Beds – Mattress
Reexamination Certificate
2000-01-21
2001-10-02
Trettel, Michael F. (Department: 3628)
Beds
Mattress
C005S659000, C005S700000, C005S740000, C005S722000
Reexamination Certificate
active
06295674
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to beds generally. In particular, the invention relates to a mattress therefor and its method of manufacture.
2. Description of the Related Art
Beds and mattresses have been used for ages, but sleeper sofas with foldable mattresses were developed only in the first half of the twentieth century. Springless sleeper sofa mattresses were first developed by the Englander Co., Inc. of Chicago, Ill., in the late 1950s and are exemplified by U.S. Pat. No. 3,019,456 which was issued to Ewald Kamp on Feb. 6, 1962.
Mattresses made out of multiple layers of different plastic materials were first developed in the late 1960s and were fashionable until about 1990. Such multi-layered plastic mattresses are typified by U.S. Pat. No. 3,608,106 which was issued to Parramon on Sep. 28, 1971, and by U.S. Pat. No. 4,316,298 which was issued to Russo et al. on Feb. 23, 1982. In England, such mattresses are typified by British Patent Specification No. 1,257,962 published on Dec. 22, 1971, and by British Patent Specification No. 1,604,401 published on Dec. 9, 1981.
About 1990, the bedding market began to diversify with a variety of new springless mattresses, such as the following: compactible futons, exemplified by U.S. Pat. No. 4,928,337 issued to Chauncey on May 29, 1990; multiple component mattresses with removable covers, exemplified by U.S. Pat. No. 5,136,741 issued to Balonick et al. on Aug. 11, 1992; mattresses with impermeable PVC coatings, exemplified by U.S. Pat. No. 5,265,294 issued to McClure et al. on Nov. 30, 1993; and mattresses with temperature sensitive top layers, exemplified by U.S. Pat. No. 5,669,094 issued to Swanson on Sep. 23, 1997.
Other springless mattresses of general interest are shown in U.K. Patent Application Ser. No. 2,244,000 published on Nov. 20, 1991; U.S. Pat. No. 5,819,349 granted to Schwartz on Oct. 13, 1998; and U.S. Pat. No. 5,966,759 granted to Sanders et al. on Oct. 19, 1999.
However, it remains a problem in the prior art to make a springless foldable mattress which provides a comfortable night of sleep on a sofa bed.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a combination of multiple layers selected and laminated together to produce superior comfortable mattress, unlike any prior art product, for a sofa bed.
A preferred embodiment of the present inventive mattress includes a top layer of an antimicrobial synthetic polyester textile fiber such as DACRON®, a polyurethane quilting foam layer, a natural latex rubber layer, a flexible polyurethane foam layer, and a bottom insulator pad. All layers are bonded with an adhesive to increase durability and all exterior surfaces are covered with a moisture-resistant damask fabric.
A preferred embodiment of the present inventive process is a multi-layered lamination method. Starting with the bottom layer, an insulator pad is laminated to the bottom of the flexible polyurethane foam layer. This insulator pad adds extra cushioning to the bottom to protect a sleeper against feeling any metal support bars in all bed frames that actually hold the mattress. The layer of flexible polyurethane foam varies in thickness to allow a thinner mattress to be accommodated inside current styles of interior frame cavities of sofa beds or to be accommodated inside future styles of interior frame cavities that may house a thicker and plusher mattress for a sofa bed. The flexible polyurethane foam layer is then laminated to a 100% pure latex rubber layer which gives extra support and longevity to the mattress. This rubber layer is believed to outperform any competing type of foam product for a mattress, thus allowing the mattress to hold its shape and to permit a comfortable night's sleep, even for heavy adults. The product resulting from the present inventive method performed well in tests conducted by constantly opening, unfolding and closing the mattress inside the cavity of the sleeper sofa.
The damask fabric covering the complete exterior of the mattress is either polyester or polypropylene or a combination of both. DACRON® is a synthetic polyester textile fiber which may be mixed with silk and blended wool fibers that are bonded together and are sprayed with an EPA-approved antimicrobial agent. This mixture gives the mattress a nicely quilted top for an additional layer of comfort. Also, the moisture-resistant damask fabric helps to protect the inside of the mattress from most kinds of liquids that may be spilled thereon.
The layers are then bound together with binding tape. Subsequently, the top and bottom sides of the mattress are given straps near each corner to allow the mattress to be tied down to the metal support frame. As a result, the mattress is kept from sliding and shifting during the steps of opening and closing the cavity inside the sofa bed. Likewise, the tie-down straps allow the mattress to be retained on the frame when a user sleeps thereon.
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily recognized as the invention becomes better understood by reference to the following detailed description when considered with the accompanying drawing.
REFERENCES:
patent: 3019456 (1962-02-01), Kamp
patent: 3051601 (1962-08-01), Schick
patent: 3608106 (1971-09-01), Parramon
patent: 3846857 (1974-11-01), Weinstock
patent: 4035853 (1977-07-01), Platter
patent: 4316298 (1982-02-01), Russo et al.
patent: 4928337 (1990-05-01), Chauncey
patent: 5136741 (1992-08-01), Balonick et al.
patent: 5138730 (1992-08-01), Masuda
patent: 5265294 (1993-11-01), McClure et al.
patent: 5579549 (1996-12-01), Selman et al.
patent: 5669094 (1997-09-01), Swanson
patent: 5701623 (1997-12-01), May
patent: 5819349 (1998-10-01), Schwartz
patent: 5966759 (1999-10-01), Sanders et al.
patent: 1 257 962 (1971-12-01), None
patent: 1 604 401 (1981-12-01), None
patent: 2187113-A (1987-09-01), None
patent: 2 244 000 (1991-11-01), None
Holliday J. Scott
Smith-McKelvey Sharon Lynne
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
Sleeper Solutions
Trettel Michael F.
LandOfFree
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