Beds – Mattress – Having confined gas
Reexamination Certificate
1998-08-04
2002-09-10
Browne, Lynne H. (Department: 3628)
Beds
Mattress
Having confined gas
C005S420000, C005S706000, C005S654000, C005S655300, C005S731000
Reexamination Certificate
active
06446289
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to certain new and useful improvements in inflatable and deflatable mattresses and, more particularly, to inflatable and deflatable mattresses which have a cratered or non-level upper surface configuration on the upper or body supporting surface which thereby lends to improved body supporting comfort.
2. Brief Description of the Related Art
Inflatable mattresses of the type involved in the present invention are sometimes referred to as “camping mattresses” or “self-inflating” mattresses. The mattresses are sometimes referred to as “pads”.
Generally, these mattress include an inner foam core in an outer fabric which may be disposed around or otherwise bonded to the inner foam core. Moreover, mattresses of this type are constructed with voids on the interior so as to allow an introduction of air when a valve on the mattress is opened. They also provide for a deflating by compressing the mattress, such as by rolling the mattress, to force the air out through the valve.
Mattresses of the aforesaid type are often referred to as self-inflating mattresses, as aforesaid, inasmuch as air will rush into the interior of the mattress if the valve is opened and the latter is unrolled. If the valve is then closed, the air remains in the mattress and the mattress is inflated. In like manner, upon compressing the mattress and opening the valve again, the air escapes and the mattress can be rolled or folded.
The initial self-inflating air mattress was disclosed in the Lea, et al Pat. No. 4,025,974, which had an inner foam core and an outer fabric cover surrounding that foam core. The mattress was effective, although it did not provide for a pillow construction in the mattress and, moreover, it contained a relatively flat upper body supporting surface.
The concept of shaping foam with a polygonal pattern, such as a hexagonal pattern, has also been taught in U.S. Pat. No. 5,688,538 to Barr, et al, and U.S. Pat. No. 5,534,208 to Barr, et al. Nevertheless, and heretofore, there has not been any body supporting mattress of the type in which the outer fabric cover is fully integrally bonded to the foam core and the foam core and fabric cover together form an upper surface shape having a non-level cratered surface configuration, that is, one with a raised portions and grooves therebetween.
It has been found in connection with the present invention that self-inflating mattresses of the aforesaid type often times can be relatively uncomfortable if they are not disposed on a perfectly flat surface. However, in camping conditions and the like, the surface upon which the mattress is disposed is rarely flat. As a result, any rocks, branches or the like which may be disposed beneath the bottom surface of and bearing against the bottom surface of the mattress will be felt by the user laying on the mattress. In addition, these mattresses only have an average depth or thickness of approximately a few inches when inflated. Thus, if the user should lie on this mattress in a position in which a portion of the body, such as an elbow, knee or the like, compresses the foam, the user will feel the hard surface of the ground which, again, may present an uncomfortable feeling.
There have been attempts in the past to provide an inflatable mattress having a dimpled upper surface, that is, an upper surface having an egg-crate type construction. This mattress construction relied primarily upon a foam core having this dimpled construction with a fabric cover disposed over the entire foam core. However, there was no attempt to seal the fabric cover to the foam core inasmuch there was no effective sealing means to obtain an integral bond throughout the entire dimpled surface area.
Efforts have been made to provide somewhat of an even body distribution on the surface of the mattress. However, it has been found that in most prior art devices, the foam will shift relative to the outer cover somewhat distorting the configuration of the mattress. In addition, it has also been found that a party attempting to recline on the mattress is not necessarily held in a fixed position on that mattress, since any turning movement of the party reclining on the mattress will tend to cause a shifting of the fabric with respect to the foam core. Not only is this uncomfortable, but it precludes a fixed retention of the reclining individual on the mattress.
There have been attempts in the past to use a partial bonding of a fabric cover to a foam core. These attempts also relied upon the so-called “spot bonding” and which was often referred to as “diamond bonding”. In effect, the fabric was bonded to the foam core in selected areas. However, this construction proved to shorten the overall longevity of the mattress inasmuch as a body reclining on the mattress might tend to cause the fabric to shift with respect to the foam core in the event of movement of the reclining individual and this, in turn, caused the fabric to literally pull away from the foam core. In many cases, the fabric would actually tear thereby destroying the air impervious structure of the mattress.
It would be desirable to provide a self-inflating mattress of this type which had a non-level surface pattern and in which the foam core and the outer fabric cover also presented the same non-level surface pattern without any shifting movement therebetween.
In addition, there have been self-inflating mattresses of the aforesaid type which also have a pillow portion constructed into the mattress. One such mattress is more fully illustrated and described in U.S. Pat. No. 5,117,517, dated Jun. 2, 1992, to Ping-Hung Su, one of the applicants herein. It would also be desirable to provide a mattress of the aforesaid type having a non-level body supporting surface construction and also with a pillow constructed therein.
OBJECTS OF THE INVENTION
It is, therefore, one of the primary objects of the present invention to provide a self-inflating mattress which has a non-level upper surface construction and which is relatively comfortable to a user when the mattress is disposed on a ground surface.
It is another object of the present invention to provide a self-inflating mattress of the type stated which can be constructed with a polygonal surface pattern of grooves and raised portions on an upper surface thereof.
It is a further object of the present invention to provide a self-inflating mattress of the type stated which can be constructed with or without a pillow therein.
It is an additional object of the present invention to provide a self-inflating mattress of the type stated in which an outer fabric cover is disposed around a foam core and in which the cover is bonded to the foam core, such that the non-level upper surface pattern is integral throughout the entire mattress.
It is another salient object of the present invention to provide a self-inflating mattress of the type stated which can be constructed at a relatively low cost and which is highly efficient in use and operation.
It is yet an additional object of the present invention to provide a method of making a self-inflating mattress of the type stated having an inner core and an outer fabric and bonding the fabric to the core and simultaneously forming a non-level upper body supporting surface pattern thereon.
With the above and other objects in view, our invention resides in the novel features of form, construction, arrangement and combination of parts presently described and pointed out in the claims.
BRIEF SUMMARY OF THE INVENTION
The present invention relates in general terms to an inflatable mattress and, preferably, a self-inflating mattress capable of being folded or rolled into a small compact unit and unfolded or unrolled to a relatively flat body supporting condition. In this case, the body supporting condition could be a relatively flat condition so that the mattress serves as a sleeping mattress capable of being disposed on a ground surface. Otherwise, the mattress may be in the form of a pad capable of being disposed upon chairs or the
Su David P.
Su Monica
Browne Lynne H.
Conley Fredrick
Schaap Robert J.
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