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I claim:
1. A modular mattress assembly comprising a plurality of mattress modules,
including a first mattress module having a first side wall and a first end
wall, a second mattress module having a second side wall and a second end
wall, said first side wall of said first mattress module and said second
side wall of said second mattress module facing toward each other, said
first mattress module having a first outwardly facing side wall facing
oppositely from said first side wall and a first outwardly facing end wall
facing oppositely from said first end wall, said second mattress module
having a second outwardly facing side wall facing oppositely from said
second side wall and a second outwardly facing end wall facing oppositely
from said second end wall, said side and end walls of said mattress
modules each having an upper peripheral edge and a lower peripheral edge,
and retaining means extending around the periphery of said modular
mattress assembly in pressure bearing relationship against said first and
second outwardly facing side walls and end walls to hold said plurality of
mattress modules in place, said retaining means including an elongated
retaining member of relatively thin cross-section having an inwardly
facing bearing surface facing said outwardly facing side walls and end
walls of said mattress modules, said elongated retaining member extending
continuously around said modular mattress assembly having an elongated
upper longitudinal edge, an elongated lower longitudinal edge, and an
elongated longitudinal mid-region therebetween, said inwardly facing
bearing surface of said elongated retaining member when in place facing
said side walls and end walls of said mattress modules being otherwise
unobstructed and smooth throughout, said first and second outwardly facing
side walls and end walls of said mattress modules facing said inwardly
facing bearing surface of said retaining member when in place being
otherwise unobstructed and smooth throughout, said inwardly facing bearing
surface of said retaining member extending upwardly from said longitudinal
mid-region thereof to terminate at said upper longitudinal edge thereof at
a point no higher than said upper peripheral edges of adjacent ones of
said mattress modules when in place and extending downwardly from said
longitudinal mid-region thereof a substantially equal distance to
terminate at said lower longitudinal edge thereof at a point no lower than
said lower peripheral edges of adjacent ones of said mattress modules when
in place, said mattress modules each having continuously unobstructed,
uncovered, smooth upwardly facing surfaces throughout extending laterally
to said upper peripheral edges of said side and end walls thereof and
continuously unobstructed, uncovered, smooth downwardly facing surfaces
throughout extending laterally to said lower peripheral edges of said side
and end walls thereof.
2. A modular mattress assembly as set forth in claim 1, including a third
mattress module having a third side wall and a third end wall, a fourth
mattress module having a fourth side wall and a fourth end wall, said
third mattress module having a third outwardly facing side wall facing
oppositely from said third side wall and a third outwardly facing end wall
facing oppositely from said third end wall, said fourth mattress module
having a fourth outwardly facing side wall facing oppositely from said
fourth side wall and a fourth outwardly facing end wall facing oppositely
from said fourth end wall, said third side wall of said third mattress
module and said fourth side wall of said fourth mattress module facing
toward each other, said first end wall of said first mattress module and
said fourth end wall of said fourth mattress module facing toward each
other, said second end wall of said second mattress module and said third
end wall of said third mattress module facing toward each other, said
retaining member being in bearing relationship against said third and
fourth outwardly facing side wall and end walls to hold said plurality of
mattress modules together.
3. A modular mattress assembly as set forth in claim 1, including a spacing
member between said first side wall of said first mattress module and said
second side wall of said second mattress module, said spacing member
having a first free end facing toward a portion of said inwardly facing
bearing surface of said retaining member and terminating short thereof.
4. A modular mattress assembly as set forth in claim 2, including a first
spacing member between said first side wall of said first mattress module
and said second side wall of said second mattress module, a second spacing
member between said third side wall of said third mattress module and said
fourth side wall of said fourth mattress module, a third spacing member
between said second end wall of said second mattress module and said third
end wall of said third mattress module, and a fourth spacing member
between said first end wall of said first mattress module and said fourth
end wall of said fourth mattress module, said first, second, third and
fourth spacing members each having a respective first free end facing
toward a portion of said inwardly facing bearing surface of said retaining
member and terminating short thereof.
5. A modular mattress assembly as set forth in claim 1, wherein said
elongated upper longitudinal edge of said retaining band extends adjacent
said upper peripheral edge bordering said upwardly facing surface of said
first and second mattress modules when in place around said modular
mattress assembly, said elongated lower longitudinal edge of said
retaining band extends adjacent said lower peripheral edge bordering said
downwardly facing surface of said first and second mattress modules when
in place around said modular mattress assembly.
6. A modular mattress assembly as set forth in claim 5, wherein said
elongated retaining band is made of a flexible material.
7. A modular mattress assembly as set forth in claim 5, wherein said
elongated retaining band is made of an elastic stretchable material.
8. A modular mattress assembly as set forth in claim 7, wherein said
elastic stretchable material includes rubber.
9. A modular mattress assembly as set forth in claim 5, wherein said
elongated retaining band includes a first end, a second end facing and
releasably connectable to said first end when said retaining band is in
place around the periphery of said modular mattress assembly.
10. A modular mattress assembly as set forth in claim 9, wherein said first
end of said elongated retaining band includes first cooperative releasable
connecting means, said second end of said elongated retaining band
includes second cooperative releasable connecting means for releasably
connecting said first and second ends of said elongated retaining band
together.
11. A modular mattress assembly as set forth in claim 10 wherein one of
said first and second cooperative releasable connecting means includes a
panel having a plurality of tiny hook members projecting therefrom and the
other a panel having a plurality of tiny loop members projecting therefrom
for releasable interconnection with said plurality of tiny hook members,
when said first and second ends of said elongated retaining band are
brought together.
12. A modular mattress assembly comprising a top mattress cover, a bottom
mattress cover, a top fabric flange extending downwardly from the
peripheral edge of said top mattress cover, a bottom fabric flange
extending from the peripheral edge of said bottom mattress cover, a
plurality of mattress modules in side by side relationship between said
top and bottom mattress covers and arranged to present an outwardly facing
peripheral side wall around the periphery thereof, said mattress modules
arranged to present said outwardly facing peripheral side wall each having
an outwardly facing side wall, a side wall securing strip along each of
said outwardly facing side walls, each of said side wall securing strips
having an upwardly extending flap extending upwardly toward said top
fabric flange of said top mattress cover and being releasably secured
thereto, each of said side wall securing strips having a downwardly
extending flap extending downwardly toward said bottom fabric flange of
said bottom mattress cover and being releasably secured thereto, including
releasable securing means to releasably secure said upwardly extending
flap of said side wall securing strip of each of said mattress modules to
said top fabric flange of said top mattress cover and said downwardly
extending flap of said side wall securing strip of each of said mattress
modules to said bottom fabric flange of said bottom mattress cover,
wherein said releasable securing means includes tiny hook elements and
tiny loop elements which are releasably securable to each other, wherein
each of said mattress modules comprise an innerspring assembly, wherein
said plurality of mattress modules include a first mattress module and a
first innerspring assembly thereof, a first fabric enclosure, said first
innerspring assembly being received in said first fabric enclosure, said
side wall securing strip of each of said modules including a first side
wall securing strip, said first side wall securing strip being secured to
said first fabric enclosure along said outwardly facing side wall of said
first mattress module and said first innerspring assembly thereof. |
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Description |
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BACKGROUND OF THE INVENTION
This invention relates to the field of mattresses and innersprings,
particularly to a modular mattress and modular innerspring, which is made
up of a plurality of modules held together in side by side relationship by
a retainer which extends around the periphery of the modular mattress and
modular innerspring. The individual modules may be of whatever size and
number needed to make a twin, twin extra long, full, full extra long,
queen and king size mattress or innerspring.
PRIOR ART
Relevant prior art of which the inventor is aware is set forth in the
following patents discovered during his searches for prior art.
U.S. Pat. No. 5,214,809 discloses an articulated mattress for an adjustable
bed which has hinge portions between mattress sections for limited pivotal
movement of one section relative to another.
U.S. Pat. No. 5,040,255 discloses a cushion or mattress structure
comprising a box structure with side, top and bottom walls of foam
material, and cavity within the box to receive encased springs.
U.S. Pat. No. 4,956,884 discloses a modular box spring mattress comprising
a plurality of plate sub units in which coil springs are received and held
by flexible retaining arms. The sub units have cooperative coupling
structures to hold adjacent sub units together.
U.S. Pat. No. 4,868,941 discloses an assembled mattress having an upper
sheet with integrally formed sleeves or bellows extending downward and a
lower sheet with integrally formed sleeves or bellows extending upward,
with individual coil springs seated in each of the sleeves or bellows.
U.S. Pat. No. 2,547,840 discloses a sectional mattress comprising three
separate sections positioned end to end, with one end of a coil spring
connected at each end of the middle section and on both sides thereof,
having the other end of each coil spring connected to the adjacent
mattress section at each opposite end of the middle section.
U.S. Pat. No. 2,446,775 discloses an innerspring mattress construction made
up of sections which are glued together along facing end walls to make up
a completed mattress.
U.S. Pat. No. 2,249,266 discloses a combined chair and bed having a
mattress like coil spring cushion supported on a hinged frame which folds
down into a bed and angularly to form a chair in one position and a
recliner in another.
U.S. Pat. No. 2,216,991 discloses three mattress units which are connected
end to end to make a complete mattress. The units are connected by a
transverse cylindrical bar insert on one unit which is received in a
sleeve have a split cylindrical wall around its through passageway on the
adjacent unit.
U.S. Pat. No. 1,915,674 discloses a coil spring assembly for making
cushions, comprising four or more coils in a row connected by an elongated
endless loop of twisted wire which includes one elongated strand connected
to one side of each coil in the row and a second parallel strand connected
to the opposite side of each coil in the row, such rows of coils in turn
being connected to adjacent rows of coils by C-wires or fasteners known as
hog rings.
U.S. Pat. No. 1,459,540 discloses a sectional mattress comprising three
separate sections that are laid end to end to make up a complete mattress
and can be interchanged in their relationship to each other. The
innersprings within each section are encased in bags.
The inventor's own U.S. Pat. No. 5,435,026 discloses a do-it-yourself type
of mattress which can be put together by the customer after purchasing the
necessary component parts.
The inventor's own U.S. Pat. No. 5,471,688 discloses a modular innerspring
assembly for a mattress and a modular box spring assembly on which the
mattress is placed.
The inventor's own U.S. Pat. No. 5,485,639 discloses an S-shaped metal
connecting clip having a spring characteristic to more easily connect the
border wire around the top and bottom of an innerspring assembly to the
top and bottom coils of adjacent coil springs.
In addition to the prior art found by the inventor's own searches, the
following prior art has been cited by the Patent and Trademark Office in
connection with other patent applications for somewhat related inventions:
______________________________________
U.S. Patent Documents
Date
U.S. Pat. No. Month Year Inventor
______________________________________
163,131 May 1875 Alvord
272,076 Feb. 1883 Mueller
428,637 May 1890 Schmitt
757,420 April 1904 Smith
825,391 July 1906 Horton
871,244 Nov. 1907 Smith
879,232 Feb. 1908 Young
1,185,575 May 1916 Anthony
1,343,620 June 1920 Gainer
1,497,710 June 1924 Cole
1,618,852 Feb. 1927 Tiffany
1,725,356 Aug. 1929 Kiwi
1,746,942 Feb. 1930 Hise
2,086,767 July 1937 Haas
2,180,500 Nov. 1939 Bernstein
2,567,550 Sept. 1951 Clark
2,639,764 May 1953 Fernberg
3,176,325 April 1965 Levine
3,293,670 Dec. 1966 Anson
4,055,337 Oct. 1977 Laiche
4,402,097 Sept. 1983 Scott
4,956,884 Sept. 1990 Hwang
5,144,706 Sept. 1992 Walker
______________________________________
Foreign Patent Documents
Date
Patent No. Month Year Country
______________________________________
188399 Sept. 1907 Austria
609691 April 1925 France
806711 June 1951 Germany
______________________________________
SUMMARY OF THE INVENTION
The present invention constitutes an improvement over the prior art in that
a plurality of mattress or innerspring modules can be assembled to make up
a modular mattress or innerspring of any desired size and held in place by
an elongated retaining member or assembly around the periphery thereof.
In one embodiment, a retaining band has a width corresponding to the
peripheral side wall dimension of the mattress or innerspring modules
which make up the completed modular assembly. The retaining band is
preferably elastic, and includes Velcro type fastening panels or strips at
each opposite end, or a buckle assembly or the like to enable drawing the
retaining band up tight and then holding it in such position until it is
desired to release the retaining band for purposes of removing one or more
modules and replacing with another.
The retaining band can also be a continuous length of material, preferably
elastic, and slipped over the side by side modules when compressed
together by a compression machine enough for the continuous band to be put
in place. The compression machine then releases the modules from their
compressed side by side and end to end position whereupon they expand to
bear tightly against the peripheral retaining band.
By providing a retaining band with a width as great as the peripheral side
wall of the modules, uniform pressure is thereby applied to all surface
areas of the module side walls. Such uniform pressure is applied by the
peripheral retaining band in the direction which urges each of the side by
side and end to end modules toward each other. By providing a structure
which supplies that pressure uniformly over the entire surface areas of
the module side walls, the tendency of the modules to buckle is lessened
and substantially eliminated and the stability of the modular assembly is
substantially improved.
Spacing strips of urethane foam or the like are provided between the
adjacent modules. Such spacing strips are slightly compressible when the
peripheral retaining band is tightened around the side by side and end to
end modules, and help to retain the standard dimensional width and length
of the various size mattresses and innersprings which can be made by the
modular assembly in accordance with this invention, when the peripheral
retaining band is drawn up tight and secured.
The modules in accordance with this invention may be of any convenient
size, so that when assembled in side by side and end to end relationship,
they will make up any of the standard size mattresses and innersprings
desired.
The mattress modules may be of the traditional mattress construction,
having an innerspring assembly, cushioning material over the upper and
lower surfaces of the innerspring assembly, a mattress cover over such
cushioning materials on both surfaces, and a peripherally extending border
around the side wall between the mattress cover over the upper surface and
the mattress cover over the lower surface.
The peripheral retaining band in accordance with this invention can also be
used as described to hold innerspring modules by themselves in place, with
spacing strips placed between side by side and end to end innerspring
modules, in the same manner as for the mattress modules.
In another embodiment of the invention, a modular mattress comprises a top
and bottom mattress cover, each having a fabric flange extending from and
around its peripheral edge with a strip of Velcro type fastening elements
(tiny hooks or loops) extending around the peripheral free edge of each
fabric flange. A plurality of inner spring mattress modules are enclosed
between the mattress covers, each having a strip of material along its
outer edge from which an upwardly extending flap having corresponding
Velcro type fastening elements extends to releasably fasten to the strip
of Velcro type fastening elements on the flange of the top mattress cover,
and a downwardly extending flap having corresponding Velcro type fastening
elements extends to releasably fasten to the strip of Velcro type
fastening elements on the flange of the bottom mattress cover.
Before the mattress module strips are releasably fastened to the fabric
flanges of the top and bottom mattress covers, layers of insulating
material and cushioning material are placed over the upwardly and
downwardly facing surfaces of the mattress modules and under the
respective top and bottom mattress covers.
After the mattress module strips and flanges of the top and bottom mattress
covers have been releasably secured together by the Velcro type fastening
elements, a peripheral border strip secured to the peripheral edge of one
mattress cover is connected by a zipper assembly to the other mattress
cover, thereby covering the peripheral side wall of the modular mattress
and the mattress modules held therein.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a top plan view of a modular mattress in accordance with this
invention.
FIG. 2 is a perspective view of the modular mattress shown in FIG. 1 in
which the peripheral retaining band is shown in its unconnected position
and with end portions broken away to illustrate the releasable securing
members which hold the peripheral retaining band together when its
respective ends are connected.
FIG. 3 is a side elevation view of a modular mattress assembly in
accordance with another preferred embodiment of the invention.
FIG. 4 is a side elevation view of a modular mattress assembly as shown in
FIG. 3 but with its border strip removed to better illustrate internal
portions of the assembly.
FIG. 5 is a perspective view of an innerspring module of the type that make
up the modular mattress as shown in FIGS. 3 and 4 when a plurality of such
modules are arranged in side by side relationship therein; the innerspring
module is shown received in a fabric enclosure, a portion of which is
shown broken away to show the coils of the innerspring module.
FIG. 6 is a top plan view of a modular mattress assembly as shown in FIGS.
3 and 4, but with the top mattress cover and layers of cushioning and
insulating material removed to illustrate the innerspring modules within
their fabric enclosures arranged and held in side by side relationship.
FIG. 7 is a side elevation view of a modular mattress assembly as shown in
FIG. 3, but with a portion of the border strip broken away, a portion of
the upper and lower flaps of the cooperative releasable connecting portion
of the fabric innerspring enclosure also broken away, and a portion of the
fabric flange of the top and bottom mattress covers also broken away to
better illustrate interior portions of the modular mattress assembly.
DESCRIPTION OF PREFERRED EMBODIMENTS
A modular mattress 2 in accordance with the present invention comprises
four or more separate mattress modules 4 which can be of different sizes,
held together by an elongated retaining band 6 that extends around the
entire periphery 8 of the modular mattress.
The inner surface 10 of the retaining band 6 has a first removably
connecting panel 12 secured thereto at its first end 14. The outer surface
16 of the retaining band has a second removably connecting panel 18
secured thereto at the second end 20 of the elongated retaining band 6.
The connecting panel 12 includes a plurality of tiny hook shaped
projections 22 extending therefrom of the Velcro type, which interengage
with a corresponding plurality of tiny loop members 24 of the
corresponding Velcro type, projecting outward from the second connecting
panel 18, when the two connecting panels are brought together.
The elongated retaining band 6 is preferably made of an elastic stretchable
material, such as rubber or interwoven fabric encased lengths of
stretchable material. However, the retaining band 6 can also be made of
flexible non-stretchable material, as long as it can be drawn up tight
around the periphery of the modular mattress 2 to hold the plurality of
modules 4 in place next to adjacent modules.
Relatively narrow or thin spacing members 26 of urethane foam or the like
may be provided and placed between adjacent modules to space them apart a
uniform but relatively close distance when the retaining band 6 has been
drawn tight around the periphery of the modular mattress 2 to hold the
mattress modules 4 in place. Spacing member 28 is provided for placement
between mattress modules 30 and 32. Spacing member 34 is provided for
placement between mattress modules 32 and 36. Spacing member 38 is
provided for placement between mattress modules 36 and 40, and spacing
member 42 is provided for placement between mattress modules 40 and 30.
The spacing members 26 have a length corresponding to the lineal dimension
of the side of the mattress module they are to be placed adjacent to. The
spacing members 26 have a width corresponding to the thickness of the
mattress module they are to be placed adjacent to, that is the dimension
or distance between the downwardly facing surface 44 of each mattress
module 4 and its upwardly facing surface 46.
The elongated retaining band 6 also has a width corresponding to the
thickness, or spaced apart dimension or distance of the upwardly facing
and downwardly facing surfaces, of each mattress module 4. Thus, when the
retaining band 6 is drawn up tight around the periphery 8 of the modular
mattress 2, the retaining band 6 applies uniform pressure against all
facing portions of each mattress module in a direction toward each
corresponding adjacent mattress module, from the upper peripheral border
edge 48 down to the lower peripheral border edge 50. Such uniform pressure
along all portions of the peripheral side wall 52 of the modular mattress
2 helps to prevent the adjacent mattress modules 4 from buckling, and
helps to hold them in place thereby forming a modular mattress 2 which has
comparable stability to a unitary mattress when the elongated retaining
band 6 is drawn up tight and its ends secured together.
When it is desired to change one or more of the mattress modules 4, or to
disassemble the modular mattress 2 for any reason, the ends of the
elongated retaining band 6 are separated or loosened enough for the
mattress modules to be removed. Worn mattress modules can be replaced with
new, and the modular mattress then re-assembled by drawing the elongated
retaining band 6 up tight around the periphery 8 of the mattress modules
in side by side and end to end relationship, and securing the ends of the
retaining band 6 together.
The description set forth above for mattress modules held in place by the
peripheral retaining band in accordance with this invention applies also
to innerspring modules used to create a modular innerspring of any desired
standard size, such as twin, full, queen and king in both standard and
extra long versions.
A preferred embodiment of this invention as shown in FIG. 3, comprises a
modular mattress 102, having a plurality of innerspring mattress modules
104, a peripheral border strip 106 extending around the entire periphery
108 of the mattress between a top mattress cover 110 and a bottom mattress
cover 112. The border strip 106 is connected to one or the other of the
top or bottom mattress covers by sewing, and releasably connectable to the
other by a zipper assembly 114 which extends around the entire periphery
of the mattress cover to which it is secured, and around the entire
periphery of the edge 116 of border strip 106 adjacent to such mattress
cover.
Each mattress cover includes a fabric flange 118 extending from its
peripheral edge 120 around the entire periphery thereof. A cooperative
fastening strip 122 of Velcro type fastening elements, such as tiny loops
124, extends along the free edge 126 of each fabric flange 118 around the
entire periphery thereof.
Each innerspring mattress module 104 has a side wall strip of material 128
along its outwardly facing side wall 130, having an upwardly extending
flap 132 that extends upwardly to terminate in a free edge 134 adjacent
the free edge 126 of fabric flange 118 of the top mattress cover 110, and
a downwardly extending flap 136 that extends downwardly to terminate in a
free edge 138 adjacent the free edge 126 of fabric flange 118 of the
bottom mattress cover 112.
A cooperative fastening strip 140 of Velcro type fastening elements, such
as tiny hooks 142, extends along the free edge 134 of the upwardly
extending flap 132, to releasably fasten such upwardly extending flap 132
of each mattress module 104 to the peripherally extending fabric flange
118 of the top mattress cover 110.
A cooperative fastening strip 144 of Velcro type fastening elements, such
as tiny hooks 142, extends along the free edge 138 of the downwardly
extending flap 136, to releasably fasten such downwardly extending flap
136 of each mattress module 104 to the peripherally extending fabric
flange 118 of the bottom mattress cover 112.
Before the flaps of the mattress modules 104 are secured to the flanges 118
of the mattress covers, a layer of insulating material 146 and a layer of
cushioning material 148 are placed over the upwardly facing surface 150
and downwardly facing surface 152 of the mattress modules 104, and under
the top mattress cover 110 over the upwardly facing surface 150 of the
modules 104, under the bottom mattress cover 112 over the downwardly
facing surface 152 of the mattress modules 104.
When the insulating and cushioning materials are in place between the
mattress covers and the mattress modules, and the flaps 132 and 136 along
the outer side walls 130 of the mattress modules 104 have been releasably
secured to the fabric flanges 118 of the top mattress cover 110 and of the
bottom mattress cover 112 by the Velcro type fastening elements, the
border strip 106 permanently secured to one mattress cover by sewing is
then releasably secured to the other mattress cover by zipping up the
zipper assembly 114 around the entire periphery of the modular mattress
102.
In the embodiment shown and described herein, the innerspring modules 102
are enclosed within a fabric bag or enclosure 154. The side wall strip of
material 128 having the upwardly extending flap 132 and downwardly
extending flap 136 for releasable connection to the fabric flanges of the
top and bottom mattress covers is connected to the fabric enclosure 154
along the side 156 which borders the outwardly facing side wall 130 of the
innerspring module 104 therein.
The side wall strip of material 128, and the flaps 132 and 136 which are
releasably connectable to the fabric flanges of the top and bottom
mattress covers respectively, can be secured to the innerspring modules
104 along their outwardly facing side walls 130 in other ways. It is not
necessary to have the innerspring modules 102 enclosed in a fabric bag in
which the side wall strip of material 128 is connected to or made a part
of such bag. For example, a panel could be secured to the outwardly facing
side wall 130 of the innerspring module 102, and the flaps 132 and 136
which extend upwardly and downwardly could then be secured to or
integrally formed with such panel.
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