Patent Application
20080078026
In the drawings:
Referring to the
The integrated mattress and foundation 10 has a low profile and reduced weight as compared to a traditional mattress and box springs that makes it especially suitable for such environments as the RV environment, although the application of the present invention is not so limited. As used herein, the term “low profile”, in the context of describing mattress and foundation structures means that the integrated mattress and foundation 10 has a thickness T that is less than the combined thickness of a separate mattress and foundation. The thickness T of the integrated mattress and foundation 10 can vary, but should be appropriate for low profile applications. Preferably, the low profile integrated mattress and foundation 10 has a thickness T that is equal to or less than 8 inches.
In an RV environment, the 8 inch limitation is important because the structure on which the integrated mattress and foundation 10 is placed normally performs the dual function of a bed frame and a storage device, with a door being provided and the mattress resting on the door. Referring to
Referring to
The frame 16 defines an interior area 24 and the webbing support 18 spans the interior area 24. The frame 16 can be configured to be fit onto a bedstead or other support structures, or may be placed on a floor surface. As illustrated, the frame 16 comprises four slats 26 that are attached at their respective ends to form a generally rectangular structure. The frame 16 can be quickly constructed during assembly by using mechanical fasteners 28 such as gang-nail or truss plates. The frame slats 26 can be constructed of wood, metal, or plastic, however, wood is preferred.
The webbing support 18 is illustrated as comprising a plurality of spaced longitudinal webbing strips 30 that are crossed by spaced traverse webbing strips 32. The webbing strips 30, 32 are preferably equidistantly spaced and cross one another at generally right angles. The webbing support 18 can have a basket-weave construction, with the webbing strips 30, 32 forming a woven matrix for supporting the padding element 20. The webbing strips 30, 32 can be attached to the frame 16 using glue, staples, nails, or any other suitable attaching means. Preferably, the webbing strips 30, 32 are attached to the frame sides 26 using staples 34 to allow for a quick, simplified assembly. The webbing support 18 can have a customized tension based on a user's specifications. The tension of the webbing strips 30, 32 can be adjusted by stretching the strips 30, 32 when attaching them to the frame 16. In an alternate embodiment (not shown) the webbing support 18 can comprise a sheet of webbing material attached to the four frame sides 26. An example of suitable resilient webbing strips 30, 32 and resilient webbing sheets are Ultra-Flex® strap webbing and sheet webbing, and is commercially available from Ultraflex Corporation (High Point, N.C.).
The spring-less padding element 20 comprises one or more layers of material that will yield or compress under a weight placed on top of the integrated mattress and foundation 10 and thus provides a comfortable resting place for a user. The padding element 20 is spring-less, in that is does not comprise an innerspring. The padding element 20 can be batting made from cotton, wool, or synthetic fibers; foam; or other suitable material. The padding element 20, including the type of material, material properties, number of layers, layer properties, and the thickness of the padding element, Tp, can be customized based on a user's specifications. In the illustrated embodiment, the padding element 20 comprises two layers of foam, 36, 38 having different material properties. The first or lower layer 36 can be more dense and/or more firm than the upper layer 38. Types of suitable foam include, but are not limited to polyurethane, latex, viscoelastic, and rubber foams. The padding element 20 does not contain any springs and preferably is non-inflatable. The thickness Tp of the padding element 20 can vary according to dimensions of the other components of the integrated mattress and foundation 10, but in either case, the thickness Tp should be selected to provide an overall thickness T that is appropriate for low profile applications. The thickness Tp of the padding element 20 preferably ranges from 2 to 7 inches.
The casing 22 covers the top surface of the padding element 20 and preferably also covers the peripheral sides of the padding element 20 and frame 16. The casing 22 can alternately completely enclose the padding element 20 and not cover the frame 16. The casing 22 can comprise a quilted material. A sheet of ticking 40 can cover the bottom side of the frame 16 and span at least a portion of the interior area 24. The casing 22 and ticking 40 can be attached to the frame 16 using glue, staples, nails, or any other suitable attaching means. The ticking 40 can also be attached or sewn to the casing 22.
The integrated mattress and foundation 10 is suited for incorporation into static structures, such as houses, apartments, condominiums, hotels, gyms, and other buildings, and ideally suited for mobile structures, such as recreational vehicles (RVs), trailers, mobile homes, cruise ships, and houseboats. Due to its low profile and light weight structure, the integrated mattress and foundation 10 is particularity suitable for use in the RV or marine market where size and weight are a concern. Mattress life is preserved by using a resilient webbing support 18 as a major portion of the foundation component 14. The tension of the resilient webbing support 18 and the firmness of the padding element 20 can be customized to a user's specifications. By employing a webbing support 18 and a spring-less padding element 20, the overall height of the integrated mattress and foundation 10 is kept low. Furthermore, the integrated mattress and foundation 10 has a simplified construction and can be quickly assembled.
While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.
