress Co. Llc Cushioning devices and methods
WO2013041894A1 (en) * 2011-09-20 2013-03-28 GAÀLHAB Szivacsfeldolgozó Kft. Method for manufacturing a foam coating, as well as a spring mattress insert and a foam based article manufactured by the method

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR708666A (en) * 1930-03-28 1931-07-27 Spring mattress, cushion metal springs and spring hammock
FR771512A (en) * 1933-07-04 1934-10-10 A method for enhancing and arm cushions and other compressible objects rubberized horsehair
US2320425A (en) * 1940-08-02 1943-06-01 Mishawaka Rubber & Woolen Mfg Combining foam rubber
US2425728A (en) * 1947-08-19 Mattress
US2540441A (en) * 1949-08-09 1951-02-06 Allen Ind Mattress construction
US2615180A (en) * 1949-05-07 1952-10-28 Simmons Co Spring assembly

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2425728A (en) * 1947-08-19 Mattress
FR708666A (en) * 1930-03-28 1931-07-27 Spring mattress, cushion metal springs and spring hammock
FR771512A (en) * 1933-07-04 1934-10-10 A method for enhancing and arm cushions and other compressible objects rubberized horsehair
US2320425A (en) * 1940-08-02 1943-06-01 Mishawaka Rubber & Woolen Mfg Combining foam rubber
US2615180A (en) * 1949-05-07 1952-10-28 Simmons Co Spring assembly
US2540441A (en) * 1949-08-09 1951-02-06 Allen Ind Mattress construction

Cited By (57)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3083381A (en) * 1960-03-01 1963-04-02 Theodore L Bailey Mattress construction
US3178735A (en) * 1962-05-18 1965-04-20 Prelude Corp Construction for cushion, mattress and chair
US3425068A (en) * 1967-08-07 1969-02-04 Barber Mfg Co Inc Spring-foam cushion
US3513491A (en) * 1968-03-13 1970-05-26 Donald W Gordon Athlete's landing pit with foam-block cushion units
US3869739A (en) * 1973-11-16 1975-03-11 Marspring Corp Cushion or mattress construction
EP0052389A1 (en) * 1980-11-19 1982-05-26 N.V. Bekaert S.A. Spring assembly for cushion or mattress and method and machine for making such assembly
US4578834A (en) * 1984-03-09 1986-04-01 Simmons U.S.A. Corporation Innerspring construction
US4566926A (en) * 1984-03-09 1986-01-28 Simmons U.S.A. Corporation Method and apparatus for manufacturing innerspring constructions
AU577545B2 (en) * 1984-03-09 1988-09-29 Dreamwell, Ltd. Innerspring construction
US5438718A (en) * 1988-08-05 1995-08-08 Slumberland Holdings Limited Spring units for mattresses and the like
US5040255A (en) * 1990-06-06 1991-08-20 Barber Manufacturing Company, Inc. Cushion or mattress structure
US5699998A (en) * 1993-02-01 1997-12-23 Zysman; Milton Manufacture of pocket spring assemblies
US6315275B1 (en) 1995-09-18 2001-11-13 Furniture Row Technologies, Llc Pocket spring assembly and methods
US6698166B2 (en) 1995-09-18 2004-03-02 Springquilt Industries Ltd. Pocket spring assembly and methods
US6467240B2 (en) * 1995-09-18 2002-10-22 Furniture Row Technologies, Llc Pocket spring assembly and methods
US6159319A (en) * 1996-04-29 2000-12-12 L&P Property Management Company Method and apparatus for forming pocketed coil spring mattresses
US6175997B1 (en) 1998-01-22 2001-01-23 L&P Property Management Company Pocketed coil spring mattress cores
US6574811B1 (en) 1998-07-24 2003-06-10 L & P Property Management Company Pocketed spring assembly and associated method
US6295673B1 (en) 1998-07-24 2001-10-02 L & P Property Management Company Reinforced pocketed spring assembly
US6143122A (en) * 1998-09-15 2000-11-07 L&P Property Management Company Adhesive bonding of strings of pocketed coil springs
US6176961B1 (en) 1998-09-15 2001-01-23 L&P Property Management Company Adhesive bonding of strings of pocketed coil springs
US6176960B1 (en) 1998-09-15 2001-01-23 L&P Property Management Company System and method for adhesive bonding of strings of pocketed springs
US6367881B1 (en) 1999-10-14 2002-04-09 L & P Property Management Company Coil seating assembly
US7096528B2 (en) 2000-01-13 2006-08-29 Dreamwell, Ltd. Bed construction with reduced sagging
US7444706B2 (en) 2000-01-13 2008-11-04 Dreamwell Ltd. Bed construction with reduced sagging
US20070151034A1 (en) * 2000-01-13 2007-07-05 Dreamwell, Ltd. Bed construction with reduced sagging
US20040117913A1 (en) * 2000-01-13 2004-06-24 Dreamwell, Ltd. Bed construction with reduced sagging
US6760940B2 (en) * 2000-01-13 2004-07-13 Dreamwell, Ltd. Bed construction with reduced sagging
US6681428B2 (en) 2000-01-28 2004-01-27 L&P Property Management Co. Method of making pocketed coil spring unit with combination of scrim sheets and inter-row bonding
US6374442B1 (en) 2000-01-28 2002-04-23 L&P Property Management Co. Pocketed coil spring unit with combination of top and bottom sheets and inter-row bonding
US6643876B2 (en) * 2001-11-21 2003-11-11 Denver Mattress Co., Llc No-flip mattress and methods for their construction
US6952850B2 (en) 2001-11-21 2005-10-11 Denver Mattress Llc No-flip mattress systems and methods
US20040148706A1 (en) * 2001-11-21 2004-08-05 Denver Mattress Co. Llc No-flip mattress systems and methods
US20050000026A1 (en) * 2002-10-15 2005-01-06 Gladney Richard F. Tray support for a mattress
US7210181B1 (en) 2003-10-10 2007-05-01 Atlanta Attachment Company Spring construction
US7200884B2 (en) 2003-10-17 2007-04-10 Dreamwell Ltd. Mattress assembly and manufacturing process for a mattress using adhesive patches
US7424762B2 (en) 2003-10-17 2008-09-16 Dreamwell, Ltd. Mattress assembly and manufacturing process for a mattress using adhesive patches
US20070186350A1 (en) * 2003-10-17 2007-08-16 Dreamwell, Ltd. Mattress assembly and manufacturing process for a mattress using adhesive patches
US20050081298A1 (en) * 2003-10-17 2005-04-21 Wright Richard S. Mattress assembly and manufacturing process for a mattress using adhesive patches
US20050097676A1 (en) * 2003-11-10 2005-05-12 Denver Mattress Co. Llc High comfort mattresses and methods for constructing them
US20060096032A1 (en) * 2003-11-10 2006-05-11 Denver Mattress Co. Llc High comfort mattresses having fiberballs
US20110067215A1 (en) * 2003-11-10 2011-03-24 Denver Mattress Co. Llc High comfort mattresses having fiberballs
US8448315B2 (en) 2003-11-10 2013-05-28 Denver Mattress Co., Llc High comfort mattresses having fiberballs
US7284494B2 (en) 2003-11-10 2007-10-23 Denver Mattress Co., Llc High comfort mattresses having fiberballs
US20080092302A1 (en) * 2003-11-10 2008-04-24 Denver Mattress Co. Llc High comfort mattresses having fiberballs
US6895620B1 (en) 2003-11-10 2005-05-24 Denver Mattress Co., Llc High comfort mattresses and methods for constructing them
US7617788B2 (en) 2003-11-10 2009-11-17 Denver Mattress Co., Llc High comfort mattresses having fiberballs
WO2005065493A1 (en) * 2003-12-31 2005-07-21 Dreamwell, Ltd. Methods for manufacturing encased mattresses
US7617556B2 (en) 2004-09-17 2009-11-17 Denver Mattress Co., Llc Mattress systems and methods of making
US20060059631A1 (en) * 2004-09-17 2006-03-23 Denver Mattress Co., Llc Mattress systems and methods of making
US7640611B1 (en) * 2005-01-25 2010-01-05 Kluft Earl S Mattress design
US20070204407A1 (en) * 2006-08-14 2007-09-06 Youn Jae Lee Foam Integrated Innerspring Mattress And Method of Manufacture
US7644461B2 (en) * 2006-08-14 2010-01-12 Zinus, Inc. Foam integrated innerspring mattress and method of manufacture
US20090222985A1 (en) * 2008-03-06 2009-09-10 L&P Property Management Company Stackable bedding foundation having pocketed topper
US20110047708A1 (en) * 2009-09-02 2011-03-03 Denver Mattress Co. Llc Mattresses with heat dissipation
US20110173757A1 (en) * 2009-09-02 2011-07-21 Denver Mattress Co. Llc Cushioning devices and methods
WO2013041894A1 (en) * 2011-09-20 2013-03-28 GAÀLHAB Szivacsfeldolgozó Kft. Method for manufacturing a foam coating, as well as a spring mattress insert and a foam based article manufactured by the method

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