Search Images Maps Play YouTube News Gmail Drive More »
Sign in
Screen reader users: click this link for accessible mode. Accessible mode has the same essential features but works better with your reader.

Patents

  1. Advanced Patent Search
Publication numberUS3732586 A
Publication typeGrant
Publication dateMay 15, 1973
Filing dateAug 6, 1971
Priority dateAug 6, 1971
Publication numberUS 3732586 A, US 3732586A, US-A-3732586, US3732586 A, US3732586A
InventorsFrey L
Original AssigneeFrey L
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Mattress construction
US 3732586 A
Abstract
A mattress formed of soft, low density resilient foam material which conforms to the body weight and contour. The upper portion of the mattress is divided into a plurality of separate portions which are individually compressible in respect to body weight. A plurality of partially compressed coil springs are mounted within cylindrical slits formed in the lower part of the mattress beneath each separate portion. The springs provide added strength for body support and assure prompt return of the upper part of the resilient material to its normal shape when weight is removed from it.
Images(1)
Previous page
Next page
Claims  available in
Description  (OCR text may contain errors)

United States Patent 1 1 Frey [541 MATTRESS CONSTRUCTION [76] Inventor: Louis Elliott Frey, 1271 East Sixth Street, Los Angeles, Calif. 90021 [22] Filed: Aug. 6, 1971 21 Appl. No.: 169,652

[52] U.S. C1 ..5/345, 5/91 [51] Int. Cl ..A47c 23/00 [58] Field of Search ..5/24 6, 248, 256, 5/345, 351, 353, 91, 357

[56] References Cited UNITED STATES PATENTS 3,191,197 6/1965 Frey ..5/353 X 3,623,171 11/1971 Arkin....=...

3,401,411 9/1968 Morrison ..5/353 11 3,732,586 51 May 15, 1973 Primary Examiner-James T. McCall Assistant ExaminerAndrew M. Calvert A ttorney Robert C. Comstock 57 ABSTRACT A mattress formed of soft, low density resilient foam material which conforms to the body weight and contour. The upper portion of the mattress is divided into a plurality of separate portions which are individually compressible in respect to body weight. A plurality of partially compressed coil springs are mounted within cylindrical slits formed in the lower part of the mattress beneath each separate portion. The springs provide added strength for body support and assure prompt return of the upper part of the resilient material to its normal shape when weight is removed from it.

9 Claims, 3 Drawing Figures BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a new and improved construction for mattresses.

2. Description of the Prior Art The present invention relates to an improvement over the mattress construction shown and described in my prior U.S. Pat. No. 3,191,197. The mattress shown in that patent was divided into a plurality of separate block-like sections, each of which was capable of limited independent vertical movement.

The most feasible material for use in constructing such a mattress is resilient foam. It has been found, however, that resilient foam which has sufficient density to support the weight of a person is hard to the touch and does not provide the type and degree of softness which is desirable for a mattress. Such material also has a slow recovery due to its heavy density and it accordingly tends to take and hold a set. This is an undesirable and unsatisfactory characteristic in a mat tress.

SUMMARY OF THE INVENTION The invention comprises a mattress which is formed of relatively low density resilient foam material which will substantially conform to the contour of every part of the body and which provides the degree of softness which is desirable in a mattress. The upper portion of the mattress is divided into a plurality of separate block-like sections of the type shown in my prior U.S. Pat. No. 3,191,197. Mounted beneath each of these block-like sections is a compressed spring which provides the strength necessary to support the body and which acts to prevent the foam material from taking a set, as it is inherently inclined to do.

The spring is inserted and held in a compressed condition within the lower portion of the mattress beneath each block, to provide the necessary body support and strength when the upper portion of the block is depressed by the weight of a portion of the body. This construction provides the body-responding comfort of a soft light form with strength and support equal to that of more dense and rigid foam material.

The spring preferably comprises a substantially frusto-conical coil spring which is mounted in a cylindrical slit cut or otherwise formed beneath the center of each block-like section of the mattress. A frusto-conical spring provides the desired amount of progressively increased support as it is depressed in use.

It is accordingly among the objects of my invention to provide a mattress construction having all of the advantages and benefits of the structure set forth above and described in detail hereinafter in this specification.

Another object of the invention is to provide a mattress having a plurality of block-like sections which are capable of independent vertical movement and which also have the desired softness and comfort combined with the strength for proper body support.

A further object of the invention is to provide a mattress of the type described which will not take a set and in which the upper surface will return to a flat horizontal position as soon as the weight of the body is removed from it.

' Still another object of the invention is to provide such a mattress which is simple and economical to manufacture, so that it can be manufactured and sold at a reasonable price. My invention also comprises such other objects, advantages and capabilities as will later more fully appear and which are inherently possessed by my invention.

While I have shown in the accompanying drawings preferred embodiments of my invention, it should be understood that the same are susceptible of modification and change without departing from the spirit of my invention.

DESCRIPTION OF THE DRAWINGS FIG, 1 is an isometric view of a mattress constructed in accordance with my invention, with the springs shown in phantom lines, the upper portion of the left hand side of the mattress being divided into block-like sections and the right hand side being divided into elongated sections;

FIG. 2 is a partial sectional view of the same taken along line 2-2 of FIG. 1;

FIG. 3 is a bottom plan view of one of the block-like sections shown on the left hand side of FIG. 1, showing the slit before the spring is inserted.

DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment which has been selected to illustrate my invention comprises a mattress 10, which is preferably formed of suitable resilient foam material. The mattress 10 includes an integral border 11, which extends around all four sides of the mattress and an integral lower portion 12, which extends across the bottom of the entire area defined by the border 11.

The central upper portion 23 of the mattress. which is disposed above the lower portion 12 is provided as shown on the left side of FIG. 1 with a plurality of intersecting vertical and horizontal slits 13, which preferably extend downwardly approximately half the distance between the top of the mattress and the top of the lower portion 12. The slits l3 divide the central portion 23 into a plurality of adjacent block-like sections 14, each of which is individually compressible in respect to a weight placed thereon in use.

The block-like sections 14 may extend across the entire area defined by the border 11. They may also cover only the major portion of this area, as shown in FIG. 1 of the drawings, with a pair of larger rectangular blocks 15 being disposed adjacent to the head and foot of the mattress between the sections 14 and the border 11.

The exposed surfaces of the mattress may be covered with suitable cloth, flocking or other suitable covering means as desired. Various methods of forming and covering such a mattress are shown and described in my prior U.S. Pat. No. 3,191, 197, the contents of which are incorporated herein by reference. The present invention is directed toward the use of a spring member to reinforce the independently movable block-like sections of a mattress such as that shown in U.S. Pat. No. 3,191,197.

Beneath the center of each of the sections 14 a circular slit 16 is provided by cutting, molding or other suitable means. The slit 16 extends inwardly to a point substantially aligned with the lower or inner ends of the slits 13 which define the sections 14. The area within each of the slits 16 comprises a cylindrical core 17 of resilient foam material.

A frusto-conical coil spring 18 is inserted into each of the slits 16 with its larger diameter end disposed toward the inner or upper end of the slit 16. The length of the slit 16 is preferably approximately half the normal expanded length of the spring 18. The spring 18 when it is disposed entirely within the slit 16 is accordingly compressed to approximately half its normal expanded length.

The bottom of the slit 16 is preferably covered by backing material such as treated buckram or other suitahle material which is adhered or otherwise secured to the bottom of the sections 14. The backing material 20 may comprise a single piece of material which extends across the bottom of the entire spring area 23.

The backing material 20 acts to prevent the springs 18 from coming out of the slits 16. The previously mentioned engagement between the coils of the springs 18 and the cores 17 prevents the springs 18 from exerting undue pressure against the backing material 20.

The same coil spring structure described above may also be used with a mattress having a plurality of elongated longitudinal sections 19 instead of block-like sections. Such a structure is shown in FIG. 1 of the drawings on the right hand side. In such a structure, a plurality of coil springs 18 are mounted in slits spaced along the lower portion of each of the longitudinal sections, with the springs and foam material inter-acting in the same manner described above.

Coil springs 18 may also be used in part or all of the border 11 and/or the blocks 15.

In use, this structure provides all of the advantages and benefits contemplated by my prior US. Pat. No. 3,191,197 with regard to the independent movement of the mattress sections and their individual response to body weight and movement. It also provides a definite improvement in that a relatively soft foam material may be used to provide the desired body comfort and easy resilient response while the coil springs disposed within the mattress sections provide the necessary support and return the foam material to its uncompressed state.

It will be noted that the mattress has a relatively thick upper portion which is formed entirely of substantially low density resilient foam material which is divided into separate sections and which is capable of adjusting to the natural contours of the body. Beneath this relatively thick upper portion is a lower portion in which the foam material is reinforced by a compressed coil spring which serves the dual purpose of providing added strength to support the body without requiring the use of undesirable and unsatisfactory high density foam and of urging the upper portion of the mattress back to its normal condition after the weight of the body has been removed from it.

It will also be noted that the upper ends of the springs are disposed so deeply within the foam material that they do not cause discomfort to the mattress user, nor do they disturb the smooth upper surface of the mattress.

The coil springs are preferably completely enclosed within the foam material, so that they are securely held in place and the mattress user is unaware of their existence or action.

I claim:

1. A mattress comprising a resilient member constructed of substantially soft, low density foam material, the upper part of said mattress being divided into a plurality of relatively thick separate portions which are individually compressible in respect to the weight placed thereon in use, the lower part of each of said mattress portions having at least one vertically directed cylindrical slit, and a plurality of coil springs mounted within said slits, said coil springs being held within said mattress in partially compressed condition.

2. The structure described in claim 1, said coil springs being frusto-conical, with their larger ends disposed at the upper ends of said slits.

3. The structure described in claim 2, said mattress having a plurality of block-like portions of substantially square shape, one of said coil springs being mounted beneath the center of each of said portions.

4. The structure described in claim 2, said mattress having a plurality of longitudinally extending elongated portions, and a plurality of spaced coil springs mounted beneath each of said elongated portions.

5. The structure described in claim 2, each of said coil springs being completely surrounded by a substantial thickness of foam material.

6. The structure described in claim 3, each of said coil springs being completely surrounded by a substantial thickness of foam material.

7. The structure described in claim 1, the area within each of said slits comprising a cylindrical resilient core, the coils of said springs engaging said cores to hold said springs in partially compressed condition.

8. The structure described in claim 2, the area within each of said slits comprising a cylindrical resilient core, the coils of said springs engaging said cores to hold said springs in partially compressed condition.

9. The structure described in claim 8, and a layer of backing material extending across the bottom of said mattress to hold said springs within said slits.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US3191197 *Jan 9, 1962Jun 29, 1965Louis E FreyMattress construction
US3401411 *Mar 10, 1967Sep 17, 1968Morrison BenUpholstery construction
US3623171 *Nov 17, 1969Nov 30, 1971Arkin Sanford LMattress construction
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US4389743 *Jun 22, 1981Jun 28, 1983Simmons U.S.A. CorporationMattress arrangement having a removable side-insertable center core structure
US4768253 *Oct 6, 1986Sep 6, 1988Boyd William ASleeper sofa mattress
US4862540 *Oct 3, 1983Sep 5, 1989Auping B.V.Resilient body
US5564144 *Oct 25, 1994Oct 15, 1996C.A. Greiner & Sohne Gesellschaft M.B.H.Vehicle seat with a seat padding, in particular for an aircraft seat
US5724686 *Feb 25, 1997Mar 10, 1998Eastern Sleep Products, Inc.Cushion or mattress border support
US5836027 *Apr 25, 1997Nov 17, 1998Leventhal; Robert D.Integrated matrix bedding system
US5937464 *Apr 30, 1998Aug 17, 1999Niederman; Alfred G.Foldable foam mattress with coil springs and firm periphery
US6173464 *May 7, 1999Jan 16, 2001L&P Property Management CompanyPocketed bedding or seating product
US6272706Oct 16, 2000Aug 14, 2001L&P Property Management CompanyBedding or seating product having bands of springs
US6842927Mar 4, 2003Jan 18, 2005England, Inc.Mattress
US6948205 *Jan 4, 2002Sep 27, 2005Beter Bed Holding N.V.Mattress, provided with spring elements, such as coil springs
US7165282 *Jan 20, 2004Jan 23, 2007Dreamwell, Ltd.Hinged foam assembly for mattress manufacturing
US7251847Oct 13, 2005Aug 7, 2007L&P Property Management CompanyContinuous wire spring mattress or seating product and method of manufacture
US8250689 *Sep 16, 2008Aug 28, 2012Dreamwell, Ltd.Channel-cut cushion supports
US8918935 *Jul 12, 2012Dec 30, 2014Dreamwell, LtdChannel-cut cushion supports
US9003584Apr 18, 2012Apr 14, 2015Hsiu Chen LiaoFoam spring mattress with replaceable foam springs
US9066497May 5, 2014Jun 30, 2015Ascion, LlcFoam spring mattress configured with variable firmness
US9072277 *Apr 27, 2011Jul 7, 2015Hsiu Chen LiaoAdjustable mattress with interchangeable foam springs
US20040025258 *Jan 4, 2002Feb 12, 2004Van Der Wurf Cornelus JohannesMattress, provided with spring elements, such as coil springs
US20040172765 *Mar 4, 2003Sep 9, 2004Rodney EnglandMattress
US20050081301 *Jan 20, 2004Apr 21, 2005Dreamwell, Ltd.Hinged foam assembly for mattress manufacturing
US20070083996 *Oct 13, 2005Apr 19, 2007Wells Thomas WContinuous wire spring mattress or seating product and method of manufacture
US20090139033 *Sep 16, 2008Jun 4, 2009Dreamwell, Ltd.Channel-cut cushion supports
US20100090383 *Oct 16, 2009Apr 15, 2010Rawls-Meehan Martin BDistinguishing different firmness foam springs and alternatives for foam spring end caps
US20110258784 *Oct 27, 2011Rawls-Meehan Martin BUsing a software application to configure a foam spring mattress
US20120058309 *Sep 7, 2011Mar 8, 2012Iso-Chemie GmbhSealing Tape of Flexible Foam
US20120297546 *Jul 12, 2012Nov 29, 2012Richard Ferrell GladneyChannel-cut cushion supports
US20150107027 *Dec 24, 2014Apr 23, 2015Dreamwell, Ltd.Channel-cut cushion supports
DE2942284A1 *Oct 19, 1979Apr 30, 1981Richard BronnerFoam overlay for seats and reclining seats - consists of foam interior block with slits at right angles on top, and reinforcement plates
EP0777429A1 *May 1, 1996Jun 11, 1997Vincenzo A. BonaddioMattress border assembly and method of making same
WO2000045676A1 *Jan 28, 2000Aug 10, 2000L & P Property Management CoPocketed bedding or seating product
Classifications
U.S. Classification5/718, 5/727, 5/35
International ClassificationA47C27/14, A47C27/20
Cooperative ClassificationA47C27/20
European ClassificationA47C27/20