MXPA97000595A - Mixed mattress and cover for mattress that has a foam unnucleo - Google Patents

Abstract

The present invention relates to a mattress or mattress cover comprising: a generally rectangular core having perimeter sides, a width, a length, a thickness and a volume, the core consists essentially of latex rubber foam, which has a density of between about 32 kg / m3 to about 96 kg / m3 (2 to about 6 Lb / Ft3), an edge formed by two edge side sections having a thickness and a volume, the edge side sections are fixed to the Perimeter sides of the head and foot core, the side edge sections comprise urethane foam and have a density between about the thickness of the core, and the edge volume comprises at least about 15 percent of the total volume of the core. core and bor

Description

MIXED MATTRESS AND UPPER SUPPORT THAT HAS A LATEX FOAM NUCLEUS FIELD OF THE INVENTION The invention relates to the field of mattresses and, in particular, to mixed foam mattresses and upper mattress supports used for filling.

BACKGROUND OF THE INVENTION The quality of a mattress design is usually quantified by its comfort and duration. Since those characteristics are somewhat subjective, standardized tests have been developed and published for those characteristics (and other related descriptions and definitions) by the American Testing Society and Materials (such as ASTM D 3574-86 and ASTM D 1055-85 ). The ASTM tests and standards are used throughout this description and are incorporated herein by reference. Another consideration that is always present in the design of mattresses is the cost. Therefore, in the design of mattresses, among the factors that are considered is comfort, duration and cost.

Both comfort and durability are affected by the materials used in the production of the mattresses. In an effort to increase comfort and durability, some mattress designs incorporate several laminates or layers of different materials and / or support structure, such as springs, into the mattresses. An example of such a design is described in United States Patent 3,521,311 to Cohen. These types of designs can be effective but expensive in their manufacture. Other materials and manufacturing techniques are also used to improve the comfort and duration of mattresses. For example, U.S. Patent 3,320,339 to Smith discloses a mattress formed of a core of relatively low density latex material surrounded by an integrally molded high density latex core. To manufacture this mattress, the two materials are poured into two areas of a mold (a central area and the surrounding edge) that are separated by a barrier strip. During the vulcanization process, the barrier strip dissolves, and the core and the edge merge together. This is an effective design however with this method, the core and the edge must be formed simultaneously, which may not always be desirable when, for example, the different sections would be optimally vulcanized at different temperatures and / or during different periods . Likewise, because the mattress is composed entirely of latex foam rubber it is relatively expensive. Generally, the use of latex foam rubber on mattresses is desirable because the latex is durable and provides a high level of comfort and support. More specifically, latex foam rubber is known to remain elastic, even though it is used repeatedly over a long period. A mattress of latex foam can last 20 or more years without substantially decreasing its elasticity. Some mattress designs, such as those described above, use rubber latex foam on the mattresses. These designs are comfortable and durable, however, they are expensive. In addition, much of the benefit of the latex foam material is not obtained and therefore is wasted, especially along the edge of the mattress where it is not subjected to repetitive and heavy use. Therefore, what is desired is a mattress design that is relatively easy and inexpensive in its elaboration, and that includes both core and edge sections that do not need to be formed simultaneously and do not need to be comprised of the same material.

BRIEF DESCRIPTION OF THE INVENTION Accordingly, it is an object of the invention to provide a mattress with a latex foam rubber core and synthetic urethane foam edge sections or other inexpensive foams. It is another object of the invention to provide a mattress of the above feature with core and edge sections that are sized to reduce to the minimum the use of rubber latex foam relatively expensive while maintaining a high level of comfort and duration. It is even another object of the invention to provide a mattress of the above characteristics with the edge formed of a plurality of sections adhered to the periphery of the core section. It is even another object of the invention to provide a mattress of the above characteristics with the edge volume comprising at least about 15 percent of the total mattress volume and preferably at least about 30 percent of the total mattress volume. It is a further object of the invention to provide a mattress of the above characteristics with a core of latex having a density between 9.75 and 29.30 kg (2 and 6 pounds) per cubic meter.

It is another object of the invention to provide a mattress of the above characteristics with the edge having a density of between 4.88 and 19.53 kg (1 and 4 pounds) per cubic meter. It is the object of the invention to provide a thin mixed mattress of the type used as a top support for a conventional mattress. More specifically, it is an object of the invention to provide a thin mattress in the order of 0.63 to 10.16 cm thick, which is the area of a conventional mattress. This top support mattress is placed on a conventional mattress and is used to provide the comfort of latex foam without the expense of replacing the conventional mattress. These and other objects of the invention are obtained by a mattress having a latex foam rubber core section at least partially enclosed by sections of synthetic urethane foam bonded adhesively to the periphery of the core section. The edge sections are substantially equal in thickness to the core section although they may be of a different density. The core section preferably has a density between 9.76 and 29.30 kg (2 and 6 pounds) per cubic meter. The edge sections of preference have densities between 4.88 and 19.53 kg (1 and 4 pounds) per cubic meter.

According to one aspect of the invention there is provided a mattress top support and as a core section of latex foam rubber at least partially enclosed by sections of synthetic urethane foam bonded by adhesive to the periphery of the core section. The latex top support is for use on top of an existing conventional mattress to increase the comfort of the mattress while using an existing conventional mattress. The upper support can be used as a product already marketed and placed on top of a mattress. Alternatively, the upper support can be placed on an unfinished mattress (either a conventional mattress that includes steel springs or a foam mattress) and the upper support and the mattress are then covered with fabric. These and other aspects of the invention are described as greater detail below and will be better understood from the detailed description, especially when read in light of the following drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is an isometric view of the mattress of the present invention.

FIGURE 2 is a cross-sectional view along line 2-2 of Figure 1 of the matrix of the present invention. FIGURE 3 is an exploded isometric view of the mattress of Figure 1 before assembly. FIGURE 4 is an isometric view of an upper mattress support that is placed on a conventional mattress and the spring mattress. FIGURE 5 is a sectional view of a mattress upper support and the mattress assembled together and covered.

DETAILED DESCRIPTION OF THE INVENTION With reference to FIGURE 1, in one embodiment, the mattress 10 of the present invention includes a core section 12 and a frame section 14. The frame 14 is formed of a number of edge sections 16. Preferably, all the sections have substantially the same thickness (or height) so that the upper surface 18 of the mattress 10 is substantially planar. The core section 12 is located in the heaviest area of use of the mattress 10 and the area of greatest importance (ie, the central portion 20, which supports a user's back and waist). The area outside the outer periphery 22 of the core section 12 is not used with the same intensity as the central portion 20 (ie, users generally do not sleep with their back and waist on the edge of the mattress), therefore , the high durability and comfort characteristics of latex foam rubber are not required in the edge sections 16. Referring to FIGURES 2 and 3, the edge sections 16, are located around the periphery of the core section 12 and may be attached to the periphery 22 by an adhesive 24, or by any other suitable method. Preferably, the edge sections 16 are rectangular in shape with the head and foot sections 26, 28 extending laterally beyond the core to cover the ends of the side sections 30, 32, to form a rectangular mattress. Alternatively, the ends of the edge sections 16 could be angled at 45 degrees (similar to the design of a normal paint frame) to form the rectangle. The core section 12 can be made from a single layer of latex foam rubber. However, the core section 12 could also be made of multiple layers of latex foam rubber of different densities or two rubber latex foam blocks placed side by side to provide two levels of firmness in a mattress intended to be for the use of a couple.

Further, it is preferred that the core section consists essentially of 100 percent foam rubber, although it is acceptable for the core section to include small amounts of urethane or other similar synthetic foams. However, it should be appreciated, that other embodiments, four edge sections are not required and other edge configurations can be used within the scope of the invention. In this case, the core section would be only partially enclosed by the edge sections 16. For example, the mattress 10 could include a core section 12 with only two edge sections 16, for example, only the side sections 30, 32 or only the head and foot sections 26, 28 or any combination thereof. Preferably, the core and edge sections 12, 16 are approximately 7.62 to 27.94 cm (3 to 11 inches) (H, as shown in the figures). Preferably, the head and foot sections 26, 28 are between approximately 17.78 and 25.4 cm (7 and 10 inches) wide (i.e. the horizontal width, as shown in the figures) and preferably the side sections 30, 32, are approximately 10.16 and 15.24 cm (4 and 6 inches) in width approximately. Also, the volume of the edge sections 16 is at least about 15 percent of the total volume of the mattress and preferably at least about 30 percent of the total volume. Referring to Figure 4, another embodiment of the invention is shown. The mattress 40 is an upper support for a conventional mattress 42 that rests on a conventional spring mattress 44. The mattress 40 includes a core section 46 and a frame section 48. The frame and core sections have the same materials and densities as described with respect to the mattress shown and described in FIGURES 1-3. Preferably, the frame section 14 is made from four sections and adhered to the periphery. However, as in the case of the mattress described in FIGURES 1-3, the frame section has at least two edge sections. The mattress 40, which is used as a top support, is made in a manner similar to the mattress described in FIGURES 1-3. However, it is possible to manufacture a block of relatively large thickness and then cut the block to form a plurality of upper mattress supports such as the upper mattress support 40. The mattress upper support 40 has a thickness 50 that is between about 0.63 and 10.16 cm and more preferably between approximately 2.54 and 7.62 cm (approximately one inch and approximately three inches), the upper support 40 is located in the upper part of the upper surface of the conventional mattress 42 and is held in position by the friction between the mattress 40 and the top of the conventional mattress 42. In addition, a mattress pad, typically made of cushioned cotton material can be placed on the upper mattress support 40 and, the mattress cover typically has prefabricated corners that are thick enough to hold both the upper support of the mattress 40 and the co 42 together as a unit. Alternatively, as shown in FIGURE 5, the upper support 40 is placed on a mattress 52 which may be a conventional mattress with steel springs, a foam mattress (either latex foam, urethane foam or other polymeric foams) or another type of mattress. The upper support 40 and the mattress 52 are held together by a fabric cover 54 that is fired around the exterior of the mattress, as in the case of most conventional sleeping mattresses. With regard to the mattresses shown in the FIGURES 1-5, the edge sections are made from urethane foam, ie the cellular product produced by the interaction of active hydrogen compounds, water and isocyanates. The urethane foam can be a bonded foam, ie a product made by adhering small pieces of urethane foam together with an appropriate bonding agent and with or without fillers. The urethane foam can also be a molded foam, that is, a cellular foam product molded in a closed chamber or thick foam which is a section of foam cut from the inner portion of a large load. The core section is made from latex foam rubber, ie foam where the material used in the manufacture is natural rubber latex, recovered rubber latex, synthetic rubber latex or similar rubber materials used alone or in combination. In accordance with one aspect of the invention, the latex core and the urethane edge sections may have different levels of firmness. In a preferred form of the invention, the edge sections are firmer than the core to provide a firm support when a person sits on the edge of the mattress. The foregoing description is for the purpose of teaching those of ordinary skill in the art how to practice the present invention and is not intended to detail all those obvious modifications and variations of which will become apparent to the skilled worker upon reading the description. However, it is intended that such obvious modifications and variations be included within the scope of the present invention as defined in the appended claims.

Claims (13)

1. A sleeping mattress characterized in that it comprises: a generally rectangular core having perimeter sides, a width, length, thickness and volume, the core consists essentially of latex rubber foam having a density of between approximately 9.76 kg (2 pounds) per cubic meter and 29.30 kg (6 pounds) per cubic meter; at least two edge sections having a thickness and a volume, the edge sections are fixed on at least two of the perimeter sides of the core, the edge comprises urethane foam and has a density of between about 4.88 to about 19.53 kg (1 and about 4 pounds) per cubic meter, the thickness of the edge is approximately the thickness of the core; and the edge volume comprises at least about 15 percent of the total volume of the core and rim.

2. The sleeping mattress according to claim 1, characterized in that there are four edge sections having thicknesses and volumes, the edge sections are adhered to the core perimeter, the edge sections comprise urethane foam and have densities of between about 4.88. and approximately 19.53 kg (1 and approximately 4 pounds) per cubic meter.

3. The sleeping mattress according to claim 2, characterized in that the edge sections further comprise head, foot sections, and two side sections and wherein the edge volume comprises at least about 30 percent of the total core volume and the edge.

4. The sleeping mattress according to claim 3, characterized in that the side sections further comprise ends and wherein the head and foot sections extend laterally beyond the core section to cover the ends of the side sections.

5. The sleeping mattress according to claim 1, characterized in that the edge sections comprise two side sections, the side sections are adhered to opposite perimeter sides of the core.

6. The sleeping mattress according to claim 1, characterized in that the edge sections comprise a head section and a foot section, the head and foot sections are adhered to opposite perimeter sides of the core.

7. The sleeping mattress according to claim 1, characterized in that the thickness of the core is between approximately 7.62 and 27.94 cm (3 and approximately 11 inches).

8. The sleeping mattress according to claim 1, characterized in that the core thickness is between approximately 0.63 and 10.16 cm.

9. An upper mattress support for sleeping, characterized in that it comprises: a generally rectangular core having perimeter sides, a width, length, thickness and volume, the core essentially consisting of latex rubber foam having a density of between approximately 9.76 kg per cubic meter and approximately 29.30 kg per cubic meter, the core thickness is between approximately 0.63 cm and approximately 10.16 was; at least two edge sections having a thickness and a volume, the edge sections are fixed to at least two sides of core perimeters, the edge comprises urethane foam rubber and has a density of between about 4.88 and about 19.53 kg per cubic meter, the thickness of the edge is approximately the thickness of the core; and the edge volume comprises at least about 15% of the total volume of the core and the edge.

10. A sleeping mattress, characterized in that it comprises: a rectangular core of latex foam rubber having a periphery and having a thickness of between about 7.62 and 27.94 cm (3 and about 11 inches); a border of synthetic urethane foam bonded to the periphery, the edge has a thickness substantially equal to that thickness of the core; the edge comprises a head section, a foot section and two side sections, the head, foot and side sections are attached to the periphery and to each other; the head and foot sections have widths between approximately 17.28 and 25.4 cm (approximately 7 to 10 inches), the lateral sections having widths between approximately 10.16 and 15.24 cm (4 and 6 inches); and the edge volume comprises at least about 15 percent of the total volume of the edge and the core.

11. The sleeping mattress according to claim 10, characterized in that the edge volume comprises at least about 30 percent of the combined edge and core volume.

12. A method of manufacturing a mattress for sleeping, characterized in that it comprises: forming a rectangular core of latex rubber foam having a periphery having a thickness, the core having a volume; forming a synthetic urethane foam edge having a thickness substantially equal to the thickness of the core and having a head section, the edge includes a section of feet and two side sections, the head and foot sections have widths of between 17.78 and 25.4 cm (7 and 10 inches), the lateral sections have widths between 10.16 and 15.24 cm (4 and 6 inches), the edge has a volume; adhere to the edge to the periphery of the nucleus; and the edge volume comprises at least 15 percent of the combined core and edge volume.

13. The method according to claim 12, characterized in that the edge volume comprises at least 30 percent of the combined volume of the core and edge.