FIELD OF DISCLOSURE
The field of the disclosure relates generally to mattress assemblies, mattresses, and related methods providing support, including side-support members, which may be employed in bedding and seating applications.
BACKGROUND
Innerspring assemblies are a type of mattress core utilized for mattresses or seating structures and may be composed of spring coils attached together in a matrix or array. An example of a mattress 10 containing an innerspring assembly 12 (“innerspring 12”) is illustrated in FIG. 1. The innerspring 12 is comprised of conventional coils 14 arranged in an interconnected matrix to form a flexible core and support surfaces of the mattress 10. Adjacent coils 14 are secured to one another by lower interconnection helical wires 16 and upper interconnection helical wires 18. At a perimeter 20 of the innerspring 12, innerspring coils 14 are also connected to one another by upper and lower border wires 22, 24. Upper and lower border wires 22, 24 are attached to upper and lower end turns of the coils 14 to create a frame 26 for the innerspring 12. The upper and lower border wires 22, 24 may provide firmness for edge support on the perimeter 20 of the innerspring 12 where an individual user may disproportionally place weight on the innerspring 12, such as during mounting onto and dismounting from the mattress 10.
With continuing reference to FIG. 1, the innerspring 12 may be disposed on top of a base 28 to provide base support. The base 28 may be comprised of foamed polymer to provide cushioned support for the innerspring 12. To provide further perimeter structure and edge-support for the innerspring 12 in FIG. 1, edge-support members 34 (also referred to as “side-support members 34”) may be disposed around the coils 14 proximate to an edge 30 of the innerspring 12, between the base 28 and the upper and the lower border wires 22, 24. The foam side-support members 34 may be extruded from polymer foam, as an example. The foam side-support members 34 are secured to the base 28 to provide an encasement 36 for the innerspring 12. The foam side-support members 34 being disposed orthogonally to the base 28 to provide the encasement 36 provides an interior area 38 inside the encasement 36 to receive and support the innerspring 12. The foam side-support members 34, being foam in this example, can be secured to the foam base 28 through use of an adhesive or thermal bonding, as examples. One or more padding material layer 40 may be disposed on top of the innerspring 12. Upholstery 42 (“ticking”) can then be placed around the padding material layer(s) 40, innerspring 12, the foam side-support member 34, and base 28 to form the mattress 10 in its fully assembled state. The mattress structure in FIG. 1 may also be provided for other types of innersprings, including pocketed coils.
Certain components of the mattress 10 may be manufactured separately and shipped to secondary manufacturers or assemblers that assemble the entire mattress 10. It may also be desired to ship components of the mattress 10 to an end user in unassembled form, for the end user to assemble or have the components assembled into the mattress 10. In either case, it is desirable to find ways to compact the mattress 10 and/or its components to reduce their volume during shipping to reduce shipping costs. As discussed above, to assemble the mattress 10 in FIG. 1, the base 28 and the side-support members 34 must be provided and secured to each other to provide the encasement 36 for the innerspring 12. It may be desired to provide the encasement 36 in assembled form to avoid a secondary manufacturer or assembler, or an end user, from having to engage in the complexity and skill of applying adhesives or thermal bonding to secure the foam side-support members 34 to the base 28. However, shipping the encasement 36 in assembled form may still be expensive. The foam side-support members 34 of the encasement 36, being disposed around all edges of the base 28 and secured to each other, do not allow the encasement 36 to be folded to reduce the volume of the interior space 38 of the encasement 36 during shipment.
SUMMARY OF THE DETAILED DESCRIPTION
Embodiments disclosed herein include interlocking foam encasement components to form mattress encasements. Related mattress encasements, mattress assemblies, and methods are also disclosed. In certain embodiments, a mattress encasement is formed by two interlocking foam encasement components engaged with each other. Each interlocking foam encasement component is comprised of a foam base member with two foam side-support members provided in parallel or substantially parallel arrangement on opposite sides of the foam base member. The rigidity of the foam base members disposes the foam side-support members a predefined distance away from each other according to the length of the foam base members. To form the mattress encasement, first side-support members of a first interlocking foam encasement component are interlocked orthogonal or substantially orthogonal to second side-support members of a second interlocking foam encasement component to form a foam side-support perimeter of side-support members for the mattress encasement. The foam side-support perimeter provides an interior area to receive and encase a mattress innerspring or mattress core. The foam base members of the first interlocking foam encasement component and the second interlocking foam encasement component are disposed on top of each other to maintain the interlocking of the foam side-support members together in the foam side-support perimeter.
In this manner as a non-limiting example, the mattress encasement can be easily assembled by providing two interlocking foam encasement components that can easily be interlocked together to form a foam side-support perimeter of side-support members about the base. Further, as another non-limiting example, because the mattress encasement is formed from foam encasement components having parallel or substantially parallel arranged side-support members, each foam encasement member can be folded or rolled about the foam side-support members to reduce or eliminate the volume that would otherwise by consumed by an interior area of an assembled encasement for reduced-volume storage and/or shipment.
In this regard, in one embodiment, a mattress encasement for encasing a mattress innerspring or mattress core is provided. The mattress encasement comprises a first interlocking foam encasement component. The first interlocking foam encasement component comprises a first foam base member having a first pair of foam side-support members provided on first opposite ends of the first foam base member and disposed in parallel or substantially parallel arrangement in a first longitudinal direction. The mattress encasement also comprises a second interlocking foam encasement component. The second interlocking foam encasement component comprises a second foam base member having a second pair of foam side-support members provided on first opposite ends of the second foam base member and disposed in parallel or substantially parallel arrangement in a second longitudinal direction. The first interlocking foam encasement component is received by the second interlocking foam encasement component to interlock the first pair of foam side-support members in the first longitudinal direction orthogonal or substantially orthogonal to the second longitudinal direction of the second pair of foam side-support members, forming a foam side-support perimeter. The foam side-support perimeter is comprised of the first pair of foam side-support members interlocked with the second pair of foam side-support members and an interior area inside the foam side-support perimeter configured to encase a mattress innerspring or mattress core.
In another embodiment, a method of assembling a mattress encasement for encasing a mattress innerspring or mattress core is provided. The method comprises providing a first interlocking foam encasement component. The first interlocking foam encasement component comprises a first foam base member having a first pair of foam side-support members provided on first opposite ends of the first foam base member and disposed in parallel or substantially parallel arrangement in a first longitudinal direction. The method also comprises providing a second interlocking foam encasement component. The second interlocking foam encasement component comprises a second foam base member having a second pair of foam side-support members provided on first opposite ends of the second foam base member and disposed in parallel or substantially parallel arrangement in a second longitudinal direction. The method also comprises receiving the first interlocking foam encasement by the second interlocking foam encasement component to interlock the first pair of foam side-support members in the first longitudinal direction orthogonal or substantially orthogonal to the second longitudinal direction of the second pair of foam side-support members, forming a foam side-support perimeter. The foam side-support perimeter is comprised of the first pair of foam side-support members interlocked with the second pair of foam side-support members and an interior area inside the foam side-support perimeter configured to encase a mattress innerspring or mattress core.
The aforementioned mattress assemblies may be compatible with various types of mattress cores, for example, innerspring coil mattress cores, pocketed coil cores, or air bladder mattress cores having varying widths and lengths forming the mattress core perimeter. Furthermore, the side-support members may be pivoted with respect to the foam base for more compact storage and easier transportation.
BRIEF DESCRIPTION OF FIGURES
FIG. 1 is a perspective partial cutaway view of a mattress in the prior art including an innerspring disposed in an interior area of an encasement formed from side-support members secured around the edge of a base;
FIG. 2A is a perspective view of an exemplary mattress encasement formed by an exemplary first interlocking foam encasement component having first side-support members interlocked orthogonal or substantially orthogonal with second side-support members of an exemplary second interlocking foam encasement component, to form a foam side-support perimeter and an interior area therein for receiving and encasing a mattress innerspring or mattress core;
FIGS. 2B and 2C are perspective views of the first interlocking foam encasement component and second interlocking foam encasement component, respectively, of the mattress encasement in FIG. 2A;
FIG. 2D is a perspective view of the second interlocking foam encasement component in the mattress encasement in FIG. 2A positioned below the second interlocking foam encasement component, to interlock the first side-support members of the first interlocking foam encasement component with the second side-support members of the second interlocking foam encasement component to form the mattress encasement.
FIG. 2E is a perspective view of an exemplary mattress assembly that includes the mattress encasement of FIG. 2A encasing a mattress innerspring;
FIG. 2F is a perspective view of an exemplary mattress assembly that includes the mattress encasement of FIG. 2A encasing a mattress core;
FIG. 3 is a side, perspective view of an interlocking foam encasement component in the mattress encasement in FIG. 2A folded about the foam side-support members to volume-reduce the interlocking foam encasement component for storage and/or shipment;
FIG. 4A is a perspective, side view of an alternative exemplary foam base member that may be employed in interlocking foam encasement components in the mattress encasement of FIG. 2A, wherein beveled cuts are disposed in the foam base member to facilitate the folding of the interlocking foam encasement component about the foam side-support members to volume-reduce the interlocking foam encasement component for storage and/or shipment;
FIG. 4B is a partial, left side view of an exemplary interlocking foam encasement component employing the foam base member in FIG. 4A;
FIG. 4C is a side perspective view of the interlocking foam encasement component in FIG. 4B folded about the foam side-support members to volume-reduce the interlocking foam encasement component for storage and/or shipment;
FIG. 5A-1 is a perspective view of an alternative exemplary mattress encasement with first side-support members of a first interlocking foam encasement component having interior slots configured to receive edges of the foam base member of the second interlocking foam encasement component, to further facilitate interlocking of the first interlocking foam encasement component to the second interlocking foam encasement component;
FIG. 5A-2 is a close-up, perspective view of FIG. 5A-1 illustrating of a corner of the first interlocking foam encasement component interlocked with the second interlocking foam encasement component;
FIG. 5B-1 is a perspective view of the first interlocking foam encasement component in the mattress encasement in FIG. 5A-1 positioned below the second interlocking foam encasement component, to insert the first side-support members of the first interlocking foam encasement component inserted between the second side-support members of the second interlocking foam encasement component;
FIG. 5B-2 is a close-up, perspective view of FIG. 5B-1 illustrating of a corner of the first interlocking foam encasement component positioned below the second interlocking foam encasement component;
FIG. 6A is a perspective view of another exemplary mattress encasement formed by an exemplary first interlocking foam encasement component having first side-support members interlocked orthogonal or substantially orthogonal with second side-support members of an exemplary second interlocking foam encasement component to form a foam side-support perimeter, wherein the second interlocking foam encasement component has a foam base member containing a plurality of parallel-arranged, elongated protrusions forming elongated channels therebetween, to facilitate motion isolation in a mattress innerspring disposed in the mattress encasement;
FIGS. 6B and 6C are perspective views of the first interlocking foam encasement component and second interlocking foam encasement component, respectively, of the mattress encasement in FIG. 6A;
FIG. 7A is a perspective view of another exemplary mattress encasement formed by an exemplary first interlocking foam encasement component having first flip-up side-support members interlocked with second flip-up side-support members of an exemplary second interlocking foam encasement component;
FIGS. 7B-1 and 7B-2 are perspective views of the first interlocking foam encasement component of the mattress encasement in FIG. 7A, illustrating the second side-support members before being flipped-up, and the second side-support members after being flipped-up, respectively;
FIGS. 7C-1 and 7C-2 are perspective views of the second interlocking foam encasement component of the mattress encasement in FIG. 7A, illustrating the first side-support members before being flipped-up, and the first side-support members after being flipped-up, respectively;
FIG. 8A is a perspective view of another exemplary mattress encasement formed by an exemplary first interlocking foam encasement component having first side-support members interlocked with second side-support members of an exemplary second interlocking foam encasement component to form a foam side-support perimeter, wherein the first and second side-support members further contain protrusions configured to insert between coil springs in a mattress innerspring disposed in the mattress encasement, to facilitate attachment of the first and second side-support members to the mattress innerspring; and
FIGS. 8B and 8C are perspective views of the first interlocking foam encasement component and second interlocking foam encasement component, respectively, of the mattress encasement in FIG. 8A.
DETAILED DESCRIPTION
With reference now to the drawing figures, several exemplary embodiments of the present disclosure are described. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
Embodiments disclosed herein include interlocking foam encasement components to form mattress encasements. Related mattress encasements, mattress assemblies, and methods are also disclosed. In certain embodiments, a mattress encasement is formed by two interlocking foam encasement components engaged with each other. Each interlocking foam encasement component is comprised of a foam base member with two foam side-support members provided in parallel or substantially parallel arrangement on opposite sides of the foam base member. The rigidity of the foam base members disposes the foam side-support members a predefined distance away from each other according to the length of the foam base members. To form the mattress encasement, first side-support members of a first interlocking foam encasement component are interlocked orthogonal or substantially orthogonal to second side-support members of a second interlocking foam encasement component to form a foam side-support perimeter of side-support members for the mattress encasement. The foam side-support perimeter provides an interior area to receive and encase a mattress innerspring or mattress core. The foam base members of the first interlocking foam encasement component and the second interlocking foam encasement component are disposed on top of each other to maintain the interlocking of the foam side-support members together in the foam side-support perimeter.
In this manner as a non-limiting example, the mattress encasement can be easily assembled by providing two interlocking foam encasement components that can easily be disposed together to form the perimeter of side-support members about the base. Further, as another non-limiting example, because the mattress encasement is formed from foam encasement components having parallel or substantially parallel arranged side-support members, each foam encasement member can be folded or rolled about the foam side-support members to reduce or eliminate the volume that would otherwise by consumed by an interior area of an assembled encasement for reduced-volume storage and/or shipment.
In this regard, FIG. 2A is a perspective view of an exemplary mattress encasement 40 comprised of interlocking foam encasement components in assembled form. As will be discussed in more detail below, the interlocking foam encasement components form a foam side-support perimeter 42 providing an interior area 44 for encasing a mattress innerspring or mattress core. In this regard, the mattress encasement 40 in this embodiment includes a first interlocking foam encasement component 46A and a second interlocking foam encasement component 46B. The first and second interlocking foam encasement components 46A, 46B are illustrated in not-interlocked form in FIGS. 2B and 2C, respectively. The first interlocking foam encasement component 46A includes first foam base member 48A. A first pair of foam side-support members 50A(1), 50A(2) are provided on first opposite ends 52A(1), 52A(2) of the first foam base member 48A and disposed in parallel or substantially parallel arrangement in a first longitudinal direction D1 along longitudinal axes A1(1), A1(2) (i.e., longitudinal axes A1(1), A1(2) are parallel or substantially parallel (e.g., longitudinal axes A1(1), A1(2) disposed less than approximately ten (10) degrees between each other)). Similarly, the second interlocking foam encasement component 46B includes second foam base member 48B. A second pair of foam side-support members 50B(1), 50B(2) are provided on second opposite ends 52B(1), 52B(2) of the second foam base member 48B and disposed in parallel or substantially parallel arrangement in a second longitudinal direction D2 along longitudinal axes A2(1), A2(2) (i.e., longitudinal axes A2(1), A2(2) are parallel or substantially parallel (e.g., longitudinal axes A2(1), A2(2) disposed less than approximately ten (10) degrees between each other)). As illustrated in FIG. 2D, the first interlocking foam encasement component 46A is configured to be received by the second interlocking foam encasement component 46B.
As illustrated in FIG. 2A, the first interlocking foam encasement component 46A receives the second interlocking foam encasement component 46B, thereby disposing the first pair of foam side-support members 50A(1) 50A(2) in the first longitudinal direction D1 orthogonal or substantially orthogonal to the second longitudinal direction D2 of the second pair of foam side-support members 50B(1), 50B(2). This interlocking of the first and second pairs of foam side-support members 50A(1), 50A(2), 50B(1), 50B(2) forms the foam side-support perimeter 42 and the interior area 44 therein to provide the mattress encasement 40. A mattress innerspring or mattress core can be disposed in the interior area 44 surrounded by the foam side-support perimeter 42 to encase the mattress innerspring or mattress core to form a mattress assembly. FIG. 2E illustrates a mattress assembly 54 comprising the assembled mattress encasement 40 in FIG. 2A encasing a mattress innerspring 56, which may be comprised of coils 58, such as pocketed-coils 60 as a non-limiting example. FIG. 2F illustrates a mattress assembly 62 comprising the assembled mattress encasement 40 in FIG. 2A encasing a mattress core 64, which may be comprised of a foam core 66, which may include foamed thermoset material, foamed thermoplastic material, or a combination thereof, as examples.
In this manner, as a non-limiting example, the mattress encasement 40 in FIG. 2A can be easily assembled by providing the first and second interlocking foam encasement components 46A, 46B. The first and second interlocking foam encasement components 46A, 46B can easily be interlocked together to form the foam side-support perimeter 42 comprised of the interlocked first and second pair of foam side-support members 50A(1), 50A(2) and 50B(1), 50B(2). The first and second interlocking foam encasement components 46A, 46B can be interlocked by disposing the first interlocking foam encasement component 46A into the second interlocking foam encasement component 46B, as illustrated in FIG. 2D. The foam side-support perimeter 42 is created as a result of the interlocked first and second pair of foam side-support members 50A(1), 50A(2) and 50B(1), 50B(2) as a result of disposing the first interlocking foam encasement component 46A into the second interlocking foam encasement component 46B. Further, as another non-limiting example that will be discussed in more detail below, the first and second interlocking foam encasement members 46A, 46B can easily be folded or rolled about their foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2), respectively, as illustrated in FIG. 3, to reduce or eliminate the volume that would otherwise by consumed by the interior area 44 of the assembled mattress encasement 40 for reduced-volume storage and/or shipment.
With continuing reference to the mattress encasement 40 in FIGS. 2B and 2C, in this embodiment, the first pair of foam side-support members 50A(1), 50A(2) of the first interlocking foam encasement component 46A were manufactured as separate components that were attached to the first foam base member 48A. The second pair of foam side-support members 50B(1), 50B(2) of the second interlocking foam encasement component 46B were also manufactured as separate components that were attached to the second foam base member 48B. For example, the first pair of foam side-support members 50A(1), 50A(2) and second pair of foam side-support members 50B(1), 50B(2) could be attached to their respective first and second foam base members 48A, 48B by adhesive or cohesion, such as thermal bonding. Alternatively, the first pair of foam side-support members 50A(1), 50A(2) and second pair of foam side-support members 50B(1), 50B(2) could be provided as integral components to the first and second foam base members 48A, 48B, such as by molding for example. As illustrated in FIG. 2D, elongated channels 74A(1), 74A(2), 74B(1), 74B(2) may be formed, such as through extrusion, in the first pair of foam side-support members 50A(1), 50A(2) and second pair of foam side-support members 50B(1), 50B(2), to reduce material costs and/or to provide the desired cushioning and load effect for the mattress encasement 40. As also illustrated in FIG. 2D, elongated channels 74A(1), 74A(2), 74B(1), 74B(2) may be formed, such as through extrusion, in the first pair of foam side-support members 50A(1), 50A(2) and second pair of foam side-support members 50B(1), 50B(2), to reduce material costs and/or to provide the desired cushioning and load effect for the mattress encasement 40.
With continuing reference to FIGS. 2A-2E, the first pair of foam side-support members 50A(1), 50A(2) and second pair of foam side-support members 50B(1), 50B(2) may be made from any foamed material desired. These material examples include, but are not limited to, a polymer, a polymer foam, latex, viscoelastic, polystyrene, polyolefin, polyethylene, polybutane, polybutylene, polyurethane, polyester, ethylene acrylic copolymer, ethylene-vinyl-acetate copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl-acrylate copolymer, ionomer, polypropylene, copolymer of polypropylene, latex rubber, thermoset material, and the like, as non-limiting examples. Further, the first pair of foam side-support members 50A(1), 50A(2) and/or the second pair of foam side-support members 50B(1), 50B(2) may be formed from a combination of thermoset and thermoplastic foamed material(s), to provide composite cushioning characteristics. For example, the first pair of foam side-support members 50A(1), 50A(2) and/or the second pair of foam side-support members 50B(1), 50B(2) may be comprised of a composite foamed material as provided in U.S. Pat. No. 8,356,373, entitled “Unitary Composite/Hybrid Cushioning Structure(s) And Profiles(s) Comprised Of A Thermoplastic Foam(s) And A Thermoset Material(s),” and U.S. patent application Ser. No. 13/026,979, entitled “Composite Cushioning Structure(s) With Spatially variable Cushioning Properties And Related Materials, Cushioning Assemblies, And Methods For Producing Same,” both of which are incorporated herein by reference in their entirety. Further, the first pair of foam side-support members 50A(1), 50A(2) and/or the second pair of foam side-support members 50B(1), 50B(2) may include filler, including but not limited to, a ground foam reclaim material, a nano clay, a carbon nano tube, calcium carbonate, flyash, and corc dust, as non-limiting examples.
With reference to FIGS. 2B and 2C, the first pair of foam side-support members 50A(1), 50A(2) of the first interlocking foam encasement component 46A are each of a first length L1. The second pair of foam side-support members 50B(1), 50B(2) of the first interlocking foam encasement component 46A are each of a second length L2. In this embodiment, first length L1 is greater than the second length L2. In this regard, as illustrated in FIG. 2D, end portions 68B of the second foam base member 48B are exposed by the second foam base member 48B being longer than the second length L2. Thus, as illustrated in FIG. 2D, end faces 70B(1), 70B(2) of the second pair of foam side-support members 50B(1), 50B(2) will abut end sides 72A(1), 72A(2) of the second pair of foam side-support members 50B(1), 50B(2) when the first interlocking foam encasement component 46A is disposed into and interlocked with the second interlocking foam encasement component 46B.
The first and second foam base members 48A, 48B being constructed of foam material provide rigidity to the interlocking of the second pair of foam side-support members 50A(1), 50A(2) with the second pair of foam side-support members 50B(1), 50B(2). As illustrated in FIG. 2D, a pair of opposing edges 77A(1), 77A(2) of the first foam base member 48A in the first interlocking foam encasement component 46A are configured to abut the second pair of foam side-support members 50B(1), 50B(2) when the first interlocking foam encasement component 46A is interlocked with the second interlocking foam encasement component 46B. The first foam base member 48A pushes outward on the second pair of foam side-support members 50B(1), 50B(2) to keep the second pair of foam side-support members 50B(1), 50B(2) interlocked with the first pair of foam side-support members 50A(1), 50A(2) to maintain the foam side-support perimeter 42. Also in this example, as illustrated in FIGS. 2A-2E, the second foam base member 48B includes elongated channels 76, which may be formed through extrusion as an example, to reduce material costs and/or to provide the desired cushioning and load effect for the mattress encasement 40. In this example, as a non-limiting embodiment, the first foam base member 48A is a solid sheet of foam material that does not include elongated channels. With the first foam base member 48A disposed on top of and abutting the second foam base member 48B when the first and second interlocking foam encasement components 46A, 46B are interlocked, any load placed on the first foam base member 48A will translate to the thicker second foam base member 48B to provide a cushioning and/or support base for the mattress encasement 40.
FIG. 3 is a side, perspective view of the mattress encasement 40 in FIG. 2A folded about foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2) to volume-reduce the first and/or second interlocking foam encasement component 46A and/or 46B for storage and/or shipment. The interlocking foam encasement component illustrated in FIG. 3 can be the first interlocking foam encasement component 46A or the second interlocking foam encasement component 46B. Because the first or second interlocking foam encasement component 46A or 46B only has one pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2) on opposite ends 52A(1), 52A(2) or 52B(1), 52B(2), the first or second interlocking foam encasement component 46A or 46B can more easily be folded or rolled about the first or second pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2) for storage and/or transport. Orthogonally disposed first or second pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2) are not provided by providing the first and second interlocking foam encasement components 46A, 46B as two separate components, when the first and second interlocking foam encasement components 46A, 46B, respectively, are folded or rolled up. In this manner, the interior area 44 of an assembled mattress encasement 40 does not have to be retained, which would otherwise consume volume for storage and/or shipping of the mattress encasement 40.
If the material of the first and second foam base members 48A, 48B is stiff or rigid, the first and second interlocking foam encasement components 46A, 46B may still be difficult to fold or roll-up. In this regard, to assist in the folding or rolling-up of the first and second interlocking foam encasement components 46A, 46B, one or more elongated cut out channels 78(1)-78(3) may be disposed in a bottom surface 80A, 80B of alternative interlocking foam encasement components 46A′, 46B′, as illustrated in FIGS. 4A and 4B. FIG. 4A is a perspective, side view of an alternative exemplary foam base member 48A′, 48B′ that may be employed interlocking foam encasement components 46A′, 46B′ in the mattress encasement 10 in FIG. 2A. FIG. 4B is a partial, left, side view of an exemplary interlocking foam encasement components 46A′, 46B′ in FIG. 4A. The elongated cut out channels 78(1)-78(3) in this embodiment are beveled cuts are disposed in the bottom surface 80A, 80B of the alternative interlocking foam encasement components 46A′, 46B′. The elongated cut out channels 78(1)-78(3) facilitate the folding of the interlocking foam encasement components 46A′, 46B′ about the first and second pair of foam side-support members 50A(1), 50A(2), 50B(1), 50B(2) to volume-reduce the interlocking foam encasement components 46A′, 46B′ for storage and/or shipment. This is illustrated in FIG. 4C.
FIG. 4C is a side, perspective view of the interlocking foam encasement components 46A′ or 46B′ in FIGS. 4A and 4B folded about the foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2) to volume-reduce the interlocking foam encasement components 46A′ or 46B′ for storage and/or shipment. Note that the elongated cut out channels 78(1)-78(3) are disposed in the first and second foam base members 48A′, 48B′ based on the geometry of the first or second pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2) to provide elongated bend bias channels 82(1)-82(3) along the length of the first and second foam base members 48A′, 48B′ between the opposing edges 45A(1), 45A(2) and 45B(1), 45B(2). In this embodiment, the first elongated cut out channels 78(1) are located from the opposite ends 52A(1)', 52A(2)' or 52B(1)', 52B(2)' the width W1 of the first or second pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2). The second elongated cut out channels 78(2) are located from the first elongated cut out channels 78(1) the width H1 of the first or section pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2). The third elongated cut out channels 78(3) are located from the second elongated cut out channels 78(1) the width W1 again of the first or second pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2). In this manner, the biased bend channels 80(1)-80(3) are located at the bend points that will be imposed by the first or second pair of foam side-support members 50A(1), 50A(2) or 50B(1), 50B(2) in the first or second foam base members 48A′ 48B′, respectively.
There are other exemplary features that may be employed to retain the interlocking of the first and second interlocking foam encasement components 46A, 46B (and 46A′, 46B′ in FIGS. 4A-5) to retain and maintain the foam side-support perimeter 42 for the mattress encasement 40. For example, FIGS. 5A-1-5B-2 illustrate an alternative exemplary mattress encasement 40(1). FIG. 5A-1 is a perspective view of the mattress encasement 40(1) in assembled form. FIG. 5A-2 is a close-up, perspective view of the mattress encasement 40(1) in FIG. 5A-2. The mattress encasement 40(1) in FIGS. 5A-1 and 5A-2 is essentially the same mattress encasement as mattress encasement 40 illustrated in FIG. 2A. Common elements have common element numbers and thus will not be re-described. However, in the mattress encasement 40(1) as illustrated FIGS. 5B-1 and 5B-2, the second pair of foam side-support members 50B(1)(1), 50B(2)(1) of the second interlocking foam encasement component 46B(1) having elongated slots 82B(1), 82B(2). The elongated slots 82B(1), 82B(2) may be integrally formed in the second pair of foam side-support members 50B(1)(1), 50B(2)(1), such as through a mold or cut into the second pair of foam side-support members 50B(1)(1), 50B(2)(1). The elongated slots 82B(1), 82B(2) are configured to receive the pair of opposing edges 78A(1), 78A(2) of the first foam base member 48A(1) of the first interlocking foam encasement component 46A(1). This is opposed to the pair of opposing edges 78A(1), 78A(2) of the first foam base member 48A simply abutting the second pair of foam side-support members 50B(1)(1), 50B(2)(1). In this manner, the first foam base member 48A(1) of the first interlocking foam encasement component 46A(1) is further secured and interlocked with the second interlocking foam encasement component 46B(1), to form and maintain the foam side-support perimeter 42(1) of the mattress encasement 40(1).
Other features can be provided in interlocking foam encasement components that are configured to be interlocked together as described herein to provide an interlocking mattress encasement. In this regard, FIG. 6A is a perspective view of another exemplary mattress encasement 40(2) in assembled, interlocked form. FIGS. 6B and 6C are perspective views of a first interlocking foam encasement component 46A(2) and second interlocking foam encasement component 46B(2), respectively, in unassembled form of the mattress encasement 40(3) in FIG. 6A. The mattress encasement 40(2) is similar to the mattress encasement 40 in FIG. 2A. Common element numbers between the mattress encasement 40(2) in FIGS. 6A-6C and the mattress encasement 40 in FIG. 2A signify common components, and thus will not be re-described here. However, as illustrated in FIG. 6B, the first interlocking foam encasement component 46A(2) contains elongated protrusions 84 disposed in the first foam base member 48A(2), as illustrated in FIGS. 6A and 6B. The elongated protrusions 84 are disposed along longitudinal axes A3, as illustrated in FIGS. 6A and 6B. The elongated protrusions 84 are disposed in parallel or substantially parallel arrangement in the first foam base member 48A(2) providing a plurality of elongated channels 86 disposed in the parallel or substantially parallel arrangement. Each of the plurality of elongated channels 86 is disposed adjacent to elongated protrusions 84.
As discussed in U.S. Patent Provisional Application Ser. No. 61/620,649 filed Apr. 5, 2012, the elongated protrusions 84 may facilitate motion isolation and articulation of the mattress encasement 40(2) and a mattress innerspring or core encased in the interior area 44(2). The elongated protrusions 84 may also provide additional cushioning and support in combination with the a mattress innerspring or mattress core encased by the mattress encasement 40(2). The elongated protrusions 84 each comprise the distal end surfaces 88. The distal end surfaces 88 can be configured to support bottom portions of springs of a mattress innerspring, as an example. In this manner, the distal end surfaces 88 are configured to independently collapse to cushion the weight of a user of a mattress assembly employing the mattress encasement 40(2). The elongated protrusions 84 may comprise a cushioning material configured facilitate the collapse of the distal end surfaces 88, for example, foamed thermoplastic and/or foamed thermoset. In one embodiment the elongated protrusions 84 comprise polyethylene. The elongated protrusions 84 may be integral with the first foam base member 48A(2) for efficient transfer of the weight of the user, as a non-limiting example. Integral as used herein means the elongated protrusions 84 are attached to the first foam base member 48A(2) according to a bond so that they do not detach from one another. The bond may be formed by a mechanical lock wherein material of the elongated protrusions 84 may encapsulate or flow into holes and other surface features in the structure of the first foam base member 48A(2) before solidifying. Alternatively, the bond may be derived from melting and/or chemical adhesion or cohesion between surfaces of the elongated protrusions 84 and the first foam base member 48A(2).
FIG. 7A is a perspective view of another exemplary mattress encasement 40(3) in assembled, interlocked form. In this embodiment, the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3) provided in the first and second interlocking foam encasement components 46A(3), 46B(3), respectively, are flip-up side-support members. Providing the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3) allows the first and second interlocking foam encasement components 46A(3), 46B(3) to be disposed planar when unassembled for storage and/or shipping, as illustrated in FIGS. 7B-1 and 7C-1, respectively. This is opposed to being required to fold up or roll-up the first and second interlocking foam encasement components 46A(3), 46B(3) to compact the first and second interlocking foam encasement components 46A(3), 46B(3) for storage and/or transport. Common element numbers between the mattress encasement 40(3) in FIGS. 7A-7C-2 and the mattress encasement 40 in FIG. 2A signify common components, and thus will not be re-described here.
With reference to FIGS. 7B-1 and 7C-1, when it is desired to assemble the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3) to form the respective first and second interlocking foam encasement components 46A(3), 46B(3), the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3) are rotated in rotation direction R1 upward and inward towards the first and second foam base members 48A(3), 48B(3), respectively, to dispose the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3) orthogonal or substantially orthogonal to the first and second foam base members 48A(3), 48B(3), as illustrated in FIGS. 7B-2 and 7C-2, respectively. In this embodiment, as illustrated in FIGS. 7B-1 and 7C-1, a living hinge 90A(1), 90A(2) and 90B(1), 90B(2) is disposed in each of the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3), respectively, to allow the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3), to flip up about the first and second foam base members 48A(3), 48B(3), respectively.
Further, as illustrated in FIG. 7A, fasteners 92 may be employed on the assembled mattress encasement 40(3) to provide further support to secure the interlocking of adjacent first and second pair of foam side-support members 50A(1)(3), 50A(2)(3), 50B(1)(3), 50B(2)(3) together as shown. The fasteners 92 can include, but are not limited to rings, hog rings, ties, straps, female/male connections, etc. The fasteners 92 may be integral or separate component from the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3). The fasteners 92 can be provided in any embodiments of mattress encasements disclosed herein, but may be particularly relevant in this embodiment where the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3) and 50B(1)(3), 50B(2)(3) can flip down about their respective living hinges 90A(1), 90A(2) and 90B(1), 90B(2).
Alternatively, or in addition to the fasteners 92, cloth members 93 may be employed to secure adjacent first and second pair of foam side-support members 50A(1)(3), 50A(2)(3), 50B(1)(3), 50B(2)(3) together to provide additional interlocking. The cloth members 93 may be used to secure corners formed between adjacent first and second pair of foam side-support members 50A(1)(3), 50A(2)(3), 50B(1)(3), 50B(2)(3) coming together when the mattress encasement 40(3) is assembled, as shown in FIG. 7A. In this regard, the cloth members 93 would restrict movement of adjacent first and second pair of foam side-support members 50A(1)(3), 50A(2)(3), 50B(1)(3), 50B(2)(3) with respect to each other. The cloth members 93 may be woven or non-woven material. The cloth members 93 may be adhesively or cohesively bonded to the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3), 50B(1)(3), 50B(2)(3). The cloth members 93 may be thermally bonded to the first and second pair of foam side-support members 50A(1)(3), 50A(2)(3), 50B(1)(3), 50B(2)(3).
More information on flip-up side-support members that can be employed in any of the present embodiments is disclosed in U.S. patent application Ser. No. 12/870,316 filed on Aug. 27, 2012 and entitled “Assemblies, Systems, And Related Methods Employing Interlocking Components To Provide At Least A Portion Of An Encasement, Particularly For Bedding And Seating Applications,” which is incorporated herein by reference in its entirety.
FIG. 8A illustrates another mattress encasement 40(4) that is the same as mattress encasement 40 in FIG. 2A with one notable exception. Thus, the previous description of the mattress encasement 40 in FIG. 2A is applicable to the mattress encasement 40(4) in FIG. 8A with the exception. To facilitate securing the first and second pair of foam side-support members 50A(1)(4), 50A(2)(4) and 50B(1)(4), 50B(2)(4) of the first and second interlocking foam encasement components 46A(4), 46B(4), respectively, the first and second pair of foam side-support members 50A(1)(4), 50A(2)(4) and 50B(1)(4), 50B(2)(4) includes a plurality of protrusion members 94A(1), 94A(2) and 94B(1), 94B(2), as illustrated in FIG. 8A. The protrusion members 94A(1), 94A(2) and 94B(1), 94B(2) are disposed orthogonal or substantially orthogonal into the interior area 44(4) from the interior side 96A(1), 96A(2) and 96B(1), 96B(2) of first and second pair of foam side-support members 50A(1)(4), 50A(2)(4) and 50B(1)(4), 50B(2)(4), respectively, as illustrated in FIGS. 8B and 8C. The protrusion members 94A(1), 94A(2) and 94B(1), 94B(2) are configured to each be disposed between adjacent perimeter coils in a mattress innerspring disposed in the interior area 44(4) of the mattress encasement 40(4) and encased by the mattress encasement 40(4). This assists in securing the first and second pair foam side-support members 50A(1)(4), 50A(2)(4) and 50B(1)(4), 50B(2)(4) to a mattress innerspring, and thus assists in interlocking the first and second interlocking foam encasement components 46A(4), 46B(4) to maintain the foam side-support perimeter 42(4), as illustrated in FIG. 8A.
Embodiments disclosed herein are exemplary, and may be provided together in any combination desired. Based on this disclosure, mattress assemblies may be assembled using the foam side-support member disclosed herein around any of a variety of mattress cores, including for example, air bladder mattress cores, innerspring coil mattress cores, pocketed coil spring mattress cores (e.g. Marshall coil mattress cores), and mattress cores formed from a cellular material (e.g. foam). Because each elongated side-support member disclosed herein is adaptable to be disposed around a variety of types and dimensions of mattress cores, the embodiments disclosed herein enable mattress core manufacturers to more easily store and transport the elongated side-support members.
Those skilled in the art will recognize improvements and modifications to the embodiments disclosed herein. Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which the disclosure pertains having benefit of the teachings presented in the foregoing descriptions and the associated drawings. The materials or compositions of the aforementioned components can be varied as well, including but not limited to whether foam may be exclusively thermoset or thermoplastic materials, or a composite of both. All such improvements and modifications are considered within the scope of the concepts disclosed herein.
It is also noted that the operational steps described in any of the exemplary embodiments herein are described to provide examples and discussion. The operations described may be performed in numerous different sequences other than the illustrated sequences. Furthermore, operations described in a single operational step may actually be performed in a number of different steps. Additionally, one or more operational steps discussed in the exemplary embodiments may be combined.
Further, it is to be understood that the embodiments are not limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. It is intended that the embodiments cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The previous description of the disclosure is provided to enable any person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Patent Application
20130263380
