WO2011072294A1 - Matelas présentant un panneau en mousse qui verrouille un ensemble de ressorts et un ensemble ouatiné - Google Patents

Matelas présentant un panneau en mousse qui verrouille un ensemble de ressorts et un ensemble ouatiné Download PDF

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Publication number
WO2011072294A1
WO2011072294A1 PCT/US2010/060111 US2010060111W WO2011072294A1 WO 2011072294 A1 WO2011072294 A1 WO 2011072294A1 US 2010060111 W US2010060111 W US 2010060111W WO 2011072294 A1 WO2011072294 A1 WO 2011072294A1
Authority
WO
WIPO (PCT)
Prior art keywords
coils
mattress
panel
receptacle
foam
Prior art date
Application number
PCT/US2010/060111
Other languages
English (en)
Inventor
Billy Joe Frame
Original Assignee
Spring Air International Llc
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 Spring Air International Llc filed Critical Spring Air International Llc
Publication of WO2011072294A1 publication Critical patent/WO2011072294A1/fr

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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
    • A47C27/04—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
    • 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
    • A47C27/06—Spring inlays
    • A47C27/062—Spring inlays of different resiliencies
    • 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
    • A47C27/06—Spring inlays
    • A47C27/063—Spring inlays wrapped or otherwise protected
    • A47C27/064—Pocketed springs

Definitions

  • This application discloses an invention which is related, generally and in various embodiments, to a mattress having a foam panel which interlocks a spring assembly and a quilted assembly.
  • Conventional mattresses are constructed in many different ways to provide uniform or varied firmness along their lengths, such as conventional coil spring mattresses or synthetic foam mattresses.
  • Other mattresses include housings made of synthetic polymer/copolymer plastic material generally formed by upper and lower layers or panels and a peripheral border therebetween.
  • a spring unit or series of springs are housed within the chamber of the mattress housing.
  • Conventional mattresses utilizing springs can be zoned to provide varying firmness. Typical zoned mattresses are divided into at least three longitudinal zones of differing firmnesses.
  • FIG. 1 illustrates various embodiments of a mattress
  • FIG. 2 illustrates various embodiments of a housing of the mattress of FIG. 1;
  • FIGs. 3 and 4 illustrate various embodiments of a spring assembly of the mattress of FIG. 1;
  • FIGs. 5 -9 illustrate different arrangements of first and second coils for different embodiments of the mattress of FIG. 1;
  • FIG. 10 illustrates various embodiments of a foam panel of the mattress of FIG. 1; and [ 10 ] FIG. 11 illustrates other embodiments of the mattress of FIG. 1.
  • FIG. 1 illustrates various embodiments of a mattress 10. For purposes of clarity, a partially exploded view of the mattress 10 is shown in FIG. 1.
  • the mattress 10 includes a housing 12, a spring assembly 14, a quilted assembly 16, and a foam panel 18 which interlocks the spring assembly 14 and the quilted assembly 16.
  • FIG. 2 illustrates various embodiments of the housing 12 of the mattress 10 of
  • the housing 12 is substantially rectangular in shape, defines a receptacle 20 that is substantially rectangular in shape, having first and second ends, and also defining first and second lengths LI, L2, first and second widths Wl, W2, and first and second heights HI, H2.
  • the first length LI, the first width Wl, and the first height HI define the respective "outer" dimensions of the housing 12.
  • the second length L2, the second width W2, and the second height H2 define the respective "outer" dimensions of the receptacle 20. It will be appreciated that any of the first and second lengths LI and L2, the first and second widths Wl and W2, and the first and second heights HI and H2 can be different for different embodiments.
  • the housing 12 includes a panel 22 and a border 24 connected to the panel 22.
  • the panel 22 may be fabricated from any suitable foam material.
  • the panel 22 is substantially rectangular in shape, is fabricated to substantially the same length and width as the first length LI and the first width Wl, and has a substantially uniform thickness. The difference between the first height HI and the second height H2 is the thickness of the panel 22.
  • the border 24 may be connected to the panel 22 in any suitable manner.
  • the border 24 is connected to the panel 22 with an adhesive (e.g., a glue).
  • the border 24 may be fabricated from any suitable foam material, and is generally fabricated from the same foam material that the panel 22 is fabricated from.
  • the border 24 is substantially uniform in cross-section also and is substantially rectangular in shape, and defines a first surface 26 and a second surface 28.
  • the first surface 26 may be considered the "outer" surface of the border 24 and the second surface 28 may be considered the "inner" surface of the border 24.
  • the border 24 is connected to the panel 22 such that the "outer" surface 26 of the border 24 is substantially aligned with the perimeter of the panel 22, and the “inner” surface 28 of the border 24 defines the respective "outer” dimensions of the receptacle 20, and thus defines the perimeter of the receptacle 20.
  • the border 24 includes a plurality of individual border members (e.g., one for each of the four sides of the rectangular shape) which are adhered together to form the entirety of the border 24.
  • the border 24 is fabricated as a single molded component substantially rectangular in shape.
  • the border 22 is fabricated as a single piece of material having a first end and a second end. The single piece of material is subsequently bent to form three corners, then the first end and the second end are adhered together to form the fourth corner of the substantially rectangular shape.
  • FIG. 3 illustrates various embodiments of the spring assembly 14 of the mattress
  • the plurality of first and second coils 30, 32 may be arranged in any manner to substantially cover the entire length L2 and width W2 of the receptacle 20, and the respective first and second coils 30, 32 may be of any suitable size, height, shape (rectangular, cylindrical, etc.), wire gauge, composition, etc.
  • each individual coil is positioned in a fabric pocket. All of the fabric pockets for a given "row” may be fabricated as a single “row” of pockets, and the fabric of each "row” may be connected to the fabric of adjacent "rows" by an adhesive (e.g., glue).
  • first and second coils 30, 32 may include different arrangements of the first and second coils 30, 32, different numbers of first coils 30, different numbers of second coils 32, different sizes (e.g., heights, wire gauges, diameters, etc.) of the first and second coils 30, 32, etc.
  • first and second coils 30, 32 are shown in FIG. 4 as arranged in straight lines, it will be appreciated that according to other embodiments, a "row" of either first coils 30 or second coils 32 may be arranged in a staggered or other type of configuration.
  • the first coils 30 are of a first height and the second coils 32 are of a second height, but the first and second coils 30, 32 are otherwise identical regarding the diameter, style, metal composition, wire gauge, etc. It will be appreciated that according to other embodiments, the first and second coils 30, 32 may have different resistances to compression by being different in size, shape, style, metal composition, wire gauge, etc. In the illustrated embodiment, the first coils 30 are less resistant to compression than the second coils 32 due to the greater height of the first coils 30.
  • a first group of the first coils 30 collectively define a first zone 34, and a first group of the second coils 32 collectively define a second zone 36.
  • the first zone 34 is smaller than either the length L2 or the width W2 of the receptacle 20, and the second zone 36 is smaller than either the length L2 or the width W2 of the receptacle 20.
  • the first zone 34 may be positioned anywhere on the panel 22 and within the receptacle 20, and the second zone 36 may similarly be positioned anywhere on the panel 22 and within the receptacle 20.
  • each of the first and second coils 30, 32 includes a first end and a second end; and wherein the first ends of the first and second coils 30, 32 are disposed adjacent the housing panel 22 and lie in a first plane parallel to the housing panel 22.
  • the second ends of the first coils 30 lie in a second plane and the second ends of the second coils 32 lie in a third plane, and wherein the second plane is parallel to and spaced from the third plane.
  • the number of first coils 30 which collectively define a given first zone 34 can be different than the number of first coils 30 which collectively define another first zone 34. Stated differently, the length of a given first zone 34 can be different than the length of another first zone 34. Similarly, the number of second coils 32 which collectively define a given second zone 36 can be different than the number of second coils 32 which collectively define another second zone 36. Stated differently, the length of a given second zone 36 can be different than the length of another second zone 36.
  • different embodiments of the mattress 10 having substantially the same size may include different arrangements of second coils 32.
  • a first embodiment of the mattress 10 as shown in FIG. 5 may utilize five "rows" of second coils 32 to collectively define a second zone 36A (e.g., a head zone), seven "rows" of second coils 32 to collectively define another second zone 36B (e.g., a torso or lumbar zone), and five "rows" of second coils 32 to collectively define yet another second zone 36C (e.g., a foot or leg zone), a second embodiment of the mattress 10 as shown in FIG.
  • first and second coils 30, 32 may include different sizes and arrangements of first and second coils 30, 32.
  • a first embodiment of the mattress 10 as shown in FIG. 7 utilizes two "rows" of first coils 30 having respective first diameters at the two ends of the spring assembly 14
  • a second embodiment of the mattress 10 as shown in FIG. 8 also utilizes two "rows” of first coils 30 having respective second diameters at the two ends of the spring assembly 14
  • a third embodiment of the mattress 10 as shown in FIG. 9 utilizes three "rows" of first coils 30 having respective third diameters at the two ends of the spring assembly 14.
  • first and second coils 30, 32 are coil springs, although each of the first and second coils 30, 32 in a given embodiment had the same respective diameter, it will be appreciated that the first coils 30 of a given embodiment may include any number of different coil diameters, the second coils 32 of a given embodiment may include any number of different coil diameters, and a given embodiment may include any number of different first coil diameters and different second coil diameters.
  • the respective heights of the first coils 30 are substantially the same as the second height H2. Therefore, it will be appreciated that the portions of the receptacle 20 which are aligned with the first zones 34 are substantially filled by the first coils 30. As the respective heights of the second coils 32 are less than the respective heights of the first coils 30, and thus are less than the second height H2, it will be appreciated that the portions of the receptacle 20 which are aligned with the second zones 36 are not substantially filled by the second coils 32.
  • the resulting unfilled volumes or voids 38 are positioned directly above the second firmness zones and are collectively defined by the border 24 and the second coils 32.
  • FIG. 10 illustrates various embodiments of the foam panel 18 of the mattress 10 of FIG. 1.
  • the foam panel 18 is substantially rectangular in shape, may be fabricated from any suitable material, is fabricated to substantially the same length and width as the first length LI and the first width Wl , and includes projections 40 configured to substantially fill any voids 38 (the number of projections 40 corresponds to the number of voids 38).
  • the projections 40 are substantially rectangular in shape, are smaller than either the length L2 or the width W2 of the receptacle 20, and provide for an increased level of comfort "above" the second zones 36. Due to the projections 40, different portions of the foam assembly 18 have different respective heights.
  • the projections 40 are connected to the spring assembly 14 and may be connected in any suitable manner.
  • the foam panel 18 may be fabricated from any suitable material, and may be fabricated in any suitable manner. According to various embodiments, the foam panel 18 is fabricated from a slab of foam having a thickness equal to the largest height of the foam panel 18. Portions of the foam panel 18 which are aligned with the first zones 34 are removed from the slab to define the projections 40. According to other embodiments, the foam panel 18 is fabricated by connecting (e.g., adhering) individual foam panels which are the same size as the projections 40 to a slab of foam substantially the same length and width as the first length LI and the first width Wl to form the foam panel 18.
  • the quilted assembly 16 is substantially rectangular in shape, and is fabricated to substantially the same length and width as the first length LI and the first width Wl .
  • the quilted assembly 16 may include a foam panel 42 substantially the same length and width as the first length LI and the first width Wl , and a quilt top 44 which covers the foam panel 42.
  • the foam panel 42 may be fabricated from any suitable foam.
  • the foam panel is fabricated from a polyurethane foam.
  • the foam panel 42 may include a plant based mix such as, for example, a mix which includes a soy component. It will be appreciated that the quilted assembly 16 may include any number of foam panels 42, and the respective foam panels 42 may be fabricated from the same foam or different foams.
  • the quilted assembly 16 is connected to the foam panel 18, and may be connected in any suitable manner.
  • the foam panel 42 is connected to the foam panel 18 with an adhesive (e.g., a glue). Due to its connection to the foam panel 18, and the connection of the foam panel 18 to the spring assembly 14, it will be appreciated that the foam panel 18 also functions to interlock the spring assembly 14 and the quilted assembly 16.
  • FIG. 1 1 does not include the housing 12.
  • the length and width of the foam panel 18 is substantially the same as the overall length and width of the coil assembly 14, and the length and width of the quilted assembly 16 is substantially the same as the length and width of the foam panel 18.
  • the length and width of the foam panel 46 is substantially the same as the respective lengths and widths of the foam panel 18 and the quilted assembly 16.
  • a fabric may be utilized to encapsulate the entirety of the mattress 10. It will also be appreciated that a fabric may be utilized to encapsulate the entirety of the mattress 10 for embodiments which do include the housing 12.

Landscapes

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

Abstract

L'invention concerne un matelas comprenant un logement qui présente un panneau formant une base et un bord relié au panneau, le panneau et le bord délimitant un contenant présentant des première et seconde extrémités. Le matelas comprend en outre un ensemble à ressort positionné sur le panneau et à l'intérieur du contenant, l'ensemble à ressort comprenant une pluralité de premières et secondes spires agencées en rangées s'étendant de manière continue de la première extrémité à la seconde extrémité du contenant, les premières spires présentant une taille différente de celle des secondes spires. Des groupes constitués d'une première spire ou de plusieurs premières spires et des groupes constitués d'une seconde spire ou de plusieurs secondes spires délimitent au moins trois zones de fermeté entre la première extrémité et la seconde extrémité du contenant, les premières extrémités des premières et secondes spires étant agencées de manière adjacente au panneau de logement et reposant dans un premier plan parallèle au panneau de logement.
PCT/US2010/060111 2009-12-11 2010-12-13 Matelas présentant un panneau en mousse qui verrouille un ensemble de ressorts et un ensemble ouatiné WO2011072294A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US28564909P 2009-12-11 2009-12-11
US61/285,649 2009-12-11

Publications (1)

Publication Number Publication Date
WO2011072294A1 true WO2011072294A1 (fr) 2011-06-16

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WO (1) WO2011072294A1 (fr)

Cited By (3)

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WO2017192108A1 (fr) * 2016-05-06 2017-11-09 Istikbal Mobilya Sanayi Ve Ticaret A.S. Matelas contenant un tissu minéral et un système de ressorts ensachés possédant cinq zones
JP2018175609A (ja) * 2017-04-19 2018-11-15 株式会社ルービックＪｐ コイルスプリングシートを用いたマットレス
CN110328309A (zh) * 2019-06-27 2019-10-15 浙江华剑智能装备有限公司 袋装弹簧串输送装置和方法及弹簧芯体生产设备和方法

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US9861206B2 (en) * 2013-03-22 2018-01-09 Comfort Revolution, LLC Mattress toppers combining foam and pocket coil layers
US10820716B1 (en) * 2016-12-20 2020-11-03 Steven J. Antinori Dual sided innerspring mattress
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EP3656254A1 (fr) * 2018-11-26 2020-05-27 L&P Swiss Holding GmbH Noyau de ressort de poche

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