FI104880B - Bed configuration having variable support characteristics - Google Patents

Description

104880

BACKGROUND OF THE INVENTION This invention relates generally to a bed base, and more particularly to a bed base structure having support surfaces that can be optionally adjusted by means of a remote control device to provide a unique support surface that can be quickly and easily adjusted by the user. To achieve.

With regard to bedding structures, there is a need to provide structures with comfortable support surfaces. However, different users of bedding structures may have different perceptions of comfort; one user may want a less solid sleeping pad while another may want a firmer surface. This problem is highlighted when two different users, such as husband and wife, have different preferences for bed firmness but want to sleep in the same bed.

Difficulties can also arise when the same user has different needs for the bedding at different times, such as when the back pain of this user necessitates a sleeping surface with a different firmness. where from.

Thus, it can be seen that there is a need for a bed base structure having an improved support surface that can be adjusted to meet different user needs, with improved wear characteristics, and less likely to require periodic mattress rotation.

The present invention provides an improvement over prior art structures by providing an improved support surface having a plurality of adjustable capabilities within a given fixed range of 22104880, which can also be adjusted to have a different degree of solidity on either side of the bed.

Generally described, the present invention provides a mattress structure comprising a main area, a foot region, and a central region including a refillable chamber, which chamber, when stationary within the mattress, may be optionally inflated. The inner spring and mattress structure of the invention is characterized in that it comprises a plurality of adjacent rows of barrel-shaped helical springs having substantially parallel longitudinal axes and disposed in a position adjacent to the helical and at least a portion of the barrel-shaped an inflatable chamber disposed beneath the upper layer of half-sized helical springs and optionally inflatable to displace the upper layer of half-helical helical springs. SUMMARY OF THE INVENTION It is an object of the present invention to provide a bed base structure having an improved support surface. Another object is to provide a support surface that can be used by users with different firmness preferences. One more ·. another object is to provide a support surface where the solidity may be different in different areas. It is another object of the invention to provide a support surface which may have different firmness over different time periods. Another object of the present invention is to provide a support surface that can be adjusted by means of a remote control device.

Another object of the present invention is to provide a support surface where the solidity is different on each side of the bed. It is another object of the present invention to provide a mattress which requires less turning due to improved wear properties.

Other objects, features, and advantages of the present invention will become apparent upon reading the following detailed description of a suitable embodiment of the invention, with reference to the drawing and the appended claims, in which:

Figure 1 is a side elevational view of a mattress structure of the invention in which the portion of the mattress is partially opened and the various hidden elements are depicted in broken lines.

Figure 2 is a top plan view of the mattress of Figure 1, with a substantial portion of the fabric upholstery cut away to illustrate the interior details of the mattress.

Figure 3 is a side elevational view of another structure in which the portion of the mattress is partially cut away and the various hidden elements are depicted in broken lines.

Fig. 4 is a top view of the mattress of Fig. 3, with a substantial portion of the fabric upholstery cut away to illustrate the interior details of the mattress.

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Figure 5 shows a side view of an embodiment of the invention in which the mattress portion is partially cut out, the air chamber is emptied and various hidden elements are depicted in dashed lines.

Figure 6 shows a top view of the mattress of Figure 5, with a substantial portion of the fabric upholstery cut away to illustrate the interior details of the mattress.

Figure 7 is a side view of the embodiment shown in Figure 5 of the invention in which the air chamber is filled.

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Figure 8 illustrates another suitable embodiment of the invention, viewed from the side, with the mattress part partially open and the various hidden elements depicted in broken lines.

Figure 9 shows a single air chamber used in the bed base structure shown in Figures 1 and 2.

Figure 10 illustrates a side view of an embodiment of the invention, in which the mattress portion is partially cut away along line 10-10 of Figure 11, with a few curved air tubes visible in cross section, and the various hidden elements are shown by dashed lines.

Fig. 11 shows a top view of the mattress of Fig. 10, with a substantial portion of the fabric upholstery cut away to illustrate the interior details of the mattress.

Referring now to the drawing, like numerals refer to like parts for all figures, and Figures 1 and 2 illustrate a co-proprietary bedding system 10 according to the present application, comprising a mattress 12 placed on a flexible box 14. 16, upper cushion layer 18, lower cushion layer 20, enclosed springs 22, left air chamber 24, and right air chamber 26. The assembly also includes left and right remote control units 28 and 30, respectively, air pump 32 and air supply lines 4.

Again, in this application, it may be implied that some elements are "left" or "right" with respect to other elements. The references "left" and 5 104880 "right" are used as if standing at the foot of the bed and looking at the bed. "left" and "right" are only relative concepts in terms of the viewer's reference point.

As shown in Figure 2, it can be seen that the mattress 12 and the flex box 14 consist of three "regions", a main region, a central or "lumbar region", and a foot region. The head region and foot region each comprise a plurality of sealed springs 22. An example of such sealed springs is disclosed in U.S. Patent 4,234,983, entitled "Thermally Welded Spring Pockets," which is incorporated herein by reference, which utilizes seal springs. springs are formed between the coated layers of the two-layer material strip by means of separate single welding lines which connect the layers to each other.

The pressing shafts of the springs 22 are substantially parallel to each other and are located substantially perpendicular to the upper support surface 25 of the mattress. Rows of enclosed springs may extend longitudinally along the length of the mattress, or alternatively may extend transversely. The ribs can be attached * if desired. together into inner spring assemblies. An example of such an integrated assembly is disclosed in U.S. Patent 4,234,984, entitled "Pocketed Spring Assembly" and in U.S. Patent 4,401,501, entitled "Apparatus for Making Assemblies of

Pocketed Springs, "herein referred to, in which rows of enclosed upholstery springs are assembled, one at a time, into mattresses or the like. The joints of each such queue are made by means of straps between the pockets of two adjacent rows of pockets, Another type of inner spring design is disclosed in U.S. Patent 4,578,834, entitled "Innerspring Con, 104880 struction", herein incorporated by reference, which discloses an inner spring structure comprising rows of sealed helical springs attached to one another, and The adhesive spreader traverses the line of closed elasticities and delivers the exact amount of adhesive to each elastic shell. then go over the first one and apply pressure. The spreader then passes through the second row in the same way as for the first row. This is repeated until the desired internal spring structure is obtained. U.S. Patent 4,566,926, entitled "Method and Apparatus for Manufacturing Innerspring Constructions," and U.S. Patent 4, 578,834, disclose a method and apparatus for making the mattress device disclosed in U.S. Patent 4,578,834.

Without departing from the spirit and scope of the invention, the enclosed springs, rather than being fastened together, may be packed tight enough to prevent misalignment or transverse movement.

The "middle" or "lumbar" portion of the mattress comprises a left-hand air chamber 24 and a right-hand air chamber 26. These two chambers 24, 26 correspond to one another in their design and function. Referring only to Figure 9, the left-hand air chamber 24 comprises an upper wall 38, a bottom wall 40, side walls 41, and an air filling port 44. The air chamber 24 is constructed to contain air fed through the opening 44 such that air is supplied to it is obvious that the chamber is "filled", whereas when air is vented through the opening 44, it is obvious that the chamber is "emptied". Inside the chamber cavity are provided interior walls 45 which are secured to the top and bottom walls 38 and 40, respectively, to reduce the unfavorable "balloon" effect that would cause the center portions of the top and bottom walls 38, 40 to bulge outward. Chamber 24 is preferably made of vulcanized rubber, although it is possible to use other air-impermeable materials without departing from the scope of the present invention.

Referring again to Figures 1 and 2, the air supply lines 34 are connected to a respective opening in each chamber 24, 26. These air supply lines 34 allow air connection between the chambers 24, 26. Remote control units 28, 29 control the air pump in a known manner such that the user can optionally fill or empty each of the chambers 24, 26 by supplying air to the chambers by means of an air pump, or vice versa.

The air pump 32 is preferably mounted inside the resilient box 14 even though it may be located at a distance due to the noise it produces. The air supply lines 34 are located partly within the flexible box 14 and partly within the mattress 12. The air supply lines pass through the slots (not shown) in the mattress and flexible box cover, whereby the slits are covered because they are located at the points of contact between the flexible box and the mattress. However, it should be apparent that other structures could be used without departing from the scope of the present invention. For example, the air supply lines could pass through slots or circular holes formed in the vertical walls at the ends of both the mattress 12 and the flex box 14, which would allow the mattress 12 to be easily rotated if desired for the following reasons.

As can be seen from Figure 1, the air chambers 24, 26 are covered by an upper cushion layer 18, which in turn is covered by a fabric layer 16. Thus, it can be seen that if the user is sitting, lying or otherwise resting on a support surface over the air chamber user weight to some extent. As the air pressure is increased in the air chamber, it becomes evident that the user feels the support surface "firmer", i. E. the sleeping surface will not sink as much as if the chamber air pressure were lower.

The location of the air chambers is an important part of the invention. From the figure, it can be seen that the air chambers do not extend over the entire length of the mattress, but are preferably located where the "lumbar" portion of the user's back will be located while the user is in a resting position. This allows the center or "lumbar" portion of the mattress to be adjusted while the remainder of the mattress has the same characteristics as a conventional mattress. In addition, the use of two chambers enables two persons lying next to each other to adjust their respective lumbar region of the mattress, essentially independently.

This adjustability is another important part of the invention since it can be stated that an unlimited adjustability range can be achieved by using suitable air pumps and flow control valves. It is also obvious that different air pump sizes can be used without departing from the scope of the invention. Larger pumps can be used for rapid air filling while smaller pumps can be used for quiet operation.

As shown in Figure 2, the bedding system 10 also comprises a circumference structure 36 surrounding the enclosed springs 22 and air chambers 24, 26. The circumferential structure 36 may be a foam structure, or alternatively may be assembled without departing from two or more rows of enclosed springs. framework. Edge yarns (not shown) may also be included in the perimeter structure 36 in a known manner to secure the structural integrity of the perimeter structure.

Thus, it can be seen that the user can independently and independently adjust the firmness of the support surfaces on the left and right 9104880 air chambers via remote control units 28, 30 only to the user's personal preference. If the user on the left side of the bed wants to change the firmness of the lumbar spine on his / her side of the bed, he / she will only need to use the left-hand remote control. Such a measure will preferably affect the rigidity of the right side of the mattress to a minimum, although some effects may occur due to contact between the two chambers and the resulting pressure. Such contact and pressure can be further minimized by placing foam or another padding layer (not shown) between the chambers.

Reference is made in this connection to Figures 3 and 4, which show another structure which per se also relates to the patent application which is parallel to this application. The bed base structure 50 comprises a mattress 52 and a flexible box 54. The mattress 52 comprises a fabric upholstery 56, an upper cushion layer 58, a lower cushion layer 60, and enclosed cushions 62. One of the differences in structure described above is from the left and right which are located in the previously mentioned central or "lumbar" region of the mattress 52 as best shown in Figure 4.

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Similarly to the method described in connection with structure 10, the left and right remote control units 68 and 70 respectively control the air flow supplied by the air pump 72 through the respective air supply pipes 74 and manifolds 75. By means of the manifold 75, each of the two pipes 74 is connected to a corresponding series of air cylinders 64 or 66, so that the air pressure in each cylinder of each series is substantially equal. Thus, it is obvious that the user can adjust the amount of air supplied to the left and right air cylinder series using the respective remote control device 68 or 70.

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Referring to Figures 5 and 6, a preferred embodiment of the present invention will now be discussed. The bedding system 80 corresponds to the bedding systems previously discussed in that it comprises a mattress 82 and a spring box 83, wherein the mattress 82 comprises a fabric upholstery 84, an upper and a lower cushion layer 85 and 86, respectively, and closed cushions 88. previously disclosed in the sense that closed springs 90, which are only half the size of the former, are used to "lay" the left and right chambers 91, 92.

The flexible box assembly 83 comprises similar elements as previously described, such as an air pump 96, a left and right remote control unit 93 and 94, respectively, and two air supply pipes 95. Previously, respectively, or removed from the air chamber 91 and 92, respectively.

Referring now to Figures 5 and 7, which illustrate the filling of the left-hand air chamber 91. It can be seen that when the air chamber 91 is filled from the structure shown in Fig. 5 to the structure shown in Fig. 7, it moves ... the upper layer consisting of half-sized elastic, so that the upper cushion layer 85 is similarly displaced. Thus, it is evident that when the air chamber 91 is filled, the middle or "lumbar" portion of the mattress will feel more solid with respect to the structure shown in Figure 7 than with the structure shown in Figure 5.

Referring further to Figure 8, another suitable embodiment 100 is shown. The bed base system 100 comprises a mattress 102, a flexible box 104, and fabric layers, cushion layers, full-size helical springs, and air control devices similar to those previously described. However, this embodiment differs from the previous ones in that it comprises a layer of half-sized sealed springs 106 and a right-hand air chamber 108 and a left-hand air chamber 108 (not shown), wherein the half-sized springs 106 are disposed over each chamber. Similarly to other structures, each of these chambers may be independently controlled via respective remote control units 110, 111 which control the flow of air from the air pump 112 through the conduits 114.

The lumbar support member 115 extends over the mattress from side to side and is positioned on top of each air chamber but below a layer of half-sized recessed springs 106 so that the half-sized recessed springs form a slightly upward bulging approximately in the area where resting on his back. This bulge will allow the user to "adapt" the lumbar spine to the shape of the mattress support surface so that the lumbar spine is better supported than a conventional mattress. It will be apparent that this member 115 could be used in other parallel embodiments of the invention disclosed herein without departing from the scope of the present invention. Such a design element could for example be located in air chambers and one or both. between the padding layer in the first suitable embodiment. Of course, it should be clear that two "shaping members" should be used to provide the "symmetrical" mattress structure shown below.

With reference to another suitable embodiment, it should be apparent that this particular embodiment 110 is not "symmetrical" with respect to the horizontal plane of the center of the mattress as in the previously described mattresses 12, 52 and 82. Symmetric mattress designs may often be desirable since there is often from time to time for better wear and tear • «12 104880. Any discrepancy between the "feel" of the chamber and the semi-enclosed retractor springs can be minimized by optionally increasing the thickness or firmness of the padding layers while allowing the mattress to rotate so that the difference in feel of the mattress is minimal. However, such mattress structures do not necessarily need to be rotated because the main reason for such a need for rotation is often due to the excessive wear of the central portion of the mattress which can be avoided by the new types of structures provided by this invention. Instead, the thickness of the cushion layers may be reduced to take advantage of the sensory difference between the air chambers and the cushions of the inclusions since the user may, if desired, consider rotating the mattress to satisfy his bedding preference at a particular time.

Referring further to Figures 10 and 11, one embodiment of the granule is shown. The bed base structure 130 comprises a mattress 132 and a flexible box 134. The inner spring portion of the mattress 132 corresponds to that disclosed in U.S. Patent 4,578,834. However, the inner spring member comprises a left and right inflatable / emptying support air tube 136 and 137, respectively, which are disposed in the lumbar region of the mattress in the form of convoluted closed springs 135. The air tubes 136, ..-137 are closed at one end and are supplied with air from the other end via air supply lines 139, which in turn are connected to an air pump 140 controlled by a left and right remote control unit 141, 142 similar to the systems described above. Air tubes extend through a hole in the mattress cover and extend through the interior of the mattress to reach tubes 136, 137. It should be obvious that this method of placing the tubes on the mattress can also be used in other embodiments.

Obviously, when the sealed springs 143 are placed side by side, as shown in the drawing, as shown in the drawing, the "barrel" shape of the sealed springs 143 provides a gap 150 at the top and bottom of the springs. This allows the left and right air tubes 136, 137 to be located between the sealed springs 143 and the slots 150 below the padding layer 145. When the springs are located mainly in straight rows and strings, it can be seen that the tubes can be easily inserted by inserting between rows or queues for trips of varying lengths. It is evident that the "strings" of elasticity extend in the longitudinal direction of the mattress and the "strings" of elastic members extend perpendicularly to the strings of springs, whereby the air tubes of the fourth preferred embodiment enter between two rows of four elastices; then turn again at right angles and pass between two rows of four ribs each, repeating this pattern several times. It is also possible to use another serpentine or non-serpentine pattern without departing from the scope of the invention.

As the air tubes are filled, they increase the firmness of the mattress 132 by filling the gaps 150 and limiting the flexibility of the springs 143 per unit load. Instead, when the pipes are emptied, the solidity is reduced. The tubes may be made of latex rubber to provide some stretch during filling, but may also be made of a flexible but relatively non-stretchable material such as vinyl.

It will be apparent that, although a suitable embodiment contemplates the use of convulsive tubes only in the lumbar region of the mattress, they may also be placed in other parts without departing from the scope of the invention. For example, winding tubes could be used over the entire length of the mattress. In addition, more than two parallel • · 14 104880 tubes could be used in each mattress. Finally, the tubes could be placed on each side of the mattress.

It will be apparent that suitable modifications may be made to many embodiments without departing from the scope of the present invention. For example, an inflexible tray could be used instead of a flexible box. Known vibration members could be attached to a mattress or elastic mat (or base) to achieve the desired effect. Instead of dual chambers, a single chamber could be used. Water could be used instead of air.

The air supply device (not shown) could also be provided with a back-zip arrangement which would allow the user to "select" the desired air pressure (and corresponding solidity) or special chamber regardless of whether the chamber is profitable for a heavy user, light user or anyone.

Instead of the enclosed strings, plastic strings such as the "Mattress or Cushion Spring Array" disclosed in U.S. Patent 4,895,352, which is incorporated herein by reference, could be used. Extruded plastic spring elements, as disclosed in U.S. Patent 4,895,352, could also be used in the above mattress or enclosed springs.

Finally, either the mattress or the sealed springs could use extruded high power plastic component parts. When used in sealed springs, the plastic components should be designed to "snap" onto the wire mesh, which in turn could be positioned over the conventional open springs so that the plastic components fit inside the open springs. The use of such plastic components reduces the creep in many metal spring structures, which will make consumers more satisfied.

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Thus, it can be noted that the present invention provides an improvement over prior art structures by providing an improved support surface for the central or "lumbar" portion of the mattress while avoiding the undesirable effects of full-length chambers. The present invention also provides an improvement over prior art structures by providing a personal air control system that allows the user at any time to select the desired firmness for each side of the bed simply by using a remote control device. This adjustability is an important part of the present invention since it can be stated that infinite adjustability over a certain range can be achieved by using suitable air pumps and flow control valves.

The present invention also provides desirable features in the head and foot region for sealed springs or similar conventional structures, while providing improved wear properties and improved firmness control over the middle or "lumbar" portion of the mattress. The quality of the air chambers located in the lumbar region, which is typically the first to fail due to prolonged wear or "collapse" of conventional helical springs, eventually extends mattress life, resulting in increased user satisfaction not only for longer mattress life but also "throw" the mattress the other way around.

While the present invention has been described in detail with reference to the particular embodiments disclosed, it will be apparent that it may be subject to numerous modifications and variations in many ways within the scope of the invention as set forth in the appended claims.

Claims (10)

1. Inner spring structure, characterized in that it comprises a plurality of adjacent rows of thin-shaped enclosed coil springs (88) which have substantially parallel longitudinal axes and which are positioned adjacent to each other, wherein at least a portion of the thin-formed coiled springs an upper layer of half-sized enclosed coil springs, and that there is an inflatable chamber (91, 92, 108) located below the upper layer formed by the half-sized enclosed coil springs and which can be optionally filled to displace this upper layer formed by the half-sized enclosed coil springs. 2. Inner spring construction according to claim 1, characterized in that there are lower layers formed by half-sized enclosed coil springs, which layer is placed so that said inflatable chambers (91, 92) are placed on a sandwich-like between the upper and lower layers formed by half-sized coil springs. Inner spring structure according to claim 1 or 2, characterized in that there is also a lumbar support member (115) located above the inflatable. the chamber (91, 92, 108) and under the upper layer formed by half-sized coil springs, thus, that the half-sized enclosed coil springs have a somewhat ascending bulge. 4. Inner spring construction according to any of the preceding claims, characterized in that there is also an upper padding layer (85) which is placed above all said enclosed coil springs (88, 106). 5. Inner spring construction according to any of the preceding claims, characterized in that in addition. there are means (93, 94, 96, 110, 11, 112) for filling said inflatable chambers (91, 92, 108). A mattress construction comprising: a main area; a foot region, and a center region, comprising a plurality of adjacent rows of thin-formed enclosed coil springs (88) having substantially parallel longitudinal axes and positioned in position adjacent to each other, at least some of the thin-shaped enclosed coil springs forming layers of half-sized enclosed coil springs (90, 106), and an inflatable chamber (91, 92, 10 8) located below the upper layer formed by the half-sized enclosed coil springs and which can optionally be filled to bring it out of the half-sized enclosed coil springs formed the upper layer out of position. 7. Mattress construction according to claim 6, characterized in that it further comprises a lower layer of half-sized enclosed coil springs (90) which is positioned so that said inflatable chambers (91, 92) will in a sandwich-like manner. are located between the upper and lower layers formed by the half-sized enclosed coil springs. • 8. Mattress construction according to claim 6, characterized in that it further comprises a lumbar support member (115) located above said inflatable chamber (91, 92, 108) and below the layer formed by the half-sized enclosed the coil springs thus, that the half-sized enclosed coil springs receive a somewhat ascending bulge. Mattress construction according to any of the preceding claims 6 ... 8, characterized in that there is also an upper padding layer (85) placed on top of all of the said coiled springs. 104880 21 Mattress construction according to any of the preceding claims 6 ... 9, characterized in that there are also means (93, 94, 96, 110, 111, 112) for filling said inflatable chambers (91, 92, 108). ). I · • ·