Air mattresses are used to provide a comfortable support on which a person or persons can sleep. The pressure of the air within the mattress is intended to support the weight of the person and allow the surface of the mattress to conform to the person's body. The pressure of the air within the mattress is also intended to provide cushioning of the person's body from contact with any hard surfaces underlying the mattress. Currently available air mattresses have not been completely successful in meeting these goals. Currently available air mattresses have a tendency to sink in the middle and subject the person lying on them to the discomfort of contact with the hard surfaces underlying the mattress. Currently available air mattresses lack sufficient rigidity and would push through a bed frame unless provided with closely spaced supports or with a continuous supporting surface such as provided by a box spring. As a result, bed framing associated with current air mattresses is heavier and less portable than desired. The need persists in the art for an air mattress that would obviate the problems associated with currently available air mattresses.
The present invention is directed to an air mattress assembly including an air mattress and a cover system including a top cover for the top of the mattress and a bottom cover for the bottom of the mattress. The air mattress and at least the top and bottom covers are adapted and configured such that, when the air mattress assembly is inflated to a pressure with the pressure range suitable for use of the air mattress assembly, at least the top and bottom covers are in tension. The tension in the top and bottom covers provides enhanced comfort and structural integrity to the mattress.
Accordingly, it is an aspect of the present invention to provide an air mattress assembly comprising:
an air mattress, wherein the air mattress is flexible and inflatable and is capable of containing a volume of air under pressure, wherein the air mattress has a closable inlet for filing the air mattress with air, the air mattress having a top, a bottom and sides extending between the top of the air mattress and the bottom of the air mattress; and
a cover system including a top cover and a bottom cover, the top cover covering the top of the air mattress, the bottom cover covering the bottom of the air mattress, the air mattress assembly being inflated to a pressure within a correct operating pressure range for use, the air mattress assembly having a length and a width when the air mattress assembly is inflated to the pressure within the correct operating pressure range,
wherein the air mattress has a length and a width prior to assembly with the cover system and when inflated to the pressure within the correct operating pressure range, wherein at least the width of the air mattress prior to assembly with the cover system, when inflated to the pressure within the correct operating pressure range, is greater than the width of the air mattress assembly when the air mattress assembly is inflated to the pressure within the correct operating pressure range, such that both the top cover and the bottom cover are in tension when the cover system is assembled with the air mattress and the air mattress assembly is inflated to the pressure within the correct operating pressure range.
It is another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the length of the air mattress prior to assembly with the cover system, when inflated to the pressure within the correct operating pressure range, are greater than the length of the air mattress assembly when the air mattress assembly is inflated to the pressure within the correct operating pressure range, such that both the top cover and the bottom cover are in tension when the cover system is assembled with the air mattress and the air mattress assembly is inflated to the pressure within the correct operating pressure range.
It is still another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the air mattress is made of a first material, and wherein the top cover and the bottom cover are made of a second material that is different from the first material.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the top cover and the bottom cover form parts of a sleeve having an opening that allows the air mattress to be received within the sleeve when the air mattress is deflated, the sleeve being too small to receive the air mattress within the sleeve when the air mattress is inflated to the pressure within the correct operating pressure range.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the opening of the sleeve is provided with closure means to selectively close the opening even after the air mattress assembly is inflated to the pressure within the correct operating pressure range and to selectively allow the opening to be opened for insertion or removal of the air mattress at least when the air mattress is deflated.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the top cover and the bottom cover each have a length and a width before they are tensioned by inflation of the air mattress assembly to a pressure within the correct operating pressure range, wherein at least the width of the top cover before tensioning is less than the width of the air mattress when the air mattress is inflated to the pressure within the correct operating pressure range prior to assembly with the cover system.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the length of the top cover before tensioning is less than the length of the air mattress when inflated to the pressure within the correct operating pressure range prior to assembly with the cover system.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the width of the bottom cover before tensioning is less than the width of the air mattress when inflated to the pressure within the correct operating pressure range prior to assembly with the cover system.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the length of the bottom cover before tensioning is less than the length of the air mattress when inflated to the pressure within the correct operating pressure range prior to assembly with the cover system.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the sides of the air mattress have a height prior to assembly with the cover system and after inflation to the pressure within the correct operating pressure range, wherein the sleeve further comprises sidewalls extending between the top cover and the bottom cover, the sidewalls having a height, the height of the sidewalls of the sleeve being less than the height of the sides of the air mattress.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the top and bottom covers are made of a woven fabric.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the cover system has a length and a width in the absence of tension in the top and bottom covers, wherein the length of the air mattress prior to assembly with the cover system, when inflated to the pressure within the correct operating pressure range, is in the range of from about one to about twenty inches greater than the length of the cover system in the absence of tension in the top and bottom covers, and wherein the width of the air mattress prior to assembly with the cover system, when inflated to the pressure within the correct operating pressure range, is in the range of from about one to about twenty inches greater than the width of the cover system in the absence of tension in the top and bottom covers.
It is an aspect of the present invention to provide an air mattress assembly comprising:
an air mattress, wherein the air mattress is flexible and inflatable and is capable of containing a volume of air under pressure, wherein the air mattress has a closable inlet for filing the air mattress with air, the air mattress having a top, a bottom and sides extending between the top of the air mattress and the bottom of the air mattress; and
a cover system including a top cover and a bottom cover, the top cover covering the top of the air mattress, the bottom cover covering the bottom of the air mattress, the air mattress being inflated to a pressure within a correct operating pressure range for use, the top cover and bottom cover each have a length and a width before they are tensioned by inflation of the air mattress assembly to a pressure within the correct operating pressure range,
wherein the air mattress has a length and a width prior to assembly with the cover system and when inflated to the pressure within the correct operating pressure range, wherein at least the width of the air mattress prior to assembly with the cover system, when inflated to the pressure within the correct operating pressure range, is greater than the width of the top cover, such that at least the top cover is in tension when the cover system is assembled with the air mattress and the air mattress assembly is inflated to the pressure within the correct operating pressure range.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the length and the width of the air mattress prior to assembly with the cover system, when inflated to the pressure within the correct operating pressure range, are greater than the length and the width, respectively, of the air mattress assembly when the air mattress assembly is inflated to the pressure within the correct operating pressure range, and wherein both the top cover and the bottom cover are in tension when the cover system is assembled with the air mattress and the air mattress assembly is inflated to the pressure within the correct operating pressure range.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the top cover has a perimeter, wherein the top cover is attached to the air mattress along the perimeter of the top cover, wherein the bottom cover has a perimeter, and wherein the bottom cover is attached to the air mattress along the perimeter of the bottom cover.
It is yet another aspect of the present invention to provide an air mattress assembly according to any of the other aspects of the present invention disclosed herein, wherein the top cover is attached to the sides of the air mattress along the perimeter of the top cover, and wherein the bottom cover is attached to the sides of the air mattress along the perimeter of the bottom cover.
These and other aspects and advantages of the present invention will be further elucidated by the following Detailed Description, drawing figures, and Claims.
Examples of air mattresses with tensioned top and bottom covers are described herein. The top and bottom covers become tensioned when the air mattress is fully inflated. The tension in the top and bottom covers act against each other, which stabilizes the assembly. The cover tensile resistive forces will determine how the surface of the mattress assembly feels and behaves. The connections of the covers, which are ultimately attached to a sidewall of the mattress, must be capable of resisting the equal and opposite forces due to the tension in the top and bottom covers. This can be accomplished through a series of straps, cords, or clips, which may be permanently attached to the air mattress or be removable. Alternatively, adhesives and/or welding, or any other suitable method, can be used to secure the top and bottom covers to the sidewalls of the air mattress, which will allow the covers to tension (and elongate if the cover fabric has that property) when the air mattress is inflated.
One embodiment of the air mattress assembly includes an air mattress with a raised perimeter on the top and bottom of the air mattress. Without the tensioned fabric cover, this shape for an air mattress would not be practical. The raised perimeter on the top and bottom means the majority of the mattress bottom would not touch the ground. When weight is applied, for example when a person lies on the mattress, the raised perimeter would simply collapse and allow the entire mattress bottom to contact the floor. With the added top and bottom cover, tensioned when mattress is inflated, the top cover fabric would span from perimeter to perimeter support points. It would be a balanced assembly because the same tension exists in the bottom cover creating equal and opposite forces. The top cover fabric would support the person's weight generating tension in the top and bottom covers, which would then cause lateral forces to be applied to the air mattress, through the perimeter supports, that tend to keep the raised perimeter from collapsing. This arrangement provides the added benefit of the ability to control the tension in the top and bottom covers by how much air is used to inflate the air mattress portion. Preferably, air is allowed to flow between the air mattress shell and the top and bottom covers to avoid excessive firmness due to air trapped between the top cover and the lower central majority of the top surface of the air mattress. Accordingly, it is preferable that a fabric that can breathe is used for the top cover in this embodiment. The same applies to the bottom cover.
The above-described mattress assembly has several advantages. The first is that a person lying on the air mattress assembly can adjust the tension of the mattress surface. Also, the elevated central majority of the bottom surface of the air mattress and the tensioned bottom cover fabric better isolate the person lying on the mattress from rocks and roots that may be under the mattress in camping applications.
In another embodiment, the air mattress assembly includes an air mattress having a profiled top. The profiled top of the air mattress has a bellows or accordion-like profile. The addition of a tensioned fabric on the profiled top surface will ensure that the high points of the profile will not sag excessively. The body would derive support by the high points of the air mattress as well as the tensioned fabric. This arrangement maintains the advantages of the profiled top such as allowing air circulation under the body to help with cooling and preventing excessive perspiration in hot weather and the massaging sensation provided by the high points of the profile. As with all the embodiments described herein, which use tensioned covers, the bottom cover is provided to offset or balance the tension forces created by the top cover.
A nylon/spandex fabric could be used in the above application compared to the raised perimeter mattress. Any fabric with high tensile strength properties can also be used. For example, a 100% cotton sheet could be tensioned in the same fashion. The result would be a taut top sheet/cover which would be well suited for the medical industry for eliminating bed sores. In this application, the cover system would be replaceable by the user so it can be washed.
The surface cover of the described air mattress assemblies can be just the tensioned fabric, or it may include an additional topper that can be added for additional comfort. Optionally, hook-and-loop fasteners, or other suitable means such as for example tacky adhesive pads, can be provided at various points between the air mattress surface and the inner surface of the cover sleeve to prevent the cover sleeve from slipping sliding relative to the air mattress portion of the air mattress assembly.
Another added benefit of the disclosed embodiments is that the materials and attachments described above adds tensile resistive forces and in turn structural rigidity to the entire air mattress assembly. The mattress assembly can now resist the weight of a person when only supported on the perimeter. Accordingly, the air mattress assembly can be supported by perimeter bed frame with no support slats or box spring. If a conventional air mattress was placed on such a perimeter bed frame without slats or a box spring, the added the weight of a person would cause the air mattress to fall through the bed frame. If you added the covers and then tensioned by inflating, depending on the structural tension properties of the fabric and the strength of the connections to the air mattress sidewalls, a person could easily be supported. The embodiments claimed herein provide an air mattress assembly that can span greater lengths without continuous support or closely spaced support points.
The disclosed tensioned covers are generally of two types. One type can be used as an add-on or retro-fit to an existing air mattress with known dimensions. The second type of air mattress assembly is made as a complete assembly, including both an air mattress and tensioned covers, in a manufacturing plant. With an add-on cover, there would be no positive connections or attachment points between the cover sleeve and the air mattress. With an air mattress assembly manufactured as a complete unit, the air mattress and the top and bottom covers would have integral connections or attachment points. Optionally, reinforced sidewalls can be provided for the air mattress assemblies that are manufactured as a complete assembly. Positive connection as used herein is defined as a mechanical fastener, weld or any connection that physically attaches two materials at a certain location.
Referring to
The air mattress 2 can be made out of vinyl, PVC, polyethylene, thermoplastic elastomer (TPE), natural or synthetic rubber, any other suitable thermoplastic or thermosetting plastic, or any suitable polymer material with or without some degree of crosslinking.
Referring to
Referring to
The sleeve 1 has at least four sides. Preferably the sleeve 1 is six sided as shown in the drawing. Materials that are easily stretchable are not at present the preferred choice for use in the cover system. Such material may expand after several uses and not return to its original dimensions in its un-deformed state. A test sleeve made of a spandex/nylon hybrid fabric having an original width of thirty five inches expanded to thirty eight inches wide in its un-deformed state. The test sleeve lost its tension properties when the air mattress assembly was fully inflated and lying on the air mattress assembly with this test sleeve felt essentially like lying on an air mattress with no sleeve.
Accordingly, it is preferred that the material used for the cover system does not stretch. All materials, having a finite modulus of elasticity, stretch under a tensile force. However, non-stretch fabric is a term of art used in the textile industry. Such fabrics include fabrics made of yarns that stretch ten percent or less at maximum load. In contrast, stretch fabrics or elastic materials can be stretched eighty five to one hundred percent and then return to their original shape. Non-stretch material or fabric as used herein refers to material that shows no practically significant or appreciable stretching during the normal intended use of the disclosed air mattress assemblies.
The panels or sheets of material used to form the top cover, bottom cover, and the sidewalls of the cover system should always have dimensions, such as length, width, and height, that are smaller than corresponding dimensions of panels or sheets of material that form the top bottom and sides of the air mattress.
One example of the present air mattress assemblies uses an air mattress having the dimensions of sixty inches by eighty inches by eight and three quarter inches, while the sleeve has dimensions of fifty seven inches by seventy nine inches by five inches. The material used for the sleeve in this example is a polyester/cotton canvas fabric with no noticeable stretch factor.
Preferably the non-stretch materials used in the present invention stretch twenty five percent or less at maximum load. More preferably, the non-stretch materials used in the present invention stretch ten percent or less at maximum load.
In some embodiments, the fabric for the top and bottom covers can be secured to the sides or sidewalls of the air mattress by using welding or adhesive either directly or through the use of a sealing strip placed over the edge of the cover fabric. In addition, welting cord may be used for added strength and reinforcement. The sealing strip can be welded or cemented to the air mattress material through perforations provided in the cover along the perimeter of the cover. Alternatively, glue, cement, or other adhesive can saturate the cover material and bond the sealing strip to the air mattress material.
Using a six sided sleeve avoids some of the manufacturing complexities of the bonded cover systems, and the six sided sleeve can be just as effective. The six sided sleeve can be removed and washed if needed, and no positive connection is required to the air mattress portion.
A greater comfort level can be achieved, and the person lying on the air mattress assembly prevented from sinking uncomfortably far into the air mattress, by providing tensioned top and bottom covers acting on the top and bottom sides, respectively, of an air mattress. This arrangement obviates the need for any outside apparatus, such as tensioners connecting the top cover to a bed frame, for creating tension in the top cover.
An air mattress with the tensioned sleeve is more comfortable due to the body being elevated by the fabric or top cover, while still providing sufficient cushioning or give for comfort. A pillow or cushioned topper can be added to the top cover to adjust the firmness or softness of the air mattress assembly. For example, a one inch cushioned topper can be used for a relatively firm feel, a two inch cushioned topper can be used for a medium feel, and a three inch cushioned topper can be used for a relatively soft feel. The air mattress assembly according to the claimed embodiments avoids one of the biggest problems associated with standard mattresses, namely, that it does not sink or sag in the middle.
Referring to
The air mattress assembly 200 includes an air mattress 202 a sleeve 201. The sleeve 201 is made of a fabric that is durable and can provide significant tension tensile force when the air mattress 202 is inflated. The same types of materials that were mentioned with respect to the sleeve 1 and the top and bottom cover material 7 and 7′ will also be suitable for the sleeve 201. The opening 212 of the sleeve 201 is provided with a slide fastener 203, commonly referred to as a zipper, which can be used to close off the opening 212 or to open the opening 212 for the insertion and removal of the uninflated air mattress into or from the sleeve 201. Accordingly, the zipper 203 replaces the buttons 3 in the sleeve 201. Also, the closure flaps 13 and 14 are replaced by a simple slit defining the opening 212 in the sleeve 201. In the illustrated embodiment, the slit defining the opening 212 and the zipper 203 extend over a first side, preferably one of the longer sides, of the sleeve 201 or the air mattress assembly 200 and over portions of two other sides of the sleeve or air mattress assembly that are adjacent to the first side.
Alternatively, the slit defining the opening 212 and the zipper 203 may extend over a portion of the length of a side of the sleeve 201 or the air mattress assembly 200, or the slit defining the opening 212 and the zipper 203 may extend over essentially the entire length of a side of the sleeve 201 or the air mattress assembly 200.
To assemble the sleeve 201 and the air mattress 202 together, the air mattress 202 is inserted into the sleeve 201, through the opening 212, before the air mattress is inflated. The zipper 203 is then moved the majority of the way to the closed position such that only a small opening that is large enough to allow access to the air intake valve 215 is left. Accordingly, the edges of the opening 212 are essentially secured together before the air mattress 202 is inflated. The air mattress 202 has an air intake valve 215 that is located near one end of the opening 212 such that, with at least a majority of the opening 212 closed by the zipper 203, the air intake valve 215 can be engaged with a pump and the air mattress can be inflated. Once the air mattress is inflated to a pressure within the recommended range, the remainder of the opening 212 is closed by moving the slide of the zipper 203 completely to the closed position. The air mattress assembly 200 is then complete and the air mattress assembly 200 is ready for use. The air mattress 202 can be made of the same material as the air mattress 2.
The air mattress 202, as illustrated in
Referring to
Each of the top and bottom covers 307 and 307′ is also provided with a sealing strip 318 that is attached to the sidewall 309 of the air mattress 302 on one side of the corresponding cord 317 and channel 316. The sealing strip 318 can be attached to the sidewall 309 of the air mattress 302 by any suitable method including, for example, ultrasonic welding, heat fusion, cementing, and gluing or using adhesives. Each sealing strip 318 then extends over and covers the corresponding channel 316 and cord 317 and is attached to the air mattress 302 or the sidewall 309 of the air mattress 302 by glue/adhesive to anchor the corresponding top or bottom cover to the air mattress 302. The glue/adhesive saturates the corresponding top or bottom cover to attach the corresponding sealing strip to the air mattress 302 or the sidewall 309 of the air mattress 302 through the corresponding top or bottom cover. Preferably, each sealing strip 318 is essentially coextensive with the perimeter of the corresponding top or bottom cover 307 or 307′. Alternatively, each sealing strip 318 may extend along portions of the four sides of the air mattress assembly 300. Each sealing strip 318 may be continuous or may be provided in segments along the perimeter of the air mattress assembly 300. Preferably, each sealing strip 318 extends at least along a majority of the length of each of the four sides of the air mattress assembly 300.
Referring to
Each of the top and bottom covers 407 and 407′ is also provided with a sealing strip 418 that is attached to the sidewall 409 of the air mattress 402 on one side of the corresponding cord 417 and channel 416. The sealing strip 418 can be attached to the sidewall 409 of the air mattress 402 by any suitable method including, for example, ultrasonic welding, heat fusion, cementing, and gluing or using adhesives. Each sealing strip 418 then extends over and covers the corresponding channel 416 and cord 417 and is attached to the air mattress 402 or the sidewall 409 of the air mattress 402 by any suitable method through perforations or windows 419 provided in the top and bottom covers to anchor the corresponding top or bottom cover to the air mattress 402. The windows 419 are distributed along portions, or all, of the perimeter of the top and bottom covers. The attachment between each sealing strip 418 and the air mattress 402, through the windows 419, may be accomplished by any suitable method including, for example, ultrasonic welding, heat fusion, cementing, and gluing or using adhesives. The attachment between each sealing strip 418 and the air mattress 402, through the windows 419, may be used in place of, or in addition to, the glue/adhesive saturating the corresponding top or bottom cover to attach the corresponding sealing strip to the air mattress 402. Otherwise, the remarks regarding the embodiment of
Referring to
Each of the channels 515 is provided with a plurality of cutouts 519 that expose portions of the corresponding cord 517. A number, and preferably most or all, of the exposed portions of the cord 517 for the top cover 507 are then connected to corresponding exposed portions of the cord 517 for the bottom covers 507′ by corresponding ties or tethers 520 to hold the top and bottom covers 507 and 507′ around the air mattress 502. This arrangement allows the tension in the top cover to be counterbalanced by the tension in the bottom cover and relieves some or most of the stress imparted to any attachment between the top and bottom covers 507 and 507′ and the air mattress 502. The air mattress assembly 500 is also provided with a sealing strip 518 that covers at least a portion of the ties 520 extending along the sidewall 509 of the air mattress 502. The sealing strip 518 is attached to the sidewall 509 of the air mattress 502 intermediate the ties 520 in the same manner as the sealing strips of the embodiments of
The cutouts 519 are distributed along portions, or all, of the perimeter of the top and bottom covers. Otherwise, the remarks regarding the embodiments of
The air mattresses 202, 302, 402, 502, and 2 can be made of the same materials and have the same structure. The sleeves 201, 301, and 1 and the top and bottom covers 7, 7′, 407, 407′, 507, and 507′ can be made of the same materials.
The rectangular air mattresses, such as the air mattresses 202, 302, 402, 502, and 2, may have sides of equal length, i.e. they may be square, or they may have two parallel longer sides and two parallel shorter sides. For example, the common mattress sizes twin, full, queen, and king all have two longer sides and two shorter sides.
It should be understood that the present invention is not limited to the specific embodiments described above, but includes any and all variations or modifications within the spirit and scope of the appended claims.
This application claims the benefit of U.S. Provisional Application No. 62/521,735, filed on Jun. 19, 2017, which is incorporated herein by reference in its entirety.
Number | Name | Date | Kind |
---|---|---|---|
2537652 | Churchill | Jan 1951 | A |
5491854 | Music | Feb 1996 | A |
5666680 | Hackett, Jr. | Sep 1997 | A |
9737153 | Chaffee | Aug 2017 | B2 |
20040003471 | VanSteenburg | Jan 2004 | A1 |
20050005363 | Giori | Jan 2005 | A1 |
20120233776 | Agarwall | Sep 2012 | A1 |
20120233832 | Hooley | Sep 2012 | A1 |
20120272456 | Lemmer | Nov 2012 | A1 |
Number | Date | Country | |
---|---|---|---|
20180360228 A1 | Dec 2018 | US |
Number | Date | Country | |
---|---|---|---|
62521735 | Jun 2017 | US |