WO2007055880A1 - Mattress with a water resistant cover and interchangeable cushions - Google Patents

Mattress with a water resistant cover and interchangeable cushions Download PDF

Info

Publication number
WO2007055880A1
WO2007055880A1 PCT/US2006/040740 US2006040740W WO2007055880A1 WO 2007055880 A1 WO2007055880 A1 WO 2007055880A1 US 2006040740 W US2006040740 W US 2006040740W WO 2007055880 A1 WO2007055880 A1 WO 2007055880A1
Authority
WO
WIPO (PCT)
Prior art keywords
mattress
cover
base foam
package
foam package
Prior art date
Application number
PCT/US2006/040740
Other languages
French (fr)
Inventor
Arnold Balonick
Curtis Wyatt
Original Assignee
B.G. Industries
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 B.G. Industries filed Critical B.G. Industries
Publication of WO2007055880A1 publication Critical patent/WO2007055880A1/en

Links

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
    • A47C27/001—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with several cushions, mattresses or the like, to be put together in one cover
    • 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
    • A47C27/002—Mattress or cushion tickings or covers
    • A47C27/005—Mattress or cushion tickings or covers liquid-impermeable
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/001—Fireproof means
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/007—Anti-mite, anti-allergen or anti-bacterial means
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/10—Loose or removable furniture covers
    • A47C31/105—Loose or removable furniture covers for mattresses

Definitions

  • This invention relates to mattresses, and in particular, to home care or healthcare mattresses.
  • the present invention provides a mattress which includes a base foam package, a plurality of cushions fastened to a top side of the base foam package, and a top cover that includes a water resistant material, the top cover coveting the cushions and is connected to the base foam package.
  • Figure 1 is a partial exploded view of a mattress according to an embodiment of the present invention.
  • Figure 2 is a cutaway view showing the base foam package of the mattress of Fig. 1 turned upside down.
  • Figure 3 is an exploded view of the base foam package of Fig. 2 without the cover.
  • a mattress 1 includes a top cover 11, a plurality of quilted cushions 12 (three equal sized cushions are shown in Fig. 1), and a base foam package 13.
  • the base foam package 13 includes one or more foam pieces 14 (see Fig. 3, where four foam pieces are shown) enclosed in a cover 15.
  • the lower side 15a of the cover 15 of the base foam package 13 has four linen locks 21 at the corners, a zipper 16 providing access to the foam pieces 14, and a number of handles 17 on the side (four handles total, two on each side, are shown in Fig. 1).
  • the upper side of the cover 15 has two VelcroTM strips 18 extending the full length of the base foam package. Alternatively, the Velcro strips may be intermittence as long as they collectively cover substantially the full length of the base foam package.
  • Each of the quilted cushions 12 has two Velcro strips 19 on the bottom side corresponding to the Velcro strips 18 on the cover 15.
  • the three quilted cushions 12 are fastened to the base foam package 13 by the Velcro strips 18 and 19, and their positions are interchangeable.
  • the top cover 11 covers the cushions 12.
  • the top cover 11 and the bottom cushion cover 15 are connected together by a 360-degree zipper 20 around the side edge of the mattress 1. Alternatively, although less preferred, a 270-degree zipper may be used.
  • the size of the mattress is 191x88.5x13 cm 3 (Model 1) or 191x80.5x13 cm 3 (Model 2).
  • the top cover 11 is made of a cotton/poly terry knit (Periwinkle) material with a 1 mil urethane film laminate.
  • the cover 11 is moisture resistant with a MVTR (moisture vapor transfer rate per ASTM 96- 95 Method B) of 156.8 g/ni 2 /24hrs.
  • the cover 11 is also flame retardant and passed the California Technical Bulletin #117E test.
  • the cover 11 is antimicrobial and passed the AATCC 147 test.
  • the cushions 12 include three equal sized sections, which are 885(W)x640(L) mm 2 for Model 1 and 805(W)x640(L) mm 2 for Model 2. Each cushion is made of three layers. The top layer is made of 1.5 oz. thermo-bonded polyester fiber (18- 20% recycled fiber); the bottom is made of 1.4 oz. needle punched polyester fiber, and the center booster layer is made of 1.0 oz needle punched polyester fiber. Covering all around each cushion section 12 is cotton/polyester sheeting with loop side of Velcro loop/hook strip for attaching the cushions to the base foam package 13.
  • the cover 15 of the base foam package 13 includes a bottom panel 15a and top and side panels 15b.
  • the bottom panel 15a is made of a waterproof material, and top and side panels made of another material.
  • the bottom panel 15a is made of polyester Poly-Tuff with PVC laminate.
  • the material is flame retardant (passed California Technical Bulletin #117E) and antimicrobial (passed AATCC 147).
  • the zipper 16 is a spiral zipper located off center and extending the full length of the foam package 13 for core access.
  • the four handles (2 on each side of bottom panel) are centered at 550 mm apart.
  • the top and side panels 15b of the cover 15 are made of nylon taffeta fabric with PVC laminate. It is waterproof with a MVTR of 14.4 g/m 2 /24hr.
  • the material is also flame retardant (passes California Technical Bulletin #117) and antimicrobial (passed AATCC 147-1988).
  • Hook side strips of Velcro loop/hook strips are sewn on the top surface of the bottom cushion cover 15 on lengthwise sides of the bottom cushion cover. Loop side strips of Velcro loop/hook stripes are sewn onto the corresponding sides of the individual cushions 12.
  • the 360-degree zipper 20 is 559 cm in length for Model 1 and 543 cm for Model 2.
  • the base foam package 13 is formed of multiple foam pieces 14, forming a two layer foam core (see Fig. 3).
  • the top layer 14a is made of Visco foam (3 lbs./ft 3 15 IFD Visco Elastic) covering the full length and width of the mattress with a height of 1.5".
  • the bottom layer includes a full length foam 14b (1.85 lbs./ft 3 42 IFD foam) of 1.75" in height, and a 4" wide, full length extra firm side rail 14c made of 1.80 lbs./ft 3 55 IFD foam on each side.
  • the polyurethane foam is treated with an anti-microbial agent (for example, Vinyzene) injected into the mixture at the mixing head at the foaming process.
  • the foam is manufactured to meet California Technical Bulletin #117.
  • the mattress according to embodiments of the present invention has the following advantageous features.
  • the mattress has a three- section cushion 12, i.e. it has three equal sized cushions 12 that can be interchanged. This allows different sections to be rotated or replaced to prevent uneven wear.
  • the top cover 11 is moisture resistant in order to minimize or prevent foreign liquid materials from entering the mattress. It includes a terry cloth laminated to a stretchable polyurethane backing. The cover is antimicrobial and flame retardant according to California Technical Bulletin 117E and has an acceptable moisture vapor transfer rate (MVTR) per ASTM 96-95 Method B (for example, a MVTR of less than 170 g/m 2 /24hr will typically be acceptable).
  • An existing mattress had a 75/25% terry cloth absorbable, stretchable top cover. There is no waterproof terry cloth cover used in the U.S. for full-sized hospital mattresses that the inventors are aware of.

Abstract

A home care or healthcare mattress (1) includes a base foam package (13), a plurality of interchangeable equal sized quilted cushions (12) fastened on the top of the base foam package, and a top cover (11 ) covering the cushions and connected to the base foam package by a zipper (20) on the side of the mattress. The base foam package includes one or more foam pieces enclosed in a cover. The top cover is water resistant, flame retardant and antimicrobial.

Description

MATTRESS WITH A WATER RESISTANT COVER AND INTERCHANGEABLE
CUSHIONS
This application claims priority from U.S. Provisional Patent Application No. 60/733,483, filed November 4, 2005, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to mattresses, and in particular, to home care or healthcare mattresses.
SUMMARY OF THE INVENTION
The present invention provides a mattress which includes a base foam package, a plurality of cushions fastened to a top side of the base foam package, and a top cover that includes a water resistant material, the top cover coveting the cushions and is connected to the base foam package.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a partial exploded view of a mattress according to an embodiment of the present invention. Figure 2 is a cutaway view showing the base foam package of the mattress of Fig. 1 turned upside down.
Figure 3 is an exploded view of the base foam package of Fig. 2 without the cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As illustrated in Fig. 1, a mattress 1 according to an embodiment of the present invention includes a top cover 11, a plurality of quilted cushions 12 (three equal sized cushions are shown in Fig. 1), and a base foam package 13. The base foam package 13 includes one or more foam pieces 14 (see Fig. 3, where four foam pieces are shown) enclosed in a cover 15. As shown in Fig. 1 and 2, the lower side 15a of the cover 15 of the base foam package 13 has four linen locks 21 at the corners, a zipper 16 providing access to the foam pieces 14, and a number of handles 17 on the side (four handles total, two on each side, are shown in Fig. 1). The upper side of the cover 15 has two Velcro™ strips 18 extending the full length of the base foam package. Alternatively, the Velcro strips may be intermittence as long as they collectively cover substantially the full length of the base foam package. Each of the quilted cushions 12 has two Velcro strips 19 on the bottom side corresponding to the Velcro strips 18 on the cover 15. The three quilted cushions 12 are fastened to the base foam package 13 by the Velcro strips 18 and 19, and their positions are interchangeable. The top cover 11 covers the cushions 12. The top cover 11 and the bottom cushion cover 15 are connected together by a 360-degree zipper 20 around the side edge of the mattress 1. Alternatively, although less preferred, a 270-degree zipper may be used.
A specific example of a mattress is described in more detail below. The size of the mattress is 191x88.5x13 cm3 (Model 1) or 191x80.5x13 cm3 (Model 2). The top cover 11 is made of a cotton/poly terry knit (Periwinkle) material with a 1 mil urethane film laminate. The cover 11 is moisture resistant with a MVTR (moisture vapor transfer rate per ASTM 96- 95 Method B) of 156.8 g/ni2/24hrs. The cover 11 is also flame retardant and passed the California Technical Bulletin #117E test. In addition, the cover 11 is antimicrobial and passed the AATCC 147 test. The cushions 12 include three equal sized sections, which are 885(W)x640(L) mm2 for Model 1 and 805(W)x640(L) mm2 for Model 2. Each cushion is made of three layers. The top layer is made of 1.5 oz. thermo-bonded polyester fiber (18- 20% recycled fiber); the bottom is made of 1.4 oz. needle punched polyester fiber, and the center booster layer is made of 1.0 oz needle punched polyester fiber. Covering all around each cushion section 12 is cotton/polyester sheeting with loop side of Velcro loop/hook strip for attaching the cushions to the base foam package 13. The cover 15 of the base foam package 13 includes a bottom panel 15a and top and side panels 15b. The bottom panel 15a is made of a waterproof material, and top and side panels made of another material. In the example, the bottom panel 15a is made of polyester Poly-Tuff with PVC laminate. The material is flame retardant (passed California Technical Bulletin #117E) and antimicrobial (passed AATCC 147). The zipper 16 is a spiral zipper located off center and extending the full length of the foam package 13 for core access. The four handles (2 on each side of bottom panel) are centered at 550 mm apart. The top and side panels 15b of the cover 15 are made of nylon taffeta fabric with PVC laminate. It is waterproof with a MVTR of 14.4 g/m2/24hr. The material is also flame retardant (passes California Technical Bulletin #117) and antimicrobial (passed AATCC 147-1988). Hook side strips of Velcro loop/hook strips are sewn on the top surface of the bottom cushion cover 15 on lengthwise sides of the bottom cushion cover. Loop side strips of Velcro loop/hook stripes are sewn onto the corresponding sides of the individual cushions 12. The 360-degree zipper 20 is 559 cm in length for Model 1 and 543 cm for Model 2. The base foam package 13 is formed of multiple foam pieces 14, forming a two layer foam core (see Fig. 3). The top layer 14a is made of Visco foam (3 lbs./ft3 15 IFD Visco Elastic) covering the full length and width of the mattress with a height of 1.5". The bottom layer includes a full length foam 14b (1.85 lbs./ft3 42 IFD foam) of 1.75" in height, and a 4" wide, full length extra firm side rail 14c made of 1.80 lbs./ft3 55 IFD foam on each side. The polyurethane foam is treated with an anti-microbial agent (for example, Vinyzene) injected into the mixture at the mixing head at the foaming process. The foam is manufactured to meet California Technical Bulletin #117.
Notably, the mattress according to embodiments of the present invention has the following advantageous features.
First, all parts of the mattress are replaceable. Second, the mattress has a three- section cushion 12, i.e. it has three equal sized cushions 12 that can be interchanged. This allows different sections to be rotated or replaced to prevent uneven wear. Third, the top cover 11 is moisture resistant in order to minimize or prevent foreign liquid materials from entering the mattress. It includes a terry cloth laminated to a stretchable polyurethane backing. The cover is antimicrobial and flame retardant according to California Technical Bulletin 117E and has an acceptable moisture vapor transfer rate (MVTR) per ASTM 96-95 Method B (for example, a MVTR of less than 170 g/m2/24hr will typically be acceptable). An existing mattress had a 75/25% terry cloth absorbable, stretchable top cover. There is no waterproof terry cloth cover used in the U.S. for full-sized hospital mattresses that the inventors are aware of.
The details provided in the examples above are intended to illustrate specific examples of mattresses according to embodiments of the present invention. Not all detailed features are essential to the invention, and the invention should not be limited to any specific feature described or illustrated here. It will be apparent to those skilled in the art that various modification and variations can be made in the mattress of the present invention without departing from the spirit or scope of the invention.

Claims

WHAT IS CLAIMED IS:
1. A mattress comprising: a base foam package; a plurality of cushions fastened to a top side of the base foam package; and a top cover that includes a water resistant material, the top cover covering the cushions and is connected to the base foam package.
2. The mattress of claim 1 , wherein the top cover is made of a cotton/poly terry knit (Periwinkle) material with a urethane film laminate.
3. The mattress of claim 2, wherein the top cover has a MVTR of less than 170 g/m2/24hrs.
4. The mattress of claim 2, wherein the top cover is flame retardant and antimicrobial.
5. The mattress of claim 1, wherein each cushion is made of multiple layers of fiber materials.
6. The mattress of claim 1, wherein the plurality of cushions are interchangeable.
7. The mattress of claim 1, wherein the base foam package includes a foam core and a cover.
8. The mattress of claim 7, wherein the cover of the base foam package is made of a waterproof, flame retardant and antimicrobial material.
9. The mattress of claim 7, wherein the foam core includes a plurality of foam pieces.
10. The mattress of claim 7, wherein a top side of the cover of the base foam package includes one or more Velcro strips cover substantially a full length of the base foam package.
11. The mattress of claim 10, wherein each cushion includes one or more Velcro strips on its bottom side corresponding to the Velcro strips on the cover of the base foam package for fastening the cushions to the base foam package.
12. The mattress of claim 7, wherein the base foam package further includes a plurality of linen locks and a plurality of handles attached to the cover, and a zipper on the cover for providing access to the foam core.
13. The mattress of claim 1, wherein the top cover is connected to the base foam package by a zipper located along four sides of the base foam package.
PCT/US2006/040740 2005-11-04 2006-10-17 Mattress with a water resistant cover and interchangeable cushions WO2007055880A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US73348305P 2005-11-04 2005-11-04
US60/733,483 2005-11-04

Publications (1)

Publication Number Publication Date
WO2007055880A1 true WO2007055880A1 (en) 2007-05-18

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2461033A (en) * 2008-06-17 2009-12-23 Trakker Products Ltd Manually portable furniture apparatus with removable mattress portion and inflatable element
KR101257880B1 (en) 2012-02-14 2013-04-23 한국과학기술원 Free modifying sofa
WO2017072577A1 (en) * 2015-10-30 2017-05-04 Intercoil International Co, LLC Mattresses with multiple customizable and replaceable levels and sections and methods thereof

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5136741A (en) * 1991-01-25 1992-08-11 B.G. Industries, Inc. Multiple component mattress with removable cover
US5201780A (en) * 1991-09-06 1993-04-13 Jay Medical, Ltd. Anti-decubitus mattress pad
US6651277B1 (en) * 2002-05-24 2003-11-25 Cascade Designs, Inc. Multiple chamber self-inflatable body
US6804848B1 (en) * 2003-03-14 2004-10-19 Comfortaire Corporation High-profile mattress having an upper low-profile module with an air posturizing sleep surface
US6952852B2 (en) * 1995-11-30 2005-10-11 Hill-Rom Services, Inc. Mattress structure

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5136741A (en) * 1991-01-25 1992-08-11 B.G. Industries, Inc. Multiple component mattress with removable cover
US5201780A (en) * 1991-09-06 1993-04-13 Jay Medical, Ltd. Anti-decubitus mattress pad
US6952852B2 (en) * 1995-11-30 2005-10-11 Hill-Rom Services, Inc. Mattress structure
US6651277B1 (en) * 2002-05-24 2003-11-25 Cascade Designs, Inc. Multiple chamber self-inflatable body
US6804848B1 (en) * 2003-03-14 2004-10-19 Comfortaire Corporation High-profile mattress having an upper low-profile module with an air posturizing sleep surface

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2461033A (en) * 2008-06-17 2009-12-23 Trakker Products Ltd Manually portable furniture apparatus with removable mattress portion and inflatable element
GB2461033B (en) * 2008-06-17 2010-08-25 Trakker Products Ltd Manually portable furniture apparatus
KR101257880B1 (en) 2012-02-14 2013-04-23 한국과학기술원 Free modifying sofa
WO2017072577A1 (en) * 2015-10-30 2017-05-04 Intercoil International Co, LLC Mattresses with multiple customizable and replaceable levels and sections and methods thereof

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