WO2005065493A1 - Procede de fabrication de matelas encadres - Google Patents

Procede de fabrication de matelas encadres Download PDF

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Publication number
WO2005065493A1
WO2005065493A1 PCT/US2004/044000 US2004044000W WO2005065493A1 WO 2005065493 A1 WO2005065493 A1 WO 2005065493A1 US 2004044000 W US2004044000 W US 2004044000W WO 2005065493 A1 WO2005065493 A1 WO 2005065493A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam
innercore
mattress
bottom panel
perimeter sidewall
Prior art date
Application number
PCT/US2004/044000
Other languages
English (en)
Inventor
Richard F. Gladney
Original Assignee
Dreamwell, Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dreamwell, Ltd. filed Critical Dreamwell, Ltd.
Priority to JP2006547584A priority Critical patent/JP2007516807A/ja
Publication of WO2005065493A1 publication Critical patent/WO2005065493A1/fr

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
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C23/00—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases
    • A47C23/007—Edge stiffeners
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C23/00—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases
    • 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
    • A47C27/14—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
    • A47C27/20—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

Definitions

  • the systems and methods described herein relate to the manufacture of bedding products, specifically mattresses and mattress foundations, and related manufacturing systems, mattresses and bedding products.
  • Conventional mattress systems typically consist of a foundation or box spring and a mattress.
  • the mattress assembly typically consists of a core, various layers of padding above and below the core, and a cover enveloping the assembly. Additional features or embellishments, such as support bolsters around the perimeter of the core or toppers are also well-known.
  • the mattress core may comprise a plurality of coil springs, either individually pocketed or un-pocketed, or one or more layers (or regions) of different foam materials.
  • Foam encased innercores expand the mattress' edge-to-edge sleeping surface with a foam encasement that encircles the perimeter of the innerspring. It provides a firmer seating edge and expands the sleeping surface to the full perimeter of the mattress.
  • the edge surrounds the coil unit, and sits on a support layer that supports the foam edge and the coil unit.
  • the foam edge is typically glued to the support layer and the coil unit is joined to the support layer by a border wire and hog rings.
  • the innerspring unit When manufacturing the mattress, the innerspring unit is typically attached to a lower border wire and that border wire is joined to the support layer. The foam edge is glued in place around the innerspring unit.
  • the systems and methods described herein include improved mattresses and techniques for manufacturing such mattresses.
  • a mattress core support system wherein the mattress core is encased in a tray, in particular a foam tray, and a method of manufacturing an encased mattress.
  • the system and method are compatible with (and can be sized for) all standard mattress cores, e.g., coil spring, foam, foam/coil composite, and all known sizes.
  • a method of manufacturing a mattress includes the acts of providing a tray having a bottom panel and a perimeter sidewall, wherein the bottom panel and perimeter sidewall form a cavity; applying an adhesive to the bottom panel inside the cavity at least proximate to the perimeter sidewall; and placing an innercore inside the cavity. The innercore is thereby secured to the bottom panel by the adhesive.
  • a mattress includes a substantially rigid base platform; a perimeter sidewall joined to the base platform, wherein the platform and perimeter sidewall define an interior cavity; and an innercore disposed within the cavity.
  • the innercore is secured to the bottom panel by an adhesive at least proximate to the perimeter sidewall.
  • Exemplary embodiments may include one or more of the following features.
  • Both the bottom panel and the perimeter sidewalls may be made of foam, whereby the bottom panel is preferably made of high density foam.
  • the bottom panel can be made of wood, cardboard, or plastic as long as the material is capable of providing support to the innercore.
  • the entire assembly can be topped with a conventional layer of padding and closed by a cover.
  • the innercore can be in the form of an open coil construction, fabric-encased spring coils, and/or foam-encased springs. Alternatively or in addition, the innercore can also be made at least in part of a block of resilient foam.
  • the foam tray can be manufactured of several pieces, for example, by gluing the perimeter sidewall to a peripheral region of a major surface of the bottom panel.
  • the perimeter sidewall can include a plurality of sidewall sections, preferably four sections.
  • the innercore can be secured against the substantially rigid base platform by a wire, such as a border wire.
  • the sidewall can include a joint for allowing the mattress to pivot between a reclined and an inclined position.
  • the mattresses described herein may be two-sided mattresses and may come in any suitable shape and size, including California King, king, Olympic Queen, queen, and twin. It will further be understood that the assemblies described herein may be employed in other applications, including futons, couches, or any other type of seating furniture.
  • Figure 1 illustrates one embodiment of a mattress foam tray for a foam encased mattress according to the invention
  • Figure 2 shows a foam tray assembly with a spring coil core in place, according to one embodiment of the present invention
  • Figure 3 depicts a first step in a process for making a mattress
  • Figure 4 depicts a second step in a process for making a mattress.
  • Figure 1 depicts one portion of a foam-encased mattress 10 being manufactured according to the systems and methods described herein.
  • the foam edge 12 in this embodiment, sits on top of a platform or support layer 14 that acts as the support layer of, in the depicted exemplary embodiment, a one sided mattress.
  • the foam edge 12 in conjunction with the support layer 14 define an interior cavity 16 into which a support unit 40 (see Figure 2), such as an inner spring, pocketed coil unit, latex foam core, or combination of these, may be placed.
  • a support unit 40 see Figure 2
  • a conventionally used separate foundation or box spring piece may be entirely eliminated as the support layer 14 provides sufficient mechanical support for the mattress assembly.
  • the interior periphery 18 of the foam edge 12 can be coated with, for example, a strip of a glue, adhesive, or other bonding agent, that can hold the support unit on the support layer and/or the foam edge 12, thereby providing for the ready manufacture of foam encased mattresses.
  • Sidewalls 12 can be constructed from a dense natural and/or synthetic foam material of the type commonly used in the bedding arts, such as (but not limited to) latex, polyurethane, or other foam products commonly known and used in the bedding and seating arts having a density of 1.5 to 1.9 and 20 to 35 ILD.
  • foam compositions other than one having this specific density and ILD can be used.
  • foams of various types, densities, and ILDs may be desirable in order to provide a range of comfort parameters to the buyer.
  • Platform 14 may consist of another panel of rigid foam, or it may be made of a wooden, cardboard, or plastic structure selected to provide support to the mattress core. Depending on the mattress core selected and its inherent stiffness, stiffer or more compliant base platforms 14 may be chosen.
  • Figure 2 shows an exemplary embodiment of a tray support 20 with a coil spring mattress core 40 in place. Note that, for clarity, top padding layers 50 and the cover have been peeled back.
  • top padding layers 50 and the cover have been peeled back.
  • the invention is not limited to any means of finishing the mattress and includes all such means and materials within its scope.
  • Conventional coil spring core 40 may be comprised of conventional helical or semi-helical springs.
  • the springs may also be encased in a fabric pocket, either individually, in groups, or in strings joined by fabric, all of which are well- known in the bedding art.
  • a foam core module may also be substituted for coil spring mattress core 40.
  • the foam core module is, in some embodiments, a monolithic block of a single type of resilient foam selected from foams having a range of densities (themselves well-known in the art) for supporting one or more occupants during sleep.
  • foam core is made of any industry- standard natural and/or synthetic foams, such as (but not limited to) latex, polyurethane, or other foam products commonly known and used in the bedding and seating arts having a density of 1.5 to 1.9 and 20 to 35 ILD.
  • foam compositions other than one having this specific density and ELD can be used.
  • foams of various types, densities, and ILDs maybe desirable in order to provide a range of comfort parameters to the buyer.
  • the foam core may comprise one or more horizontal layers of multiple types of foams arranged in a sandwich arrangement. This sandwich of different foams, laminated together, may be substituted for a homogeneous foam block of a single density and/or ILD.
  • the foam core may comprise one or more vertical regions of different foam compositions (including vertical regions having multiple horizontal layers), where the different foams are arranged to provide different amounts of support (also referred to as "firmness” in the art) in different regions of the sleeping surface.
  • the invention is not limited to any particular type of foam density or ILD or even to a homogenous density/ILD throughout the foam core. Furthermore, the invention is not limited to any particular type of core.
  • a conventional mattress cover envelopes the entire assembly.
  • the sides of the vertical walls and the bottom surface of the platform may be pre-finished according to conventional means and the cover attached to the side panels only. This latter attachment may be made by conventional means, as by a zipper, Nelcro, or stitching, and with or without additional decoration (such as rope welting) or embellishment (such as a mattress topper).
  • Figure 2 illustrates a mattress support comprising a perimeter sidewall and a platform, wherein the perimeter sidewall is attached to the top surface of the platform to define a cavity disposed to receive a mattress core.
  • the perimeter sidewall may comprise one or more segments, each attached to the platform.
  • the perimeter sidewall segments may also be attached to each other.
  • the mattress support may also include top padding attached to the perimeter sidewall and a cover enveloping the top padding, the perimeter sidewall, and the platform and secured thereto.
  • Figure 3 depicts the platform or support layer 14 of a one sided mattress 10.
  • an adhesive material 32 is applied by a spay gun 34 about the peripheral edge of the support layer 14.
  • the adhesive is a spray glue, such as the spray glue Super 77, manufactured and sold by the 3M company of St. Paul, Minnesota.
  • a moderate coating of spray glue is placed around the edge of the support layer.
  • the support layer 14 is also made of a foam material that will similarly dissolve on contact with the spray glue.
  • the spray nozzle depicted in Figure 3 may also be employed for spraying glue about the interior peripheral edge 18 of the support layer 14.
  • a strip 18 of spray glue having a width of for example, four inches (10 cm) may be laid down on the support layer 14 and against the interior edge of the perimeter sidewall 12.
  • a mattress core 40 such as a coil spring unit, may be lowered into the cavity 16 formed by the perimeter sidewall 12 and the support layer 14 such that the peripheral edge of the coil spring unit sits against the strip 18 laid onto the support layer 14.
  • the coil spring unit can include a plurality of pocketed coils with the pocket formed of Duon material.
  • the Duon material will bond tightly to the support layer by the action of the spray glue.
  • the coil can be an open coil unit. In this way, the coil unit can be joined to the support layer 14 without the use of a border wire or hog rings. However, in alternate embodiments depending on the particular application, a border wire and hog rings may still be employed in conjunction with the spray glue to add strength.
  • ticking and/or upholstery layers 50 may be attached to the mattress and a finished mattress will be produced.
  • the upholstery layer can be stitched to upholstery material stapled or otherwise joined to the exterior surface of the parameter sidewall.
  • the upholstery layer, as well as any intermediate padding aids in holding the innercore within the cavity defined by the parameter sidewall.
  • the mattress core 40 may be dimensioned to be slightly larger than the interior cavity 16.
  • the spring core may be made slightly larger by adding one or more additional rows of springs along the length of the core.
  • the mattress core 40 will fit snuggly against the perimeter sidewall 12, allowing frictional engagement to hold the core, at least in part, within the cavity 16. Additionally, the mattress core 40 may include one or more optional rows of springs running along the width of the core 40, to cause a snug fit against the head and foot of the perimeter wall 12. In embodiments where the mattress core 40 comprises foam, latex, an air mattress or some other support structure, the core 40 may be dimensioned to be slightly larger than the cavity 16.
  • the mattress is a one sided mattress that has a support layer 14 that is relatively rigid.
  • the systems and methods described herein maybe used with two sided mattresses as well as mattresses that are capable of being used with adjustable beds.
  • a mattress for an adjustable bed may have a foam edge that has a break or a flexible component 42 that is disposed somewhat midway along both long edges of the mattress. In this way, the adjustable bed will be more capable of pivoting around a central axis as the flexible portion built in the foam edge readily allows the mattress to pivot and bend.
  • the support layer 14 may be foam, wood, plastic or a composite of such materials and typically will be covered by a thin layer of a non-woven sheeting. It may be a high density polyurethane foam having a density of approximately 1.85 lbs./cu. ft. and a firmness above 30 ILD. The firmness may be achieved by using one substantially rigid layer, or by using a plurality of layers that in aggregate provide the desired firmness. Other rigid materials may be used and may include plastic, wood, or other non-yielding rigid materials. To the extent such materials for the layer yield to pressure, such materials are to have at least a high degree of recoverability once the pressure has been removed so that the materials are not compacted.

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

La présente invention a trait à un système de support de l'âme centrale d'un matelas (10) sous la forme d'une plaque rembourrée avec un panneau de fond (14) sensiblement rigide. Le panneau présente une paroi latérale périphérique (12) réalisée de préférence en mousse et fixée au panneau de fond (14). Le système est compatible avec (et dimensionné pour) toutes les âmes de matelas, par exemple, à ressorts hélicoïdaux, à ressorts de poche, en mousse, en composite mousse/ressort, et de toutes les dimensions existantes. L'âme centrale de matelas est fixée au panneau de fond (14) par un adhésif, ce qui simplifie l'ensemble et réduit le coût de fabrication du matelas.
PCT/US2004/044000 2003-12-31 2004-12-31 Procede de fabrication de matelas encadres WO2005065493A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2006547584A JP2007516807A (ja) 2003-12-31 2004-12-31 ケースに収容されたマットレスの製造方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/750,540 US20040261186A1 (en) 2002-10-15 2003-12-31 Methods for manufacturing encased mattresses
US10/750,540 2003-12-31

Publications (1)

Publication Number Publication Date
WO2005065493A1 true WO2005065493A1 (fr) 2005-07-21

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Country Status (4)

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US (1) US20040261186A1 (fr)
JP (1) JP2007516807A (fr)
KR (1) KR20060130633A (fr)
WO (1) WO2005065493A1 (fr)

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CN107206408A (zh) * 2015-01-23 2017-09-26 美梦有限公司 床垫制造方法和装置
US10365638B2 (en) 2015-01-23 2019-07-30 Dreamwell, Ltd. Scheduling process for automated mattress manufacturing
CN107206408B (zh) * 2015-01-23 2019-12-17 美梦有限公司 床垫制造方法和装置
US10525557B2 (en) 2015-01-23 2020-01-07 Dreamwell, Ltd. Automated mattress manufacturing process and apparatus
US10696540B2 (en) 2015-04-15 2020-06-30 Dreamwell, Ltd. Coil string staging area apparatus and method

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US20040261186A1 (en) 2004-12-30
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