US20040163180A1 - Compressible encasement tray for bedding and method for selectively modifying bedding product with such a tray - Google Patents
Compressible encasement tray for bedding and method for selectively modifying bedding product with such a tray Download PDFInfo
- Publication number
- US20040163180A1 US20040163180A1 US10/373,908 US37390803A US2004163180A1 US 20040163180 A1 US20040163180 A1 US 20040163180A1 US 37390803 A US37390803 A US 37390803A US 2004163180 A1 US2004163180 A1 US 2004163180A1
- Authority
- US
- United States
- Prior art keywords
- compressible material
- bedding product
- inserts
- tray
- rails
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims description 20
- 239000000463 material Substances 0.000 claims abstract description 38
- 239000006260 foam Substances 0.000 claims description 11
- 229920000728 polyester Polymers 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 3
- 239000006261 foam material Substances 0.000 claims description 3
- 239000004816 latex Substances 0.000 claims description 3
- 229920000126 latex Polymers 0.000 claims description 3
- 230000002093 peripheral effect Effects 0.000 claims description 2
- 239000002390 adhesive tape Substances 0.000 claims 5
- 239000003292 glue Substances 0.000 claims 5
- 239000002657 fibrous material Substances 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000011496 polyurethane foam Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910052728 basic metal Inorganic materials 0.000 description 1
- 150000003818 basic metals Chemical class 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 235000019589 hardness Nutrition 0.000 description 1
- 239000012510 hollow fiber Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
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
- A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
Definitions
- the present invention is directed to a encasement tray of compressible material suitable for use as a mattress topper, as well as to a method for selectively modifying a bedding product using such a tray.
- U.S. Pat. No. 1,371,362 discloses a mattress having a rectangular box spring frame with a central recess. A top cushion is supported by springs in the rectangular frame. An inner mattress section is removably fitted in the recess, resting on slats, which are a part of the rectangular frame.
- the inner mattress also contains spiral springs, which have a different spring constant from the springs in the outer frame, so that the outer frame affords more resistance to compression, to better accommodate persons seated at the edge of the mattress.
- a mattress with a removable insert is disclosed in U.S. Pat. No. 5,107,558 wherein a one-piece base of hollow fibers or polyurethane foam is provided with a rectangular recess at an upper side thereof, in a region, which supports the torso of a person lying on the mattress.
- This recess is filled by a removable insert, which is formed as a fabric envelope containing fragmentized polyurethane foam and polypropylene beads, or superimposed layers of foamed plastic material having different specific gravities and/or hardnesses.
- U.S. Pat. No. 5,704,085 discloses an edge support for a mattress in the form of an upholstery topper composed of multiple layers, including at least one foam layer. This foam layer has a firming edge of foam around its perimeter, again for the purpose of providing more support at the edge of the mattress.
- a mattress is disclosed in U.S. Pat. No. 2,069,415 having a basic metal spring assembly with fabric padding at the top surface thereof.
- the padding includes a marginal portion proceeding around the periphery of the top of the mattress, which is filled with filler material so as to give this marginal region more resistance to compression.
- the padding is covered with fabric stitched together so as to form a central region surrounded by the aforementioned marginal region.
- a mattress topper having a tray formed by a bottom topper sheet of compressible material, with four side rails of compressible material affixed at the periphery of one of the large faces thereof, to form a rectangular frame with a central rectangular recess therein.
- the rails preferably are formed of material with a relatively high density, so as to provide edge support when the tray is placed on a conventional mattress.
- ILD internal load deflection
- a foam topper tray of the type described above is first produced, and multiple inserts of respectively different types are made available. Depending on the overall characteristics of the completed product that are desired, inserts are selected and placed in the recess in the tray to create a mattress topper with customized characteristics.
- the inventive method and topper reduce costs by allowing layers of reduced size to be used, improving the ease of manufacture, reducing overall manufacturing costs and allowing fewer material SKUs (shop keeping units) to be kept in inventory.
- the topper tray is manufacturable with different dimensions, the dimensions being selected to match the dimensions of various types of commercially available mattresses, such as king size, queen size, twin size, etc. These dimensions are standard size in the industry and are well known to those of ordinary skill in the art.
- FIG. 1 is a perspective view of a topper tray constructed in accordance with the principles of the present invention.
- FIG. 2 is an exploded view showing the components of the topper tray and a number of inserts used in accordance with the inventive topper tray and method.
- a topper tray 1 has a bottom topper sheet 2 with a top surface, and four rails 3 disposed at the periphery of the top surface of the topper sheet 2 .
- the topper sheet 2 and the rails 3 can be composed of foam material or polyester densified fiber (PDF). Combinations of foam and PDF can be used.
- PDF polyester densified fiber
- the foam material used for the rails 3 is preferably of a relatively high density, so as to afford a higher resistance to compression at the edge regions.
- the topper sheet 2 may be formed of the same higher density material as the rails 3 , however, this is not necessary to produce the desired edge support and therefore preferably the topper sheet 2 will be formed of a compressible material of lower density than the rails 3 . Since lower density material is, in general, less expensive than a higher density material, this will reduce the overall cost.
- the rails 3 are attached to the top surface of the topper sheet 2 in a suitable manner, such as by adhesive or double-sided tape, and also are suitably attached to each other at their respective ends.
- the topper sheet 2 is a 1 ⁇ 2 inch 1.2# topper.
- the rails 3 preferably are composed of VPF-1.65# 50 ILD foam grade.
- the rails 3 preferably have a cross-section of approximately 21 ⁇ 2 inches by 21 ⁇ 2 inches.
- the outer dimensions of the topper tray 1 are matched to those of standard-size mattresses which are commercially available, since the topper tray 1 is intended to be placed on top of such a conventional mattress.
- the topper tray 1 thus will be available in different sizes, respectively corresponding to these conventionally sized mattresses. Examples of such conventional sizes are twin (371 ⁇ 2′′ ⁇ 74′′) twin XL (371 ⁇ 2′′ ⁇ 79′′), full (521 ⁇ 2′′ ⁇ 34′′), full XL (521 ⁇ 2′′ ⁇ 79′′), queen (591 ⁇ 2′′ ⁇ 79′′), king (751 ⁇ 2′′ ⁇ 79′′) and cal king (711 ⁇ 2′′ ⁇ 83′′).
- multiple inserts 4 , 5 and 6 are disposed in the central recess in the topper tray 1 formed by the rails 3 .
- the dimensions of the inserts 4 , 5 and 6 will thus be equal to the dimensions of the topper sheet 2 , less the widths of the rails 3 .
- the inserts 4 , 5 and 6 will be adhered to each other, such as by spot gluing double-sided tape, etc., but will not be adhered to the rails of the topper tray 1 .
- the inserts thus will be fitted into the recess formed by the rails 3 in the topper tray 1 without any direct attachment to the rails.
- the bottommost insert 4 may be attached to the topper sheet 2 , but this is not always necessary.
- the inserts 4 , 5 and 6 are suitable selected to provide the combination of the topper tray 1 with the inserts with desired characteristics as to compressibility, density, water permeability, etc.
- Examples of suitable inserts for the inserts 4 , 5 and 6 are 11 ⁇ 2′′ ⁇ 1 ⁇ 2′′ CV, 2′′ ⁇ 1′′ CV, 11 ⁇ 2′′ ⁇ 3 ⁇ 4′′ XL 21 ILD CV, 1′′ latex, 2′′ visco, 1′′ XL 21 ILD, 7 ⁇ 8′′ ⁇ 3 ⁇ 8′′ convoluted foam, or 1′′ visco.
- One or more of the inserts 4 , 5 , 6 may be zoned, i.e., it can have regions thereof, such as a head region or torso region, of different firmness than other regions thereof.
- the inserts 4 , 5 and 6 are combined to have a height or thickness approximating the height of the rails 3 .
- Preferably all of the combinations will have a natural crown of 1 ⁇ 2′′ or more.
Abstract
Description
- 1. Field of the Invention
- The present invention is directed to a encasement tray of compressible material suitable for use as a mattress topper, as well as to a method for selectively modifying a bedding product using such a tray.
- 2. Description of the Prior Art
- Various types of bedding products are known which have a frame or frame-like structure with a recess therein, with an insert being disposed in the recess to give the overall bedding product desired features. U.S. Pat. No. 1,371,362, for example, discloses a mattress having a rectangular box spring frame with a central recess. A top cushion is supported by springs in the rectangular frame. An inner mattress section is removably fitted in the recess, resting on slats, which are a part of the rectangular frame. The inner mattress also contains spiral springs, which have a different spring constant from the springs in the outer frame, so that the outer frame affords more resistance to compression, to better accommodate persons seated at the edge of the mattress.
- A mattress with a removable insert is disclosed in U.S. Pat. No. 5,107,558 wherein a one-piece base of hollow fibers or polyurethane foam is provided with a rectangular recess at an upper side thereof, in a region, which supports the torso of a person lying on the mattress. This recess is filled by a removable insert, which is formed as a fabric envelope containing fragmentized polyurethane foam and polypropylene beads, or superimposed layers of foamed plastic material having different specific gravities and/or hardnesses.
- U.S. Pat. No. 5,704,085 discloses an edge support for a mattress in the form of an upholstery topper composed of multiple layers, including at least one foam layer. This foam layer has a firming edge of foam around its perimeter, again for the purpose of providing more support at the edge of the mattress.
- A mattress is disclosed in U.S. Pat. No. 2,069,415 having a basic metal spring assembly with fabric padding at the top surface thereof. The padding includes a marginal portion proceeding around the periphery of the top of the mattress, which is filled with filler material so as to give this marginal region more resistance to compression. The padding is covered with fabric stitched together so as to form a central region surrounded by the aforementioned marginal region.
- Although the above products in some instances, allow a certain amount of selectivity in the material or layers which will be used as inserts, in most cases the structure is fixed at the time of manufacture, and the components of different densities or compressibility are thus built into the overall structure, or at least cannot be easily removed or interchanged. Moreover, the products themselves are intended to serve as a mattress in a bed, rather than as an accessory or attachment to a mattress.
- It is an object of the present invention to provide a mattress topper, having dimensions adapted to any of the standard-sized mattresses which are commercially available which provides edge support for a conventional mattress and which also allows selectivity in the characteristics of the central portion.
- It is also an object of the present invention to provide a method for making such a mattress topper, which affords selectivity in the respective characteristics between the central portion of the topper and a peripheral portion.
- It is a further object of the present invention to provide such a method and mattress topper for use with a conventional mattress of uniform compressibility, which allow customization of that conventional mattress to provide a selected combination of densities and compressibility characteristics.
- It is a further object to provide such a method and mattress topper which reduce the overall cost of inventory and/or manufacture.
- The above objects are achieved in accordance with the present invention in a mattress topper having a tray formed by a bottom topper sheet of compressible material, with four side rails of compressible material affixed at the periphery of one of the large faces thereof, to form a rectangular frame with a central rectangular recess therein. The rails preferably are formed of material with a relatively high density, so as to provide edge support when the tray is placed on a conventional mattress.
- The recess can be filled with multiple layers or sheets of different materials, having respectively different densities, compressibility characteristics (ILD=internal load deflection), etc., so that by appropriately selecting these inserts, the overall characteristics of the topper can be selected. In general, characteristics will be selected to produce a desired firmness or feel. Since the tray with the inserts is used on a conventional mattress this allows the conventional mattress to be converted or customized as desired.
- In the inventive method, a foam topper tray of the type described above is first produced, and multiple inserts of respectively different types are made available. Depending on the overall characteristics of the completed product that are desired, inserts are selected and placed in the recess in the tray to create a mattress topper with customized characteristics.
- The inventive method and topper reduce costs by allowing layers of reduced size to be used, improving the ease of manufacture, reducing overall manufacturing costs and allowing fewer material SKUs (shop keeping units) to be kept in inventory.
- The topper tray is manufacturable with different dimensions, the dimensions being selected to match the dimensions of various types of commercially available mattresses, such as king size, queen size, twin size, etc. These dimensions are standard size in the industry and are well known to those of ordinary skill in the art.
- FIG. 1 is a perspective view of a topper tray constructed in accordance with the principles of the present invention.
- FIG. 2 is an exploded view showing the components of the topper tray and a number of inserts used in accordance with the inventive topper tray and method.
- As shown in FIG. 1, a
topper tray 1 has abottom topper sheet 2 with a top surface, and fourrails 3 disposed at the periphery of the top surface of thetopper sheet 2. Thetopper sheet 2 and therails 3 can be composed of foam material or polyester densified fiber (PDF). Combinations of foam and PDF can be used. The foam material used for therails 3 is preferably of a relatively high density, so as to afford a higher resistance to compression at the edge regions. When thetopper tray 1 is placed on a conventional mattress, therefore, thetopper tray 1 will provide support at the edges thereof for a person sitting on the edge of the mattress. - The
topper sheet 2 may be formed of the same higher density material as therails 3, however, this is not necessary to produce the desired edge support and therefore preferably thetopper sheet 2 will be formed of a compressible material of lower density than therails 3. Since lower density material is, in general, less expensive than a higher density material, this will reduce the overall cost. - The
rails 3 are attached to the top surface of thetopper sheet 2 in a suitable manner, such as by adhesive or double-sided tape, and also are suitably attached to each other at their respective ends. Preferably thetopper sheet 2 is a ½ inch 1.2# topper. Therails 3 preferably are composed of VPF-1.65# 50 ILD foam grade. Therails 3 preferably have a cross-section of approximately 2½ inches by 2½ inches. - The outer dimensions of the
topper tray 1 are matched to those of standard-size mattresses which are commercially available, since thetopper tray 1 is intended to be placed on top of such a conventional mattress. Thetopper tray 1 thus will be available in different sizes, respectively corresponding to these conventionally sized mattresses. Examples of such conventional sizes are twin (37½″×74″) twin XL (37½″×79″), full (52½″×34″), full XL (52½″×79″), queen (59½″×79″), king (75½″×79″) and cal king (71½″×83″). - As shown in FIG. 2,
multiple inserts topper tray 1 formed by therails 3. The dimensions of theinserts topper sheet 2, less the widths of therails 3. Theinserts topper tray 1. The inserts thus will be fitted into the recess formed by therails 3 in thetopper tray 1 without any direct attachment to the rails. Thebottommost insert 4 may be attached to thetopper sheet 2, but this is not always necessary. - The
inserts topper tray 1 with the inserts with desired characteristics as to compressibility, density, water permeability, etc. - Examples of suitable inserts for the
inserts - One or more of the
inserts - The
inserts rails 3. Preferably all of the combinations will have a natural crown of ½″ or more. - Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
Claims (30)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/373,908 US20040163180A1 (en) | 2003-02-25 | 2003-02-25 | Compressible encasement tray for bedding and method for selectively modifying bedding product with such a tray |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/373,908 US20040163180A1 (en) | 2003-02-25 | 2003-02-25 | Compressible encasement tray for bedding and method for selectively modifying bedding product with such a tray |
Publications (1)
Publication Number | Publication Date |
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US20040163180A1 true US20040163180A1 (en) | 2004-08-26 |
Family
ID=32868760
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/373,908 Abandoned US20040163180A1 (en) | 2003-02-25 | 2003-02-25 | Compressible encasement tray for bedding and method for selectively modifying bedding product with such a tray |
Country Status (1)
Country | Link |
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US (1) | US20040163180A1 (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080301983A1 (en) * | 2006-06-09 | 2008-12-11 | Harrison Murphy | Method for communicating performance attributes |
WO2012097120A2 (en) * | 2011-01-14 | 2012-07-19 | Sealy Technology Llc | Mattress constructions with densified fiber components |
US8418297B2 (en) | 2005-06-24 | 2013-04-16 | Tempur-Pedic Management, Llc | Reticulated material body support and method |
US20140137331A1 (en) * | 2012-11-21 | 2014-05-22 | Bo Porter | Inflatable mattress system |
US20140208517A1 (en) * | 2013-01-25 | 2014-07-31 | Andrew Gross | Component with Multiple Layers |
USD834936S1 (en) * | 2015-03-27 | 2018-12-04 | Primapak, Llc | Package |
US20220395105A1 (en) * | 2021-06-09 | 2022-12-15 | Dreamwell, Ltd. | Hybrid side rail assemblies and mattresses including the same |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5065485A (en) * | 1990-02-15 | 1991-11-19 | George Zocco | Enclosed innerspring mattress cover and process for assembling same |
US5669094A (en) * | 1996-02-27 | 1997-09-23 | Swanson; Larry Sven | Mattress with visco-elastic, temperature sensitive top layer |
US6077378A (en) * | 1993-07-27 | 2000-06-20 | L&P Property Management Company | Method of forming densified fiber batt with coil springs interlocked therein |
-
2003
- 2003-02-25 US US10/373,908 patent/US20040163180A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5065485A (en) * | 1990-02-15 | 1991-11-19 | George Zocco | Enclosed innerspring mattress cover and process for assembling same |
US6077378A (en) * | 1993-07-27 | 2000-06-20 | L&P Property Management Company | Method of forming densified fiber batt with coil springs interlocked therein |
US5669094A (en) * | 1996-02-27 | 1997-09-23 | Swanson; Larry Sven | Mattress with visco-elastic, temperature sensitive top layer |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8418297B2 (en) | 2005-06-24 | 2013-04-16 | Tempur-Pedic Management, Llc | Reticulated material body support and method |
US8296976B2 (en) * | 2006-06-09 | 2012-10-30 | Kickball Concepts, Llc | Method for communicating performance attributes |
US20080301983A1 (en) * | 2006-06-09 | 2008-12-11 | Harrison Murphy | Method for communicating performance attributes |
WO2012097120A3 (en) * | 2011-01-14 | 2014-06-05 | Sealy Technology Llc | Mattress constructions with densified fiber components |
US20120180224A1 (en) * | 2011-01-14 | 2012-07-19 | Demoss Larry K | Mattress constructions with densified fiber components |
WO2012097120A2 (en) * | 2011-01-14 | 2012-07-19 | Sealy Technology Llc | Mattress constructions with densified fiber components |
US20140137331A1 (en) * | 2012-11-21 | 2014-05-22 | Bo Porter | Inflatable mattress system |
US20140208517A1 (en) * | 2013-01-25 | 2014-07-31 | Andrew Gross | Component with Multiple Layers |
US9538855B2 (en) * | 2013-01-25 | 2017-01-10 | Serta, Inc. | Component with multiple layers |
USD834936S1 (en) * | 2015-03-27 | 2018-12-04 | Primapak, Llc | Package |
USD899922S1 (en) | 2015-03-27 | 2020-10-27 | Primapak, Llc | Package |
US20220395105A1 (en) * | 2021-06-09 | 2022-12-15 | Dreamwell, Ltd. | Hybrid side rail assemblies and mattresses including the same |
US11806978B2 (en) * | 2021-06-09 | 2023-11-07 | Dreamwell, Ltd. | Hybrid side rail assemblies and mattresses including the same |
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Owner name: SPRING AIR COMPANY, THE, ILLINOIS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BRYANT, STEVE;OLINSKI, ROSS;REEL/FRAME:013825/0090 Effective date: 20030220 |
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STCB | Information on status: application discontinuation |
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Owner name: AMERICAN CAPITAL FINANCIAL SERVICES, INC., A DELAW Free format text: INTELLECTUAL PROPERTY SECURITY AGREEMENT TO THAT CERTAIN REVOLVING LOAN, NOTE AND EQUITY PURCHASE AGREEMENT;ASSIGNORS:CONSOLIDATED BEDDING, INC., A DELAWARE CORPORATION;NATURE'S REST MARKETING, L.L.C., A DELAWARE LIMITED LIABILITY COMPANY;NATURE'S REST, INC., A FLORIDA CORPORATION;AND OTHERS;REEL/FRAME:019562/0032 Effective date: 20070625 |
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Owner name: L&P FINANCIAL SERVICES, CO., MISSOURI Free format text: SECURITY AGREEMENT;ASSIGNORS:CONSOLIDATED BEDDING, INC.;NATURE'S REST, INC.;NATURE'S REST MARKETING, L.L.C.;AND OTHERS;REEL/FRAME:020451/0163 Effective date: 20070625 |
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