Patent Application
20170035214
The present invention generally relates to mattress and foundations attached using magnetics.
Sometimes in standard flat mattress and foundation systems and mattress and foundation systems where an area of the mattress raises and lowers, the mattress can slip or otherwise move in relation to the foundation system. It would be desirable to create a system which prevents or eliminates this shifting and slipping.
A magnetically attached mattress and foundation system comprising a foundation containing a magnetic portion and a mattress containing a magnetic portion. The magnetic portions each contain magnetizable or magnetically responsive materials.
The following detailed description and appended drawing describe and illustrate various exemplary embodiments of the invention. The description and drawing serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.
Referring to
In one embodiment, the magnetic portion 110 covers the entire upper surface of the box spring 100. In another embodiment, the magnetic portion 210 covers the entire lower surface of the mattress 200. In another embodiment, the magnetic portion 110 covers a majority of the upper surface of the box spring 100. In another embodiment, the magnetic portion 210 covers the majority of the lower surface of the mattress 200. The magnetic portions 110, 210 may be continuous or discontinuous, may have any suitable thickness, and may contain discrete elements such as bars and dots. Having discontinuous portions or other printed dots may add in saving material coats and/or helping with mattress and box spring alignment and installation. In the embodiments, where the mattress raise and lower in areas, the magnetic portions 110, 210 are only located in the areas that are always in contact (the areas that do not raise and lower).
In one embodiment, the magnetic portion 110 on the box spring 100 is directly on the outer surface of the box spring 100. This portion may be added during the manufacture of the box spring 100 or coated onto the surface of the box spring 100 after manufacture. In another embodiment, the magnetic coating is on or in a separate layer such as a fitted sheet that fits over the box spring 100. In some embodiments, the magnetic portions 110, 210 are adjacent and touching each other and in other embodiments there may be one or layers between the magnetic portions 110, 210. In one embodiment, the portions 110, 210 are applied via coating. In other embodiments, the portions 110, 210 may be applied via lamination, extrusion, or incorporating magnetically active metal wires, fibers, filaments, strands, and/or yarns into the fabrics forming a portion of the box spring 110 and/or the mattress 200.
Within the pair of magnetic portions 110, 210 at least one of the portions must be magnetizable. In one embodiment, one of the portions is magnetizable and the other is magnetically respective. In another embodiment, both of the surfaces are magnetizable.
In this application magnetizable is defined to mean the particles present in the coating are permanently magnetized or can be magnetized permanently using external magnets or electromagnets. Once the particles are magnetized, they will keep their magnetic response permanently. The magnetizable behavior for generating permanent magnetism falls broadly under ferromagnets and ferrimagnets. Barium ferrites, strontium ferrites, neodymium and other rare earth metal based alloys are some of the examples that can be applied in the coatings.
In this application magnetically responsive is defined to mean the particles present in the coating are only magnetically responsive in the presence of external magnets. Once the magnetic field is removed from the vicinity, the particles will become non-magnetic. The magnetically responsive behavior or responsive magnetic behavior falls broadly under paramagnets or superparamagnets (particle size less than 50 nm). Iron oxide, steel, iron, nickel, aluminum or their alloys that are not included in ferromagnets are some of the examples that can be applied in the coatings.
Barium ferrites, strontium ferrites, neodymium and other rare earth metal based alloys can be mixed with the appropriate binder to be coated on the substrate. There are 2 ways the surface can be permanently magnetized after the curing or during the curing.
Process 1: After the coating method, the magnetizable particles loaded in the film are cured with the appropriate binder and composition. Then the permanent magnets can be rolled over the surface coated with the film 1 to 10 times as required by the inline manufacturing. Depending upon the pole size, strength and domains on the permanent magnet or electromagnet can magnetize the magnetizable coating to a value between 10 and 5000 gauss or a value close to the maximum gauss value of the magnetizing medium. Once the film is magnetized, it will remain permanently magnetized.
Process 2: During the cure, the magnetizable particles are mixed with the appropriate binder and applied via coating technique on the substrate to be magnetized. Once the coating is complete, the particles are magnetized in the presence of external magnets during the curing process. The coating will be put in a magnetic field to align the magnetic poles and hold the dipoles in place in the presence of the magnetic field until the binder is cured.
The surface(s) of the components (100, 200) may be made to be magnetic in any suitable method. In one embodiment, the magnetic material is applied to a surface as a coating. In another embodiment, the magnetic material is applied as a separate film that is adhered to the surface of the component. In another embodiment, the magnetic material is integral (meaning that it is formed as part of the component and not added after the component is formed). Some preferred coating methods include knife coating, padding, painting, spraying, roll-on-roll, troweling, extrusion, foam coating, pattern coating, printing, and lamination. The magnetic particles may also be extruded with the component. When the material is coated on, it is preferably flexible and sew-able (meaning that the material can be sewn through with a needle and thread).
In one embodiment, the magnetic material is applied as an approximately uniform portion having approximately the same thickness, magnetic strength, and/or composition across the surface of the component. In another embodiment, the magnetic material can vary across the portions(s) of the components. The magnetic material may be in a gradient or pattern. These patterns may help with alignment of one component relative to its adjacent components.
Any type of magnetizable particles can be used, including but are not limited to: BaFe3O4, SrFe3O4, NdFeB, AlNiCo, CoSm and other rare earth metal based alloys. Any type of magnetically receptive particles can be used, including but are not limited to: Fe2O3, Fe3O4, steel, iron based particles etc (Para or Superpara). Any suitable binder may be used, including but not limited to urethanes, acrylates, silicones, thermosets (rubber and others), thermoplastics and other textile binders.
Preferably, the magnetic portions 110, 210 are flexible meaning that they can be bent to a radius of curvature of less than 10 inches without significant cracking or loss of function.
In one embodiment shown in
While the magnetic portions were described in relation to a mattress, the system could also be used for other skirted items such as couches, sofas, tables, pillows, end tables, and curtains.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
This patent application claims priority to co-pending provisional patent application 62/201,135, filed on Aug. 5, 2015.
| Number | Date | Country | |
|---|---|---|---|
| 62201135 | Aug 2015 | US |
