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Publication numberUS2835906 A
Publication typeGrant
Publication dateMay 27, 1958
Filing dateMay 7, 1954
Priority dateMay 7, 1954
Publication numberUS 2835906 A, US 2835906A, US-A-2835906, US2835906 A, US2835906A
InventorsRobbins Ralph
Original AssigneeRobbins Ralph
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Foam rubber mattress
US 2835906 A
Abstract  available in
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Claims  available in
Description  (OCR text may contain errors)

y 1958 R. ROBBINS FOAM RUBBER MATTRESS Filed May 7, 1954 INVENTOR Ralph Robbins BY W ORNEYS ATT United States Patent p FOAM RUBBER MATTRESS Ralph Robbins, Jamaica, N. Y. Application May 7, 1954, Serial No. 428,164 2 Claims. (Cl. 5-351) This invention relates to a latex foam rubber mattress which is capable of being folded through 180 for use in folding beds and sofas convertible into beds.

When conventional inner spring mattresses are manufactured for use in folding beds and sofas convertible into beds, the spring unit in the mattress must be extremely soft in order to permit the bend or fold through 180". As a result of the soft type of spring unit used, the sleeping surface is unsatisfactory and much too soft by current orthopedic standards. Often the coil springs at the hinge point break away, are distorted and otherwise forced out of position.

With the advent of the large scale use of latex foam rubber in mattresses, many of the manufacturers attempt to substitute foam rubber mattresses for inner spring mattresses. However, the manufacturers found that when a standard foam rubber mattress is folded through one hundred and eighty degrees, the mattress core suffers a great strain exerted on the under side, and after he quent folding or remaining in folded position for a considerable length of time, a crease or a corrugation at the line of fold was set in the top surface of the mattress and formed a bump which could be felt over the mattress surface and which could not be eliminated. As a result, foam rubber mattresses were not generally used as folding mattresses. Thus all the advantages of a foam rubber were not available for folding mattresses, which hitherto have been made of other types of material, and the sections of which are joined together by the ticking or the covering material containing the mattress core.

One object of my invention is to provide a latex foam rubber mattress which permits folding of the rubber without requiring an envelope or covering, and without undue strain on the mattress and which can be folded without permanent distortion of the top surface portion of the mattress and without tearing or otherwise ruining the mattress.

Another object is to provide a foldable mattress which has, when extended, full and uniform compression support throughout the top surface thereof, and affords a complete unbroken one-piece surface for its entire length, uninterrupted by seams, stitches, or additional reinforcement cloth on the top surface of the mattress.

Still another object of this invention is to provide a relatively inexpensive, one-piece, foldable, foam rubber mattress.

Other objects and advantages will be readily apparent from the following detailed description and drawings in which like numerals relate to like parts and in which:

Figure l is a top plan view of a mattress made in accordance with my invention showing the unbroken, one piece top surface;

Fig. 2 is an enlarged cross-sectional view taken along line 2-2 of Fig. 1 showing the hinge groove and reinforcement construction of my mattress; and

Fig. 3 is an enlarged cross-sectional view taken along line 3-3 of Fig. 1 further showing the hinge groove of my mattress.

, 2,835,906 Patented May 27, 1958 A plan view of a foam rubber mattress 1 made in ac cordance with my invention is shown in Fig. 1. The mattress is rectangular in shape and the top surface 2 is unbroken. The width 12 is measured along the shorter side, the length 13 along the longer side, and dotted lines 5 indicate the sides of a hinge groove on which the mattress is folded. The mattress is preferably made of latex foam rubber, .either natural rubber or synthetic rubber or mixtures of the two. It can also be made of a closed cell construction out of rubber or other suitable rubberlike material with a cellular composition. Dotted circles 3 indicate a multiplicity of cores formed in the bottom surface of the mattress to provide springlike action.

Figs. 2 and 3 are cross-sectional views of the mattress and show its basic construction which comprises a multiplicity of core portions or hollows 3 formed in the underside 4 of the mattress and continuous portions 6 which support and sustain the mattress. Intermediate the ends of the mattress and substantially parallel thereto a longitudinal section of one of the continuous portions 6 is subdivided by a cut 7 extending substantially across the width of the mattress and substantially parallel to width 12 as shown by the dotted lines in Fig. l.

Molded integral with the mattress and along both sides of the surface of the cut 7 is a reinforcement 8, made of a longitudinal strip of cloth or other suitable reinforcement material such as Fiberglas mesh or mat, which is folded back upon itself along a centraly located folding line. Also molded into the mattress is on the top surface 2, approximately above the cut 7, an additional reinforcement 9. The reinforcement 9 may be continuous or intermittent around the mattress as necessary.

As shown in Fig. 3, the cut 7 preferably does not extend across the full width of the mattress, and supporting portions 11 are located along both sides of the groove so that it cannot be seen from the top or either side. If desired, the cut 7 can extend into the sides or supporting portions 11 of the mattress. Under any circumstances, it should not be more than two inches and preferably one inch in from the side of the mattress. As shown in Fig. 2, the cut 7 should extend to within an inch or less of the top surface to provide a narrow hinge portion 14 of the mattress about which the two mattress sections bend or hinge.

The reinforcements 8 and 9 can be positioned by being located in the mold (not shown) prior to filling the mold with foamed latex.

This invention is equally suitable for solid mattress of foam rubber construction or mattress with different core structures from that shown.

Having thus described my invention, what I claim is:

1. A rectangular shaped sponge rubber mattress having unbroken top and side surfaces and a multiplicity of core holes in its bottom surface, means including an incision having a width that is a small fraction of an inch extending substantially across the width of the mattress in the middle portion thereof and terminating within about two inches from each of said side surfaces providing a hinge portion for the mattress so that the top surfaces of the mattress can be readily folded against one another through degrees, and means for reinforcing said hinge portion comprising a pair of narrow woven strips molded integral with the mattress, one of said strips extending substantially the full length of said groove and having its opposite side edges at the marginal edges of said groove and the other of said strips being integrally joined to the mattress on opposite sides of said groove and having end edges adjacent the top marginal side edges of said mattress.

2. A foam rubber mattress comprising a rectangular sponge rubber piece having unbroken top and side sur- 3 faces and a multiplicity of core holes extended thereinto from its lower surface and being subdivided into two sections by means of an incision extending substantially across the width of the sponge rubber piece in the middle portion thereof and terminating within about two inches from each of said top and side surfaces to provide a hinge portion for the sponge rubber piece so that the top surfaces of sections thereof at both sides of said incision can be folded against one another through onerhundred and eighty degrees, a first reinforcement strip having two longitudinal portions folded back upon themselves along a longitudinal folding line and being secured to those sections of said sponge rubber piece which are adjacent said incisions so as to reinforce the same from below, and

a second reinforcement strip secured to a section of the References Cited in the file of this patent UNITED STATES PATENTS Re. 19,355 Gursky et a1. Oct. 30, 1934 1,549,289 Bradley Aug. 11, 1925 2,192,601 Mattison Mar. 5, 1940 2,271,058 Binns Jan. 27, 1942 2,589,579 Slayen Mar. 18, 1952 2,626,407 Kurry Jan. 27, 1953 2,779,031 Arpin Jan. 29, 1957

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US1549289 *Oct 2, 1924Aug 11, 1925Bradley Franklin FMattress
US2192601 *Jun 8, 1939Mar 5, 1940Norman D MattisonRubber mattress
US2271058 *Sep 27, 1938Jan 27, 1942Bintex LtdMethod of making rubber cushion material
US2589579 *Apr 30, 1947Mar 18, 1952Zel SlayenFoldable mattress
US2626407 *Nov 17, 1948Jan 27, 1953Stanley E TrimbleFolding infant's crib
US2779031 *Apr 2, 1954Jan 29, 1957Arpin Frank DConvertible bed-sofa combinations
USRE19355 *May 4, 1929Oct 30, 1934 Folding cot
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US2996733 *Dec 17, 1958Aug 22, 1961Sheller Mfg CorpFormed pad
US4589151 *Jul 8, 1983May 20, 1986Behrens Robert SSlatted bed system
US5370444 *Sep 11, 1992Dec 6, 1994Sears Manufacturing CompanyAdjustable cushion
US5520438 *Sep 22, 1994May 28, 1996Sears Manufacturing CompanyAdjustable upholstered cushion
US7469437Jun 24, 2005Dec 30, 2008Tempur-Pedic Management, Inc.Reticulated material body support and method
US8356373Jan 22, 2013Noel Group LlcUnitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s)
US8418297Apr 16, 2013Tempur-Pedic Management, LlcReticulated material body support and method
US20090165213 *Dec 30, 2008Jul 2, 2009Chris CollinsReticulated material body support and method
US20100223732 *Sep 9, 2010Noel Group LlcUnitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s)
US20110072587 *Mar 31, 2011Nomaco Inc.Foam cushion having reduced cross-section area foam profiles forming hollow portion(s) for deformation
US20110197363 *Aug 18, 2011Noel Group LlcComposite cushioning structure(s) with spatially variable cushioning properties and related materials, cushioning assemblies, and methods for producing same
USD381543Oct 27, 1994Jul 29, 1997 Foam pad
USD688069Nov 9, 2012Aug 20, 2013Noel Group LlcMattress bed cushion
USD688492Nov 9, 2012Aug 27, 2013Noel Group LlcMattress bed cushion
USD690536Jul 26, 2012Oct 1, 2013Nomaco Inc.Motion isolation insulator pad
USD691400Feb 10, 2012Oct 15, 2013Nomaco Inc.Stackable base for mattress assembly
USD691401Nov 9, 2012Oct 15, 2013Noel Group, LlcMattress bed cushion
USD692690Nov 9, 2012Nov 5, 2013Noel Group LlcMattress bed cushion
USD692691Nov 9, 2012Nov 5, 2013Noel Group LlcMattress bed cushion
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USD693146Nov 9, 2012Nov 12, 2013Noel Group LlcMattress bed cushion
USD693147Nov 9, 2012Nov 12, 2013Noel Group LlcMattress bed cushion
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USD694552Nov 9, 2012Dec 3, 2013Noel Group LlcMattress bed cushion
USD694553Nov 9, 2012Dec 3, 2013Noel Group LlcMattress bed cushion
USD697337Jul 3, 2012Jan 14, 2014Nomaco, Inc.Stackable base for mattress assembly
USD701713Nov 9, 2012Apr 1, 2014Noel Group, LlcMattress bed cushion
USD704962Sep 9, 2013May 20, 2014Noel Group LlcMattress bed cushion
USD707467Nov 9, 2012Jun 24, 2014Noel Group LlcMattress bed cushion
USD707468Nov 9, 2012Jun 24, 2014Noel Group LlcMattress bed cushion
USD709301Nov 9, 2012Jul 22, 2014Noel Group LlcMattress bed cushion
Classifications
U.S. Classification5/722, 5/740
International ClassificationA47C27/14
Cooperative ClassificationA47C27/144, A47C27/146
European ClassificationA47C27/14C2, A47C27/14C4