WO2005039849A2 - Foam encased innerspring with internal foam components (triple case) - Google Patents
Foam encased innerspring with internal foam components (triple case) Download PDFInfo
- Publication number
- WO2005039849A2 WO2005039849A2 PCT/US2004/029178 US2004029178W WO2005039849A2 WO 2005039849 A2 WO2005039849 A2 WO 2005039849A2 US 2004029178 W US2004029178 W US 2004029178W WO 2005039849 A2 WO2005039849 A2 WO 2005039849A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- foam
- innerspring
- deck
- mattress
- encasement
- Prior art date
Links
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
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/20—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with springs moulded in, or situated in cavities or openings in 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
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material 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
-
- 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
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
- A47C27/144—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities inside the mattress or cushion
-
- 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
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
- A47C27/146—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
Definitions
- the present invention pertains generally to mattresses and mattress innersprings and, more particularly, to mattresses which include both wire-form innersprings and structural foam components.
- Foam components are commonly combined with wire or steel form innersprings in mattress, seating and other flexible support structures. Early versions included foam layers which were either attached directly to a wire innerspring or simply held in position by overlying upholstery. Smaller foam components are designed to fit within spaces of the innerspring. As described in the referenced related application, a new approach to the integration of innersprings and foam components involves welding or bonding of mating foam components to form a unibody structure which fits with an innerspring, forming a unitized steel and foam structure which provides flexible support. Different types of foam and foam parts have been used extensively in seating and bedding as flexible support material.
- foams results in easier compression or lower ILD which is suitable for many bedding and seating applications, particularly for support surface or topper layers underneath upholstery. They are not generally utilized as structural members in a mattress or support cushion in seating. Also, polyurethane and other non-thermoplastic type foams cannot be bonded or welded by any heat- source process due to their decomposition properties. Some foam shapes have been used integrally with springs to augment or otherwise support metal spring structures, as shown for example in U.S. Patent Nos. 5,133,116; 5,239,715; 5,467,488 and 5,687,439.
- closed-cell polyethylene foam which is molded or extruded by known processes into desired shapes. Closed-cell foam has greater support properties due to the fact that each closed cell contains a gas which maintains the cells in an inflated state when under compression, as compared to open- cell foams from which a substantial volume of air is displaced when compressed.
- Latex and polyethylene foam is commonly used in slab form as cushioning or dampening layers in mattresses and seating, held in place relative to an innerspring simply by surrounding upholstery.
- latex foam can be readily molded, and has been molded about innersprings to form a foam-encased mattress. This type of combination of foam and innerspring does not include any internal foam components which provide three-dimensional flexible, or which are bonded to any other components of a mattress or other flexible support device.
- the present invention provides a multiple component mattress or support structure which combines integrated foam materials and structures with an innerspring or other flexible core.
- An extruded polyolefm foam deck is used as an underlying flexible structural support and dampening foundation for an innerspring.
- An insulator pad such as a thermally bonded, high- density, high quality polyester fiber pad is positioned over an opposing side of the innerspring opposite the foam deck.
- a foam encasement such as a molded polymerizing reaction mixture, structurally integrates the foam deck, innerspring and insulator pad by bonding to perimeter areas of the foam deck and insulator pad, and to perimeter coils or spring elements of the innerspring, creating a fully integrated unibody assembly.
- the foam encasement forms an exterior wall about the perimeter of the innerspring and foam deck and structurally integrates these components.
- a sculpted foam topper is then positioned over the insulator pad on a support surface of the innerspring opposite the foam deck, preferably with surface design features sculpted in the support side of the topper.
- a foam deck which can be used in accordance with the invention is preferably a structural extruded foam, such as closed-cell polyolefm, which may be thermally bonded to form the described three-dimensional deck structures as described in the related application, incorporated herein by reference.
- the foam deck is formed by a plurality of extruded foam beams which are bonded or fused together by welds along abutting edges.
- the foam is preferably thermoplastic in behavior, being able to reversibly melt and solidify without decomposing.
- a thermally bonded unitized three-dimensional foam structure is combined with another support element, such as an innerspring, to provide a flexible support structure which is at least partially encapsulated in foam, such as polyurethane foam or other resilient polymer molded about a perimeter of the foam deck and innerspring.
- foam such as polyurethane foam or other resilient polymer molded about a perimeter of the foam deck and innerspring.
- the thermoplastic foam structure of the foam deck dampens and softens the feel of the innerspring, and provides edge support and stability, and a protective cover for the underside of the innerspring. It also provides a foundational slab to which walls of the foam encasement attaches.
- the thermoplastic foam components or pieces are made of extruded foam, such as gas-blown polyethylene, in a box beam or slab form.
- the vertical profile of the box beams of the foam deck defines a degree of stiffness and flexure which responds to localized loads on the overlying innerspring.
- the foam encapsulation of the innerspring and foam deck forms side walls to the mattress which are structurally integrated with the foam deck, innerspring and insulator pad opposite the foam deck.
- the side walls provide vertical support, and form a smooth unitized body ideally configured for neat application of upholstery.
- the use of a foam topper in combination with the foam encased innerspring increases the support density of the edge areas of the mattress, and allows for customization of the comfort profile by sculpting of the primary support surface.
- FIG. 1 is a cross-sectional view of a structurally integrated foam encased support device with an innerspring and internal foam components in accordance with the invention
- FIG. 2 is a perspective view of a structurally integrated foam encased support device with an innerspring and internal foam components with a sculpted foam topper, in accordance with the invention
- FIGS. 3A, 3B and 3C are cross-sectional views of alternate embodiments of a segment of a foam deck component of the invention.
- FIG. 4 is a perspective cutaway view of a structurally integrated foam encased support device of the invention
- FIG. 5 is a cross-sectional view of an alternate embodiment of a structurally integrated foam encased support device of the invention.
- FIG. 1 there is illustrated a structurally integrated foam encased support device, referenced generally as 100, which in this particular embodiment of the invention is in the form of a one-sided mattress, as further described.
- the device 100 includes an innerspring and internal and external foam components.
- the innerspring 110 (also sometimes referred to herein as an "innerspring assembly”) is made up of a plurality of wire form coils 120 which are interconnected or laced together by helical wires 130 as known in the art, in an array to form an assembly which has a first support side generally defined by aligned first ends of the coils or spring elements, and a second support side generally defined by the aligned second ends of the coils or spring elements, the first and second support sides being parallel, and a perimeter about the first and second support sides defined by perimeter coils at the edges of the array, defining a generally rectangular shape to the innerspring assembly.
- the innerspring 110 has first and second support surfaces 111 and 112, and lateral edges 113 and 114 defining a generally rectangular spring form which can be dimensioned to conventional or traditional mattress sizes, or in other shapes or sizes for use in specialty mattresses for aircraft or watercraft, or seating and furniture applications.
- the invention is equally applicable to all types of innersprings and innerspring assemblies, regardless of the form of the individual coils and the manner of interconnection of the coils, and including such variants as Marshall type pocketed coils and coils made of materials other than steel spring wire.
- the invention is also highly adaptable for use with other types of reflexive bodies or flexible cores which may be used in place of traditional innersprings having individual coils or spring elements.
- innersprings which may be used in combination with the unitized foam structures include: wire-form innersprings of any variety such as Bonnel or other helical designs, continuous wire-form designs which do not have individual helical coils, interconnected springs or coils made of plastic or composite materials, pocketed or Marshall- type coils held in an array by material which is sewn or bonded, and solid blocks of material such as latex foam or other suitable foams or layers of foam (referred to herein as a "flexible core") shown as block 190 in FIG. 5, or gas or water or any other type of reflexive body or mass.
- wire-form innersprings of any variety such as Bonnel or other helical designs, continuous wire-form designs which do not have individual helical coils, interconnected springs or coils made of plastic or composite materials, pocketed or Marshall- type coils held in an array by material which is sewn or bonded
- solid blocks of material such as latex foam or other suitable foams or layers of foam (referred to herein as a "flexible core
- an internal foam component used with the invention is in the form of a foam deck, indicated generally at 200, which is positioned adjacent to the innerspring 110, for example underlying or proximate to support surface 112.
- the foam deck 200 is preferably formed of ' extruded foam box beams 202 of the type illustrated in the cross-sectional views of FIGS. 3A- 3C, but may alternatively be simply a foam sheet or slab with first and second sides 210, 220, as shown.
- the foam deck 200 has a first panel 210 and a second panel 220 which is parallel to and spaced from panel 210, and held in this arrangement by a structure between the panels 210, 220, such as webs 230, which may be in any form which spans between the panels across the gap between the panels.
- the extent of the gap or spacing between the panels 210, 220 can be designed according to desired properties, such as desired flexibility of the foam deck 200 and overall height dimension of the mattress.
- the stiffness of the foam deck 200 can be altered.
- the structure which underlies the innerspring 110 in a one-sided mattress this in turn alters the stiffness or feel of the mattress, by altering the support response to compression of the innerspring.
- the stiffness of the foam deck 200 is transferred through the innerspring 110 to alter the overall feel of the mattress.
- the foam deck 200 also serves as the structural and protective base of a one-sided mattress, as illustrated in FIGS. 1, 2, 4 and 5.
- the mattress upholstery or covering is applied over the bottom panel 220 as further described. Because the foam deck 200 has the multiple properties of the rigidity of threedimensional structure and the closed-cell foam matrix, along with flexibility and bendability, it provides a superior one-sided mattress which is both protected from the underside, and which has shock absorption and spring dampening of the innerspring from the bottom, non-support surface 112 of the innerspring 110.
- the foam deck 200 is flexible, even when thermally bonded or welded or attached or in contact with other foam components or materials as further described, it remains flexible with the innerspring 110.
- multiple segments of box beams 202 can be bonded or fused together to form a major support surface 204 or a slab which is trimmed or cut to form a platform of the desired dimensions, which preferably corresponds to the innerspring 110.
- This type of construction of a foam deck 200 is shown in FIGS. 3 and 4, with the thermal weld or bond lines 203 indicated.
- One proprietary method of forming sheets of foam suitable for use as the deck 200 in the present invention is described in U.S. Patent No. 6,306,235.
- This method is particularly suitable for forming a deck 200 of fused box beams 202 of various cross-sectional configurations, such as those shown in the Figures and others.
- These box beam design variations are used to compliment and tune a mattress or support structure of the invention with the spring characteristics of the innerspring to provide the desired mattress support and feel properties.
- box beams 202 of varying cross-sectional configurations can be combined in a single foam deck 200 for customized mattress properties.
- the fusing of the parallel edges of the beams 202 can be automated or by manual operation of a fusing or welding instrument such as an adhesive applicator or heat-knife welder.
- the beams may be arranged to run the length or width of the mattress, or diagonally or on a slight spiral relative to the innerspring.
- the foam deck 200 performs several functions, including serving as a foundation or base for the innerspring 110 particularly when constructed as a one-sided mattress, providing dimensional stability to the innerspring in both the x and y directions (parallel to the surface) and providing a platform for formation of foam encasement about the innerspring, as further described.
- Use of the foam deck 200 underneath the innerspring 110 is advantageous over the conventional construction of one-sided mattresses which simply cover the bottom surface of the innerspring with a thin layer of material, leaving the underside of the innerspring unsupported and unprotected.
- the underlying foam deck 200 provides a soft, flexible foundation to the innerspring, and increases the overall height of the mattress without requiring any additional height to the innerspring.
- a pad 180 such as a high-density, high quality polyester fiber pad such as ResiliumTM made of thermally bonded polyester fibers, or alternatively made of polyurethane foam or other suitable material.
- the insulator pad 180 provides a contact surface over the underlying innerspring.
- the insulator pad 180 is structurally integrated with the foam deck 200 and innerspring 110 by encapsulation with a foam encasement formed of molded foam which contacts at least a perimeter area of pad 180.
- the three-part combination of the separate components of the foam deck 200, innerspring 110 and insulator pad 180 forms the internal structural components of the support device/mattress which are then permanently bonded together by foam encasement to structurally integrate the components together.
- a foam encasement 600 is provided to structurally integrate the components of the foam deck 200, innerspring 110 and pad 180. In the embodiments shown in FIGS. 1, 4 and 5, the foam encasement 600 extends about the aligned perimeters of the foam deck 200 and innerspring 110, forming an exterior foam wall 610 to the mattress.
- An internal side 620 of the foam encasement 600 extends into or otherwise contacts the foam deck 200, the perimeter coils of the innerspring 110, and the peripheral edge of the pad 180.
- the internal side 620 of the foam encasement 600 extends into the openings between the panels and webs, forming an integral lock of the perimeter of the foam deck with the foam encasement 600.
- the internal side 620 of the foam encasement also extends into the perimeter of the innerspring 110, curing securely about and gripping the coils at the perimeter.
- the foam encasement 600 also bonds or otherwise makes contact with the insulator pad 180, at least on an underside 181, and additionally at the edges 182 and partially extending over a top surface of insulator pad 180 as shown. This accurately secures the pad 180 in position on the support surface of the innerspring 110 without the use of any fasteners or other attachment device. It also keeps the insulator pad 180 in tight overlying arrangement with the innerspring so that the pad acts in unison with the innerspring and the foam deck foundation.
- the exterior foam wall 610 of the foam encasement 600 forms a smooth and uniform wall to the entire integrated structure, over which padding and/or upholstery can be placed in a very smooth and tight manner to provide the mattress or support device with a highly finished appearance. This is particularly advantageous over other mattress designs which have no substructure at the perimeter other than coils over which upholstery is applied.
- the walls of the foam encasement 600 provide substantial vertical support at the perimeter of the mattress, effectively maximizing the useable surface area of the mattress.
- a preferred method of forming the foam encasement 600 is by molding, preferably with a polymer foam reaction mixture in a fluid state, which can be injected into a mold in which the foam deck 200, innerspring 110 or flexible core and insulator pad 180 are placed in the described arrangement.
- the three main components of the foam deck 200, innerspring 110 and foam topper 700 are aligned and placed in a mold which defines the exterior wall 610.
- the polymer foam reaction mixture is then introduced into the mold cavity and around the perimeter of the assembly, contacting the various components as described, and curing by polymeric reaction into the foam encased integrated structure.
- Other methods of formation of the foam encasement 600 can be employed, and the invention is not limited to any particular method or manner of combination of the described components.
- a foam topper 700 is placed on top of pad 180, and is preferably bonded thereto by a thermoplastic adhesive.
- the foam topper 700 can be placed in the described mold with the underlying insulator pad 180, innerspring 110 or flexible core and foam deck 200, and the foam encasement 600 formed or molded to bond the foam topper 700 to the other components by contact with the underside or sides of the foam topper 700.
- foam topper 700 is a sculpted foam topper with a sculpted or textured surface features 710 arranged over a primary support surface, and side rails 720 along the longitudinal sides of the topper, or ends, or about the entire perimeter.
- the foam topper 700 can be made of polyurethane or latex foam material of any suitable density.
- Machine processing or water or laser cutting can be used to form any design of surface features 710, such as for example the six-sided tapered towers shown.
- the density of the foam topper 700 can be selected to produce a mattress or support device of any desired feel or support characteristic. The density may be selected with consideration of the stiffness of the innerspring, and the amount of dampening provided by the underlying foam deck.
- the topper 700 has the physical characteristics of a single type of foam with homogeneous foam cell structure, with the differing surface topographies altering the aggregate density and ultimate support characteristics of the zones defined by the sculpted area and rails.
- the sculpting of the support side of foam topper 700 is done by the removal of foam material in a pattern, such as the depicted matrix of valleys or voids with corresponding projections.
- the projections extend generally from the bottom of the valleys or voids so that it is the top or tip of the projections which collectively form a contoured support surface, over which an upholstery layer is laid.
- the solid form perimeter or rail sections provide a higher level of firmness than the contoured surface. Whereas a topper of uniform surface contour and density tends to become excessively compressed at the edge, which effectively reduces the usable sleeping area of a mattress, the density edge or rail zones maximize the support area of the mattress all the way to the edge of the encapsulated innerspring.
- laterally extending zones with varying topography can be formed to create a combination of varying support zones.
- the topography of the support surface of the foam topper 600 may also be formed to have gradual transitions between areas of differing topographies and corresponding densities.
- the projections of the first zone can be made to decrease in height or depth as they approach the flat second zone, so that the transition in firmness is less perceptible when felt through the upholstery layers.
- FIG. 5 illustrates an alternate embodiment of the invention wherein a second foam deck 200 is placed over the upper support surface 1 11 of the innerspring 1 10, above or below the insulator pad 180, and similarly structurally integrated by contact with the foam encasement 600.
- additional components can be thermally bonded with the foam deck 200 to form a unitized foam structure with additional foam pieces located at lateral edges of the innerspring 110, and which are thermally bonded or welded to the support surface 204 of foam deck 200.
- the foam encasement 600 can still be utilized by application over the described additional foam components.
- Other foam components of various configurations can be attached to the major support surface of the foam deck 200 for contouring or structural strength as desired.
- Different designs of innersprings and coils, including coils with different terminal configurations, such as the coils described in U.S. Patent No. 5,713,088, with terminal convolutions of coils 120 in support contact with the upper surface 210 of foam deck 200, can be used in alternate embodiments of the invention.
- foam components which interface with the coils of the innerspring can be used in conjunction with the foam deck 200 and/or foam encasement 600, such as foam pillars which are positioned within the coil bodies and extending generally perpendicular from the underlying or overlying foam decks 200, adding stiffness and support at desired locations, and working in cooperation with the foam topper 700.
- the mattress 100 can of course be upholstered with material layer or layers 500, or quilted layers, which may include an underlayment of a padding andor non- woven, and an outer upholstered material, which may be foam-backed, and closed with tape edges 510.
- the mattress can be made into virtually any upholstered mattress structure that is common to the art.
- the rigidity of the foam encasement provides the ideal form for the upholstery material 500, with smooth flat surfaces and well-defined corners over which the material can be pulled taut and secured.
- the well-defined corners of the edges of the foam encasement and foam topper provide an ideal guide and support for the overlying tape edges 510, resulting in very straight tape edges which gives the mattress a highly finished appearance.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Manufacturing & Machinery (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
Description
Claims
Priority Applications (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MXPA06004139A MXPA06004139A (en) | 2003-10-15 | 2004-09-08 | Foam encased innerspring with internal foam components (triple case). |
AU2004283189A AU2004283189B2 (en) | 2003-10-15 | 2004-09-08 | Foam encased innerspring with internal foam components (triple case) |
NZ545870A NZ545870A (en) | 2003-10-15 | 2004-09-08 | Foam encased innerspring with internal foam components (triple case) |
BRPI0415440-1A BRPI0415440A (en) | 2003-10-15 | 2004-09-08 | foam-wrapped inner springs with foam inner components |
JP2006535491A JP4956744B2 (en) | 2003-10-15 | 2004-09-08 | mattress |
EP04809701A EP1682320A4 (en) | 2003-10-15 | 2004-09-08 | Foam encased innerspring with internal foam components (triple case) |
CA2539008A CA2539008C (en) | 2003-10-15 | 2004-09-08 | Foam encased innerspring with internal foam components (triple case) |
CN2004800303723A CN1964650B (en) | 2003-10-15 | 2004-09-08 | Foam encased innerspring with internal foam components (triple case) |
IL174889A IL174889A0 (en) | 2003-10-15 | 2006-04-10 | Form encased innerspring with internal foam components (triple case) |
KR1020067007153A KR101210687B1 (en) | 2003-10-15 | 2006-04-14 | Mattres support structure and method of making same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US51184903P | 2003-10-15 | 2003-10-15 | |
US60/511,849 | 2003-10-15 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2005039849A2 true WO2005039849A2 (en) | 2005-05-06 |
WO2005039849A3 WO2005039849A3 (en) | 2006-12-21 |
Family
ID=34520040
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2004/029178 WO2005039849A2 (en) | 2003-10-15 | 2004-09-08 | Foam encased innerspring with internal foam components (triple case) |
Country Status (13)
Country | Link |
---|---|
US (1) | US7185379B2 (en) |
EP (1) | EP1682320A4 (en) |
JP (1) | JP4956744B2 (en) |
KR (1) | KR101210687B1 (en) |
CN (1) | CN1964650B (en) |
AR (1) | AR046418A1 (en) |
AU (1) | AU2004283189B2 (en) |
BR (1) | BRPI0415440A (en) |
CA (1) | CA2539008C (en) |
IL (1) | IL174889A0 (en) |
MX (1) | MXPA06004139A (en) |
NZ (1) | NZ545870A (en) |
WO (1) | WO2005039849A2 (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9962007B2 (en) | 2009-06-04 | 2018-05-08 | Mantzis Holdings Pty Ltd. | Mattress core |
US11026517B2 (en) | 2016-12-29 | 2021-06-08 | Sealy Technology, Llc | Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same |
US11033114B2 (en) | 2015-12-17 | 2021-06-15 | Sealy Technology, Llc | Coil-in-coil spring with variable loading response and mattresses including the same |
US11051631B2 (en) | 2016-01-21 | 2021-07-06 | Sealy Technology, Llc | Coil-in-coil springs with non-linear loading responses and mattresses including the same |
US11076705B2 (en) | 2014-05-30 | 2021-08-03 | Sealy Technology, Llc | Spring core with integrated cushioning layer |
Families Citing this family (39)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7082635B2 (en) * | 2003-03-28 | 2006-08-01 | Sealy Technology Llc | Unitized thermoplastic foam structures |
US7631381B2 (en) * | 2004-10-12 | 2009-12-15 | Kingsdown, Incorporated | Mattress having foam encasement and method of making the same |
US20160316926A9 (en) * | 2005-06-24 | 2016-11-03 | Chris Collins | Reticulated material body support and method |
US20070017034A1 (en) * | 2005-07-21 | 2007-01-25 | Dreamwell, Ltd. | Method of assembling mattresses using plastic tab fasteners |
WO2008088740A1 (en) * | 2007-01-18 | 2008-07-24 | Nomaco, Inc. | Method for manufacturing enhanced foam thermoplastic products |
US7845036B2 (en) * | 2007-07-09 | 2010-12-07 | Hickory Springs Manufacturing Company | Edge support for mattress assembly and method for making and using the same |
US8266747B1 (en) | 2008-06-24 | 2012-09-18 | Nomaco Inc. | Mattress side/edge support system |
US8561236B2 (en) * | 2009-06-22 | 2013-10-22 | Nomaco Inc. | Stepped-edge and side-support members, assemblies, systems, and related methods, particularly for bedding and seating |
US8646136B2 (en) | 2009-08-27 | 2014-02-11 | Nomaco Inc. | Assemblies, systems, and related methods employing interlocking components to provide at least a portion of an encasement, particularly for bedding and seating applications |
US8375493B2 (en) | 2009-08-27 | 2013-02-19 | Sealy Technology Llc | One piece foam mattress core encasement |
US20110179579A1 (en) * | 2010-01-27 | 2011-07-28 | Nomaco Inc. | Expandable edge-support members, assemblies, and related methods, suitable for bedding and seating applications and innersprings |
USD677097S1 (en) | 2010-05-06 | 2013-03-05 | Nomaco, Inc. | Slotted side support |
USD692689S1 (en) | 2010-08-17 | 2013-11-05 | Nomaco Inc. | Side support |
USD694042S1 (en) | 2010-08-17 | 2013-11-26 | Nomaco Inc. | Side support |
USD695550S1 (en) | 2010-08-17 | 2013-12-17 | Nomaca Inc. | Side support |
USD694554S1 (en) | 2010-08-17 | 2013-12-03 | Nomaco Inc. | Side support |
JP2014512936A (en) * | 2011-05-12 | 2014-05-29 | シーリー テクノロジー エルエルシー | Tension reducing foam and mattress structure |
USD673800S1 (en) | 2011-08-03 | 2013-01-08 | Nomaco Inc. | Mattress bed encasement |
USD673801S1 (en) | 2011-08-03 | 2013-01-08 | Nomaco Inc. | Mattress bed encasement |
USD675051S1 (en) | 2011-09-30 | 2013-01-29 | Nomaco Inc. | Edge support cushion |
CN103156438A (en) * | 2011-12-11 | 2013-06-19 | 夏橙越 | Venting type non-formaldehyde and mite-prevention spring mattress |
US9848711B2 (en) * | 2012-12-28 | 2017-12-26 | Tempur-Pedic Management, Llc | Mattress assembly |
US9326616B2 (en) * | 2013-01-10 | 2016-05-03 | Dreamwell, Ltd. | Active airflow temperature controlled bedding systems |
WO2014176400A1 (en) * | 2013-04-26 | 2014-10-30 | Noel Group Llc | Cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow, and related methods |
USD737074S1 (en) | 2013-07-03 | 2015-08-25 | Nomaco Inc. | Foam cushion base |
USD740053S1 (en) | 2013-07-03 | 2015-10-06 | Nomaco Inc. | Foam cushion base |
US9936815B2 (en) | 2014-05-30 | 2018-04-10 | Sealy Technology, Llc | Pocket coil spring assembly including flexible foam |
CN104398072A (en) * | 2014-12-09 | 2015-03-11 | 湖南星港家居发展有限公司 | Child mattress |
CN108243604B (en) | 2015-06-05 | 2021-02-05 | 丝涟科技有限责任公司 | Non-linear spring and mattress comprising non-linear spring |
WO2017135456A1 (en) * | 2016-02-04 | 2017-08-10 | 株式会社ジェイエスピー | Vehicle seat sheet core material |
US10485357B1 (en) | 2016-04-21 | 2019-11-26 | Hickory Springs Manufacturing Company | Foam mattress with reinforced edges |
US10598242B2 (en) | 2016-05-20 | 2020-03-24 | Sealy Technology, Llc | Coil springs with non-linear loading responses and mattresses including the same |
KR102640267B1 (en) * | 2016-12-12 | 2024-02-26 | 코웨이 주식회사 | Hardness adjustable mattress assembly comprising phase-shift material |
US11109688B2 (en) * | 2018-04-20 | 2021-09-07 | Inno-Sports Co., Ltd | Regimen mattress |
LU100788B1 (en) * | 2018-04-27 | 2019-10-28 | Variowell Dev Gmbh | A shaped body made from a foam and springs as well as uses thereof |
EP3643207A1 (en) * | 2018-10-26 | 2020-04-29 | Latexco NV | A hybrid mattress |
US12004654B2 (en) * | 2020-08-27 | 2024-06-11 | Dreamwell, Ltd. | Compressible mattress |
US20220346566A1 (en) * | 2021-04-29 | 2022-11-03 | Comfort DTC, Inc. | Heat-dissipating bedding product |
US11806978B2 (en) * | 2021-06-09 | 2023-11-07 | Dreamwell, Ltd. | Hybrid side rail assemblies and mattresses including the same |
Family Cites Families (43)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US780450A (en) * | 1904-10-13 | 1905-01-17 | Louisiana Leather Mfg Company | Tanning apparatus. |
US1906893A (en) * | 1931-01-29 | 1933-05-02 | Young Samuel | Mattress |
GB376937A (en) * | 1931-06-26 | 1932-07-21 | Ioco Rubber & Waterproofing Co | Improvements in or relating to rubber cushions, mattresses, shock absorbers or the like |
FR780450A (en) | 1934-10-30 | 1935-04-26 | Dutilleul Et Lefebvre | Improvements to elastic bases for seats and mattresses |
US2408382A (en) * | 1943-08-09 | 1946-10-01 | Englander Co Inc | Mattress |
US2826769A (en) * | 1956-01-31 | 1958-03-18 | Eclipse Sleep Products Inc | Border stabilizer |
US2940089A (en) * | 1956-12-24 | 1960-06-14 | Englander Co Inc | Mattress structure |
US3010122A (en) * | 1956-12-24 | 1961-11-28 | Englander Co Inc | Resilient pad structure |
US3099021A (en) * | 1957-05-28 | 1963-07-30 | Englander Co Inc | Foam mattress |
US3100305A (en) * | 1961-06-09 | 1963-08-13 | Freightliner Corp | Mattress |
US3262135A (en) * | 1964-05-13 | 1966-07-26 | Acd Bedding Corp | Bedding structure |
US3618146A (en) * | 1969-04-24 | 1971-11-09 | Us Bedding Co The | Border stabilizer |
GB1328222A (en) * | 1970-08-10 | 1973-08-30 | Mirabed Ag | Mattresses |
GB1383615A (en) * | 1972-08-09 | 1974-02-12 | France Bed Co | Mattress |
US4019451A (en) * | 1975-12-08 | 1977-04-26 | Autrey William L | Mattress construction and method of making |
US4067076A (en) * | 1976-08-17 | 1978-01-10 | Mirabed Ag | Upholstered body |
JPS55107054A (en) * | 1979-02-13 | 1980-08-16 | Nissan Motor Co Ltd | Air fuel mixture atomization advancing device of internal combustion engine |
JPS5712947Y2 (en) * | 1979-10-22 | 1982-03-15 | ||
JPS61176389A (en) * | 1985-01-31 | 1986-08-08 | 株式会社タチエス | Bead edge of seat |
US4686725A (en) * | 1985-10-28 | 1987-08-18 | Span America Medical Systems | Mattress cushion with securement feature |
US4677701A (en) * | 1985-11-19 | 1987-07-07 | Galumbeck Michael H | Firmness control device |
JPS63183849A (en) * | 1987-01-27 | 1988-07-29 | 凸版印刷株式会社 | Decorative board and manufacture thereof |
DE3728148A1 (en) * | 1987-08-24 | 1989-03-09 | Andreas Breckle | POCKET SPRING MATTRESS |
US4901384A (en) * | 1987-10-19 | 1990-02-20 | Eary Paul A | Body pillow |
US5048167A (en) * | 1989-03-13 | 1991-09-17 | Heffley James R | Method for restoring used mattresses |
US5040255A (en) * | 1990-06-06 | 1991-08-20 | Barber Manufacturing Company, Inc. | Cushion or mattress structure |
US5133116A (en) * | 1990-12-21 | 1992-07-28 | The Ohio Mattress Company Licensing And Components Group | Method of stabilizing and reinforcing a spring border |
US5239715A (en) * | 1992-02-11 | 1993-08-31 | The Ohio Mattress Company Licensing And Components Group | Border stabilizing and reinforcing member for use in mattresses, cushions and the like |
US5467488A (en) * | 1992-02-11 | 1995-11-21 | The Ohio Mattress Co. Licensing & Components Group | Border stabilizing member and method for making mattresses, cushions and the like using the same |
US5210890A (en) * | 1992-09-21 | 1993-05-18 | Tualatin Sleep Products | Mattress foundation with springs and foam elements |
US5469590A (en) * | 1994-03-04 | 1995-11-28 | The Spring Air Company | Mattress with compressible support members |
US5537699A (en) * | 1995-05-22 | 1996-07-23 | Foamex L.P. | Mattress border assembly and method of making same |
US5787532A (en) * | 1996-10-04 | 1998-08-04 | The Ohio Mattress Company Licensing And Components Group | Internal mattress wall structures interlockingly engageable with mattress innerspring assemblies |
US5724686A (en) | 1997-02-25 | 1998-03-10 | Eastern Sleep Products, Inc. | Cushion or mattress border support |
US6041459A (en) * | 1997-10-03 | 2000-03-28 | The Spring Air Company | Convoluted foam cushion |
US6306235B1 (en) * | 1997-10-16 | 2001-10-23 | Nomaco, Inc. | Spiral formed products and method of manufacture |
US6023803A (en) * | 1997-11-07 | 2000-02-15 | Ohio Mattress Company Licensing And Components Group | Mattress with high ILD firm topper |
US6128798A (en) * | 1998-09-04 | 2000-10-10 | Sealy Technology Llc | Cavitated pad and innerspring assembly combination having springs with free terminal convolutions |
US6154908A (en) * | 1998-09-15 | 2000-12-05 | L&P Property Management Company | Bedding or seating product with edge support |
JP4584403B2 (en) * | 2000-04-13 | 2010-11-24 | 株式会社デルタツーリング | mat |
US6263533B1 (en) * | 2000-06-02 | 2001-07-24 | Sealy Technology Llc | Extruded foam reinforcement structures for innerspring assemblies and mattresses |
JP3790856B2 (en) * | 2000-06-29 | 2006-06-28 | Kbセーレン株式会社 | Cushion material and floor slip prevention mat using the same |
KR200242165Y1 (en) * | 2001-05-10 | 2001-10-15 | 주식회사 에이스침대 | a mattress |
-
2003
- 2003-10-16 US US10/686,823 patent/US7185379B2/en not_active Expired - Fee Related
-
2004
- 2004-09-08 MX MXPA06004139A patent/MXPA06004139A/en active IP Right Grant
- 2004-09-08 BR BRPI0415440-1A patent/BRPI0415440A/en not_active Application Discontinuation
- 2004-09-08 JP JP2006535491A patent/JP4956744B2/en active Active
- 2004-09-08 WO PCT/US2004/029178 patent/WO2005039849A2/en active Application Filing
- 2004-09-08 EP EP04809701A patent/EP1682320A4/en not_active Withdrawn
- 2004-09-08 CN CN2004800303723A patent/CN1964650B/en not_active Expired - Fee Related
- 2004-09-08 NZ NZ545870A patent/NZ545870A/en not_active IP Right Cessation
- 2004-09-08 CA CA2539008A patent/CA2539008C/en not_active Expired - Fee Related
- 2004-09-08 AU AU2004283189A patent/AU2004283189B2/en not_active Ceased
- 2004-10-08 AR ARP040103679A patent/AR046418A1/en unknown
-
2006
- 2006-04-10 IL IL174889A patent/IL174889A0/en not_active IP Right Cessation
- 2006-04-14 KR KR1020067007153A patent/KR101210687B1/en not_active IP Right Cessation
Non-Patent Citations (1)
Title |
---|
See references of EP1682320A4 * |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9962007B2 (en) | 2009-06-04 | 2018-05-08 | Mantzis Holdings Pty Ltd. | Mattress core |
US11076705B2 (en) | 2014-05-30 | 2021-08-03 | Sealy Technology, Llc | Spring core with integrated cushioning layer |
US11033114B2 (en) | 2015-12-17 | 2021-06-15 | Sealy Technology, Llc | Coil-in-coil spring with variable loading response and mattresses including the same |
US11051631B2 (en) | 2016-01-21 | 2021-07-06 | Sealy Technology, Llc | Coil-in-coil springs with non-linear loading responses and mattresses including the same |
US11026517B2 (en) | 2016-12-29 | 2021-06-08 | Sealy Technology, Llc | Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same |
Also Published As
Publication number | Publication date |
---|---|
AU2004283189A1 (en) | 2005-05-06 |
JP4956744B2 (en) | 2012-06-20 |
KR101210687B1 (en) | 2012-12-10 |
AR046418A1 (en) | 2005-12-07 |
CN1964650A (en) | 2007-05-16 |
US20050039264A1 (en) | 2005-02-24 |
IL174889A0 (en) | 2006-08-20 |
WO2005039849A3 (en) | 2006-12-21 |
US7185379B2 (en) | 2007-03-06 |
JP2007508106A (en) | 2007-04-05 |
CA2539008A1 (en) | 2005-05-06 |
MXPA06004139A (en) | 2006-06-27 |
EP1682320A4 (en) | 2010-03-03 |
CA2539008C (en) | 2012-01-10 |
AU2004283189B2 (en) | 2009-12-24 |
CN1964650B (en) | 2012-07-04 |
BRPI0415440A (en) | 2006-12-05 |
EP1682320A2 (en) | 2006-07-26 |
NZ545870A (en) | 2010-02-26 |
KR20070026321A (en) | 2007-03-08 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2539008C (en) | Foam encased innerspring with internal foam components (triple case) | |
CA2752631C (en) | Unitized thermoplastic foam structures | |
US9549620B2 (en) | Channel-cut cushion supports | |
US4106139A (en) | Mattress foundation | |
AU2002337961B2 (en) | Single piece foam toppers with perimeter areas having variable support and firmness properties | |
US20180146791A1 (en) | Tunable spring mattress and method of making same |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
WWE | Wipo information: entry into national phase |
Ref document number: 200480030372.3 Country of ref document: CN |
|
AK | Designated states |
Kind code of ref document: A2 Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW |
|
AL | Designated countries for regional patents |
Kind code of ref document: A2 Designated state(s): BW GH GM KE LS MW MZ NA SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LU MC NL PL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG |
|
121 | Ep: the epo has been informed by wipo that ep was designated in this application | ||
DPEN | Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed from 20040101) | ||
WWE | Wipo information: entry into national phase |
Ref document number: 2004283189 Country of ref document: AU |
|
WWE | Wipo information: entry into national phase |
Ref document number: 545870 Country of ref document: NZ |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2539008 Country of ref document: CA |
|
WWE | Wipo information: entry into national phase |
Ref document number: 200602480 Country of ref document: ZA |
|
ENP | Entry into the national phase |
Ref document number: 2004283189 Country of ref document: AU Date of ref document: 20040908 Kind code of ref document: A |
|
WWP | Wipo information: published in national office |
Ref document number: 2004283189 Country of ref document: AU |
|
WWE | Wipo information: entry into national phase |
Ref document number: 174889 Country of ref document: IL |
|
WWE | Wipo information: entry into national phase |
Ref document number: PA/a/2006/004139 Country of ref document: MX |
|
WWE | Wipo information: entry into national phase |
Ref document number: 1020067007153 Country of ref document: KR Ref document number: 2006535491 Country of ref document: JP |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2004809701 Country of ref document: EP |
|
WWP | Wipo information: published in national office |
Ref document number: 2004809701 Country of ref document: EP |
|
ENP | Entry into the national phase |
Ref document number: PI0415440 Country of ref document: BR |
|
WWP | Wipo information: published in national office |
Ref document number: 1020067007153 Country of ref document: KR |