Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-12-02
2001-09-18
Mayes, Curtis (Department: 1734)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S093000, C156S290000, C156S291000, C156S324000, C156S361000, C156S383000, C156S548000, C156S549000, C156S555000
Reexamination Certificate
active
06290800
ABSTRACT:
BACKGROUND OF THE INVENTION
A mattress normally includes a coil spring unit defined by a plurality of interconnected coil springs which are united to each other and to upper and lower polygonal frame wires which impart a generally rectangular configuration to the coil spring unit. An upper or top mattress pad and a lower or bottom mattress pad, each formed of multiple layers or plies of materials stitched together, and a like narrow peripheral mattress pad, also formed of multiple plies or layers, are assembled to entirely encapsulate the coil spring unit and form the mattress.
The top, bottom and peripheral mattress pads are each formed as a laminate which might, for example, include a backing material layer, a foam material layer, a fiber material layer and a ticking layer, all stitched together by stitching of a conventional “quilt” pattern or design. The materials of the latter layers, the thicknesses thereof, etc. all contribute to such characteristics as softness, breathability, wear, etc. However, irrespective of the particular layers, it is important that the upper mattress pad and the lower mattress pad are manufactured as inexpensively as possible, yet provide the best mattress characteristics possible at the lowest equitable cost over the longest mattress life possible.
A typical conventional mattress corresponding to the mattress just described is disclosed in U.S. Pat. No. 5,317,768 granted on Jun. 7, 1994. The patent discloses a spring component and at least a top surface component formed as a laminate with the outer layer being the ticking or cover fabric, the next inboard layer being a fiber layer, the third layer being a convoluted foam layer, and the innermost fourth layer being a cotton layer with associated stitching holding all four of these layers together to form a quilted multi-ply mattress pad. The thickness of the fiber layer and the thickness of the convoluted foam layer are said to be matters of design choice, though specific examples of weight per square foot of the polyester fiber and the height of the convoluted foam layer are specified as being illustrative. However, it is generally conceded that the best mattresses providing the most comfort are those which include an appreciably thick layer of convoluted foam. However, foam material, particularly latex (natural rubber) foam is extremely expensive and, therefore, appreciably thick convoluted latex foam layers are found most exclusively in higher end, more expensive mattresses. It would be highly desirable to increase the latex foam content in lower end mattresses (less expensive) if costs could be maintained relatively low during the manufacture thereof such that as an end result virtually all qualities of the mattress are appreciably increased at a moderate or low increase in cost at both the wholesale and retail levels.
SUMMARY OF THE INVENTION
In keeping with the foregoing, it is a primary object of the present invention to provide as an end product a novel mattress which includes a conventional coil spring unit and at least a top or upper mattress pad formed of multiple plies or layers including at least one fiber layer and one convoluted foam latex layer having conventional peaks and valleys with the valleys being each substantially filled with a multiplicity of relatively inexpensive, small, random sized, foam latex pieces/materials which might otherwise be discarded as scrap, yet possess all of the highly desirable characteristics of a solid latex foam layer. Since the relatively small pieces of foam latex are entrapped in the valleys during lamination, as will be described more specifically herein, the manufacture of such an upper and/or lower multi-ply mattress pad is relatively inexpensive and, thus, can be utilized to enhance all grades of conventional mattresses now being produced, sold and used throughout the world.
In further accordance with the present invention, such relatively small random sized pieces of latex foam material are also preferably sandwiched between two layers of fiber material, such as conventional polyester fiber, to form an upper mattress pad, a lower mattress pad and/or a peripheral mattress pad formed of three plies, namely, a polyester fiber ply or layer, a layer of latex foam pieces and another polyester fiber ply or layer. As thus far described and as opposed to the first laminated mattress pad herein described, the small individual pieces of latex foam (hereinafter termed “latex”) would tend to shift or move when in use as part of a mattress, unless otherwise provided for, as is the case of the present invention in which the two polyester layers are stitched together by a conventional quilting machine which not only secures the layers together as a unit, but the stitching confines or limits the movement or “migration” of the latex when used, for example, as the upper and/or lower mattress pads of a mattress. Thus, conventional stitching of the quilting process not only functions to maintain the two polyester fiber layers (or any other additional layers) united, but the stitching additionally precludes undesired latex migration/shifting which essentially maintains uniform latex thickness and results in a very comfortable yet inexpensive mattress available at low and moderate prices while providing moderate to high quality comfort and softness absent localized “hard” spots, as might otherwise occur with undesired latex migration.
In keeping with the foregoing, the last described mattress pad is formed by a, novel laminating machine of the present invention which provides respective first and second means for rotatably supporting first and second rolls of polyester fiber material with an upper surface of a layer or web of the first roll being fed beneath a trough from which latex/latex pieces are fed. Downstream of the trough a second layer or web of the second roll of polyester fiber material is overlayed upon the pieces of latex at an assembly area during the continuous travel of the polyester fiber layers toward a roll forming or winding station. The thus formed laminate (polyester fiber layer/latex pieces/polyester fiber layer) are then preferably wound into a roll of laminate/laminate roll, the laminate is cut upstream of the roll, and the laminate roll is packaged and shipped to a mattress manufacturer for utilization in the manufacture of a mattress as described earlier herein. An area is provided for storing packaging material, such as a roll of transparent polymeric/copolymeric packaging material, adjacent the roll forming station to use as the packaging material for the laminate roll. Obviously, the diameter of the laminate roll and its length will vary dependent upon the thicknesses of the polyester fiber layers and the amount of latex sandwiched therebetween. No matter the length, width or diameter of the laminate roll, preferably a flying shear or flying cutter severs the laminate normal to the direction of travel in response to automated or manual controls immediately upon completion of the roll packaging operation.
Immediately upon effecting lamination at the lamination or assembly area, the longitudinal edges of the polyester fiber layers are subject to an edge-binding operation which is preferably achieved through spraying a fast drying adhesive therealong which virtually dries instantaneously under normal temperature ranges found in factories, but heaters may be used, as necessary. The adhesive thus sprayed along the longitudinal edges binds all edge-exposed latex pieces to each other and to the polyester fiber layers. Alternatively or additionally, compression edge rollers can be utilized downstream of the adhesive spray applicators, preferably spray guns, to bring the polyester layers into intimate adhesive bonding contact, thereby further assuring that the latex/latex pieces cannot escape the laminate.
In lieu of immediately forming the laminate into a roll, cutting the laminate, packaging the laminate roll and shipping the same to an end user, the laminate may be fed directly into a quilting machine and conventionally quilted or stitch
Antinori Steven
Fernandez Manuel
Harp William
Antinori Steven J.
Diller Ramik & Wight
Mayes Curtis
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