WO2006039923A1

WO2006039923A1 - Futon mattress

Info

Publication number: WO2006039923A1
Application number: PCT/DK2004/000698
Authority: WO
Inventors: Kirsten Maarbjerg Christensen
Original assignee: Dan-Foam Aps
Priority date: 2004-10-12
Filing date: 2004-10-12
Publication date: 2006-04-20
Also published as: US20090139034A1; TW200611661A; EP1804617A1; JP5025479B2; JP2008515574A

Abstract

A futon mattress (10) having a cover (14) with a plurality of pockets for retaining filler material (18). The cover (14) having a top surface (22) coupled to a bottom surface (26). A closure device (34) is coupled to the cover (14) to selectively allow access to the inside surfaces of the cover (14). In some embodiments, the closure device also allows the top (24) and bottom (26) surfaces to be selectively uncoupled from each other. The top surface (22) of the cover (14) has a first plurality of pockets (38) that are accessible only from inside the cover (14). A filler material (18), such as viscoelastic foam for example, is contained within each pocket (38, 42) of the first plurality of pockets. Some embodiments also include a second plurality of pockets (42) positioned along an inside surface of the bottom (26) of the cover (14). The second plurality of pockets (42) can also contain a filler material (18) that accessible only from inside the cover (14).

Description

FUTON MATTRESS

Background of the Invention

[0001] Futon mattresses generally have cushioning filler material encased in a protective cover. For example, some futon mattresses are filled with cotton batting, wool batting, foam, or the like to provide sufficient cushioning. However, due to the many uses for a futon cushion, the outer cover can become easily soiled. The cover of most conventional futon cushions can not be easily cleaned because the cover cannot be conveniently separated from the cushioning filler material.

Summary of the Invention

[0002] The present invention generally relates to a futon mattress having multiple pockets for storing filler material within the cover of the mattress. The filler material can be removed from the pockets and the cover to allow the cover to be easily laundered. In some embodiments, the top of the cover can be separated from the bottom of the cover to allow the top to be separately laundered.

[0003] One embodiment of the invention relates to a futon mattress including a cover having a top portion coupled to a bottom portion and a closure device coupled to the cover to selectively allow access to inside surfaces of the top and bottom portions of the cover. A first plurality of pockets are positioned along an inside surface of the top portion of the cover and contain a filler material accessible only from inside the cover. A second plurality of pockets are positioned along an inside surface of the bottom portion of the cover and contain a filler material accessible only from inside the cover.

[0004] Another embodiment relates to a futon mattress having a cover with a top portion selectively coupled to a bottom portion via a closure device positioned between the top portion and the bottom portion. The closure device is movable to selectively allow the top portion to uncouple from the bottom portion. The top portion of the cover has a first layer of pockets, while the bottom portion of the cover has a second layer of pockets. The first layer of pockets and the second layer of pockets are filled with a filler material. [0005] Another embodiment relates to a futon mattress having a cover with a top surface coupled to a bottom surface, where the top and bottom surface of the cover each have a length and a width. A zipper is positioned along the interface between the top surface and the bottom surface to selectively allow the top surface to uncouple from the bottom surface. A first plurality of pockets are positioned along an inside surface of the top of the cover and contain a first filler material accessible only from inside the cover. The first plurality of pockets are positioned side-by-side along the length of the top of the cover. A second plurality of pockets are positioned along an inside surface of the bottom of the cover and contain a second filler material accessible only from inside the cover. The second plurality of pockets are positioned side-by-side along the length of the bottom of the cover.

[0006] These and other aspects of the present invention, together with the organization and operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0007] In the drawings, wherein like reference numerals indicate like parts:

[0008] FIG. 1 is a perspective view of a futon mattress embodying aspects of the present invention, wherein the futon mattress is folded into a storage position.

[0009] FIG. 2 is a perspective view of the mattress illustrated in FIG. 1, wherein the futon mattress is unfolded.

[0010] FIG. 3 is a perspective view of the mattress illustrated in FIG. 2, where the top portion of the mattress is separated from a bottom portion of the mattress.

[0011] FIG. 4 is a perspective view of the bottom of the mattress illustrated in FIG. 3 with the filler material of the bottom portion of the mattress being partially removed.

[0012] FIG. 5 is a perspective view of the top of the mattress illustrated in FIG. 3 with the filler material of the top portion of the mattress being partially removed. [0013] FIG. 6 is a cross-sectional view of a portion of the mattress shown in FIG.

2.

[0014] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited. The use of "including," "comprising" or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms "mounted," "connected" and "coupled" are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect.

Detailed Description

[0015] FIGS. 1-6 illustrate one embodiment of the present invention. As shown in FIGS. 1 and 2, the illustrated mattress is adapted for use as a futon mattress. In other words, the mattress can be easily folded or otherwise manipulated to change the configuration of the mattress from a fully laid-out position, as illustrated in FIG. 2, to a folded position, as illustrated in FIG. 1. Manipulation of the mattress, as shown in FIG. 1, can allow it to be easily stored or used for other purposes such as seating.

[0016] As best illustrated in FIGS. 2 and 6, the illustrated mattress 10 has a fabric case or cover 14 filled with filler material 18. The cover 14 contains and protects the filler material 18. The cover 14 has a top portion 22 coupled to a bottom portion 26 along a perimeter 30. The top portion 22 can be coupled to the bottom portion via stitching, adhesive or cohesive bonds, and the like. Furthermore, a closure device 34, such as a zipper, hook and loop fastener, and the like can be coupled to the mattress to allow selective access to the interior portions of the mattress 10. The closure device 34 can form part of the coupling between the top portion 22 and the bottom portion 26 of the cover 14. The access allowed by such closure devices 34 can be used to reconfigure or remove filler material 18 from the cover 14. With the filler material removed, the cover 14 can be easily laundered.

[0017] Since the top portion 22 of the mattress 10 is more likely to be soiled, it may be desirable in some situations to only launder the top portion 22 of the cover 14 without laundering the bottom portion 26. Accordingly, in some embodiments, the closure device 34 can form the entire coupling between the top portion 22 and bottom portion 26 of the cover 14. In such embodiments, the top portion 22 can be separated or uncoupled from the bottom portion 26 to be separately laundered, if desired. For example, as illustrated in FIGS. 2 and 3, the closure device 34 or zipper can be actuated to separate or uncouple the top portion 22 of the cover 14 from the bottom portion 26 of the cover 14.

[0018] Although the illustrated embodiment shows that the top portion 22 can be separated or uncoupled from the bottom portion 26 to remove the top portion 22 from the bottom portion 26, other embodiments can allow these portions to be separated, but not removed from each other. For example, in some embodiments, the top portion 22 can be coupled to the bottom portion 26 along a substantial portion of perimeter 30 via a closure device 34, while a seam or other substantially permanent connection is used to connect the top portion 22 to the bottom portion along only a portion of the perimeter 30. In some embodiments, the top portion 22 can be substantially permanently connected to the bottom portion 26 along at least one side or edge of the cover 14. Accordingly, in these alternative embodiments, the top portion 22 can be separated from the bottom portion 26 such that it can be positioned on a support surface adjacent the bottom portion 26 to allow access to interior portions of the cover 14.

[0019] The cover 14 can be made from many different materials. In some embodiments, the top portion 22 of the cover 14 is formed from a first material, while the bottom portion 26 of the cover 14 is formed from a second material. For example, the top portion 22 of the cover 14 can have a relatively soft velour feel, while the bottom portion 26 of the cover 14 can be made from a non-slip material. However, in other embodiments, both the top portion 22 and the bottom portion 26 of the cover 14 are made from the same type of material. [0020] As illustrated in FIGS. 3-6, the cover 14 includes multiple pockets 38, 42 for holding the filler material 18. A first plurality of pockets 38 are connected to the top portion 22 of the cover 14. The first plurality of pockets 38 are arranged in a layer or positioned side-by-side along the top portion 22 of the cover 14 to substantially cover the entire length L of the cover 14. Each pocket within the first plurality of pockets 38 extends substantially across the width W of the cover 14. In other constructions, however, two or more pockets can extend across the width W of the cover 14. For example, it may be desirable in some embodiments to provide different levels of cushioning on each side of the mattress corresponding to a specific user's desire.

[0021] Each illustrated pocket within the first plurality of pockets 38 is shown as fully enclosing filler material 18 within the pocket. Each illustrated pocket within the first plurality of pockets 38 also has a closure device 46 to fully contain the filler material 18 within the pocket, prevent the filler material 18 from unintentionally escaping the pocket, and allow selective access within the pocket. As illustrated, the pocket closure device 46 can be a zipper, but in other embodiments, it can include hook and loop fasteners and the like. The illustrated pocket closure device 46 is positioned on a surface of each pocket that is only accessible from inside the cover. In other words, the cover closure device 34 must be opened prior to being able to access and manipulate the pocket closure device 46. As illustrated in FIGS. 3 and 5, the pocket closure device 46 can be located on a surface 50 of each pocket that is substantially parallel to the top surface 22 of the cover 14. With this construction, the pocket closure device 46 is positioned beneath the filler material 18 when the mattress 10 is used in the unfolded position. Accordingly, the chance that the pocket closure device 46 will be felt by a person resting on the mattress is reduced. Although the illustrated embodiment shows the pocket closure device 46 extending across the bottom surface 50 (as shown in FIG. 6) of the pocket, in other embodiments, the closure device can be positioned around at least a portion of the perimeter of each pocket.

[0022] Although the illustrated embodiment has a pocket closure device 46 on each pocket of the first plurality of pockets 38, in other embodiments, a closure device 46 is not used. For example, each pocket can be constructed to fully enclose the filler material 18 without sealing the opening 54 of the pocket. Specifically, the opening 54 of the pocket can have overlapping pieces of fabric that prevent the filler material 18 from unintentionally escaping the pocket. Furthermore, assuming that each pocket is properly sized for the filler material 18, the pocket would not have to fully enclose the filler material 18. Rather, it could merely enclose the perimeter of the filler material 18.

^• [0023] As illustrated in FIGS. 3, 4, and 6, the futon mattress also has a second plurality of pockets 42 that are connected to the bottom portion 26 of the cover 14. The second plurality of pockets 42 are arranged in a layer or positioned side-by-side along the bottom portion 26 of the cover 14 to substantially cover the entire length L of the bottom portion 26 of the cover 14. Each pocket within the second plurality of pockets 42 extends substantially across the width W of the cover 14. However, in other constructions, two or more pockets can extend across the width W of the cover 14. For example, it may be desirable in some embodiments to provide different levels of cushioning on each side of the mattress corresponding to a specific user's desire.

[0024] Unlike the first plurality of pockets 38 which are shown as being fully enclosed, the illustrated second plurality of pockets 42 do not fully enclose the filler material 18 within each pocket. Rather, each pocket within the second plurality of pockets 42 merely enclose the perimeter of the filler material 18 to prevent movement of the filler material 18 within the mattress 10. However, other embodiments can fully enclose the filler material 18 if desired. For example, it may be desirable to fully enclose the filler material 18 when a loose filler material 18, such as granular or shredded foam, foam beads, loose cotton, and the like is used within the second plurality of pockets 42. Accordingly, some constructions may also use a pocket closure device 46 as well to fully contain the filler material 18 and prevent the filler material 18 from unintentionally escaping the pocket. Like the first plurality of pockets 38, the pocket closure device 46 can be positioned on a surface of each pocket that is only accessible from inside the cover 14.

[0025] As shown in the illustrated embodiment, each of the pockets in the second plurality of pockets 42 has a fabric lip 58 that extends around one surface of the pocket to engage the perimeter of the filler material 18, such as a block of foam. The fabric lips 58 extend in a direction substantially parallel to the top and bottom surfaces 22, 26 of the cover 14. Furthermore, an opening 54 defined by the lips 58 is accessible only from inside the cover 14. [0026] Although the illustrated embodiment shows each pocket within the same plurality of pockets has having the same construction, in other embodiments, one or more pockets within the same plurality of pockets can have a different construction relative to the other pockets within the same plurality of pockets. For example, one or more pockets within the second plurality of pockets 42 can be fully enclosed while the remainder of the pockets utilize the lip 58 construction described above. Similarly, one or more pockets of the first plurality of pockets 38 can utilize a non-fully enclosed structure while the remainder of the pockets are fully enclosed.

[0027] As illustrated in FIGS. 2, 3, and 6, the first and second plurality of pockets 38, 42 can each comprise a different number of pockets. For example, in the illustrated embodiment, the first plurality of pockets 38 includes seven pockets and the second plurality of pockets 42 includes four pockets. Accordingly, as illustrated, two pockets of the first plurality of pockets 38 are generally provided for each pocket of the second plurality of pockets 42. Due to this arrangement, the end of certain pockets within the each of the plurality of pockets generally align to form a convenient fold location for the futon mattress 10. However, in some embodiments, the ends of pockets do not need to align to form fold locations. Furthermore, the size and number of pockets within each plurality of pockets 38, 42 can vary. Thus, each plurality of pockets can include more or less pockets than illustrated.

[0028] Although some pockets are illustrated as having equal lengths, the length of each pocket does not have to be the same. Rather, the length can vary depending upon the location of the pocket on the mattress 10. For example, some mattresses are divided into zones that correspond with locations of different areas of the body. Accordingly, the pockets can have different lengths corresponding to the desired size of several zones on the mattress. For example, an average person's hips will generally fall within a predetermined area on the mattress and need to sink into the mattress more than the small of the back to properly align the spine. Thus, a zone having a select length and filler material 18 characteristics can be positioned in this area. The adjacent zones can have different lengths and/or filler material 18 characteristics to properly align the back and legs with the hips. [0029] As described above, each pocket is designed to at least partially contain a filler material 18, which provides a cushioning effect for the mattress 10. The filler material 18 can include a wide variety of cushioning materials. For example, the filler material 18 of the mattress 10 can include cotton batting, wool batting, foam such as viscoelastic foam, polyurethane foam, highly resilient (HR) foam, or other foams commonly used in the industry, and the like. The selection of materials can depend upon the desired feel of the mattress. Furthermore, the filler material can be formed as blocks, strips, or webs, or it can be placed in the pockets in a loose or granular form. Additionally, a combination of different filler material types and forms can be used in a single pocket.

[0030] The filler material 18 of each pocket can be individually selected to provide a desired feel in the mattress 10. Accordingly, one or more of the pockets can be filled with the same material or one or more pockets can be filled with different materials. In the illustrated embodiment, the first plurality of pockets 38 are filled with a first type of filler material 18 and the second plurality of pockets 42 are filled with a second type of filler material 18. More specifically, the first plurality of pockets 38 are filled with a first type of foam and the second plurality of pockets 42 are filled with a second type of foam. The first type of foam is a viscoelastic foam sold by Tempur World, LLC of Lexington, Kentucky, U.S.A. under the trademark Tempur®. The second type of foam is a highly resilient foam. In possible alternative embodiments, each first plurality of pockets and/or each second plurality of pockets is filled with a combination of two or more types of foam, however, one type of foam being the primary type of foam in the pocket in question. It will also be possible filling selected first pockets with one type of foam or with more types of foam, and filling remaining first pockets with another type of foam or with other more types of foam. The same possibility applies to selected second pockets and remaining second pockets.

[0031] As illustrated in FIGS. 3 and 4, foam filler material is formed as strips or blocks. These strips are covered by a netting material 62 or other fabric and inserted into the pockets of the cover 14. The netting 62 can help to protect the foam when being inserted and removed from the pockets. Additionally, depending upon the type of material used for the netting 62, the netting 62 can control the amount of sheer force or friction force between the pockets and the filler material. For example, it may be desirable to use a material that reduces the sheer force to allow easier movement between the filler material and the pocket. This can reduce the effort needed to insert and remove the filler material 18 from the pockets. However, in some embodiments, a material with a greater sheer force can be selected to reduce the amount and/or ease of movement of the filler material within the pocket.

[0032] As illustrated, the foam blocks are roughly the same size as the pockets. However, the foam can be made slightly larger or smaller than the size of the pockets. For example, in some embodiments the pockets are designed to fit snuggly over the foam to provide a firm feel. In other embodiments, the pockets are not as snug to provide a softer feel.

[0033] The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention. For example, some embodiments of the invention have been described with reference to specific types of filler material, such as highly resilient foam and visco-elastic foam. However, the type and shape of the filler material may be different, without departing from the scope of protection. Furthermore, some embodiments referenced a specific pocket construction in specific locations on the mattress. The specific construction of the pocket relative to the location of the pocket can vary without departing from the scope of protection.

[0034] Variations and modifications of the foregoing embodiments are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. For example, various alternatives to the certain features and elements of the present invention are described with reference to specific embodiments of the present invention. With the exception of features, elements, and manners of operation that are mutually exclusive of or are inconsistent with each embodiment described above, it should be noted that the alternative features, elements, and manners of operation described with reference to one particular embodiment are applicable Io the other embodiments. All of these different combinations constitute various alternative aspects of the present invention.

[0035] Various features of the invention are set forth in the following claims.

Claims

I claim:

1. A futon mattress comprising: a cover having a top portion coupled to a bottom portion; a closure device positioned between the top portion and the bottom portion; a first layer of pockets positioned along the top portion of the cover; a second layer of pockets positioned along the bottom portion of the cover; and filler material positioned within the first layer of pockets and the second layer of pockets.

2. The futon mattress of claim 1, wherein the cover having a top portion is selectively coupled to the bottom portion.

3. The futon mattress of claim 1 or of claim 2, wherein the closure device is coupled to the cover to selectively allow access to inside surfaces of the top and bottom portions of the cover.

4. The futon mattress of any of claims 1-3, wherein the closure device is movable to selectively allow the top portion to uncouple from the bottom portion.

5. The futon mattress of any of claims 1 -4, wherein the first layer of pockets comprise a plurality of pockets positioned along an inside surface of the top portion of the cover and containing a filler material accessible only from inside the cover.

6. The futon mattress of any of claims 1-5, wherein the second layer of pockets comprise a plurality of pockets positioned along an inside surface of the bottom portion of the cover and containing a filler material accessible only from inside the cover.

7. The futon mattress of any of claims 1-6, wherein the top and bottom portion of the cover each have a length and a width, and wherein the first layer of pockets are positioned side-by-side along the length to substantially cover the top portion of the cover.

8. The fiiton mattress of claim 7, wherein the first layer of pockets substantially cover an inside surface of the top portion of the cover.

9. The futon mattress of claim 7, wherein each pocket of the first layer of pockets extends substantially across the width of the cover.

10. The futon mattress of claim 7, wherein the second layer of pockets are positioned side-by-side along the length to substantially cover the bottom portion of the cover.

11. The futon mattress of claim 10, wherein the second layer of pockets substantially cover an inside surface of the bottom portion of the cover.

12. The futon mattress of claim 10, wherein each pocket of the second layer of pockets extends substantially across the width of the cover.

13. The futon mattress of claim 1, wherein the filler material for the first layer of pockets is a first filler material, said first filler material primarily consisting of a viscoelastic foam.

14. The futon mattress of claim 13, wherein the first filler material comprising the viscoelastic foam filler material for each pocket is contained within a fabric covering.

15. The futon mattress of claim 13, wherein the filler material for the second layer of pockets is a second filler materiel, said second filler material being different than the first filler material in the first layer of pockets.

16. The futon mattress of claim 15, wherein the second filler material for each pocket of the second layer of pockets is contained within a fabric covering.

17. The futon mattress of claim 15, wherein the second filler material for the second layer of pockets primarily consists of a non-viscoelastic foam.

18. The futon mattress of claim 1, further comprising a zipper on each pocket in the first layer of pockets to selectively open and close each pocket to allow the filler material to be selectively removed, the zipper being accessible only from inside the cover.

5

19. The futon mattress of claim 1, wherein the closure device is a zipper.

20. The futon mattress of claim 1, wherein each pocket of the first and second layer of pockets is accessible only from inside the cover to remove the filler material.

10

21. A futon mattress comprising: a cover having a top portion coupled to a bottom portion; a closure device coupled to the cover to selectively allow access to inside surfaces of the top and bottom portions of the cover;

15 a first plurality of pockets positioned along an inside surface of the top portion of the cover and containing a filler material accessible only from inside the cover; and a second plurality of pockets positioned along an inside surface of the bottom portion of the cover and containing a filler material accessible only from inside the cover.

20 22. The futon mattress of claim 21, wherein the top and bottom portion of the cover each have a length and a width, and wherein the first plurality of pockets are positioned side-by-side along the length to substantially cover the inside surface of the top portion of the cover.

25 23. The futon mattress of claim 22, wherein each pocket of the first plurality of pockets extends substantially across the width of the cover.

24. The futon mattress of claim 22, wherein the second plurality of pockets are positioned side-by-side along the length to substantially cover the inside surface of the 30 bottom portion of the cover.

25. The futon mattress of claim 24, wherein each pocket of the second plurality of pockets extends substantially across the width of the cover.

26. The futon mattress of claim 21, wherein the filler material for each pocket is 5 contained within a fabric covering.

27. The futon mattress of claim 21, wherein the filler material contained within each pocket of the first plurality of pockets comprises a viscoelastic foam

10 28. The futon mattress of claim 21 , wherein the filler material for the second plurality of pockets is different than the viscoelastic foam filler material in the first layer of pockets.

29. The futon mattress of claim 21, further comprising a zipper on each pocket in the first plurality of pockets to selectively open and close each pocket to allow the filler

15 material to be selectively removed, the zipper being accessible only from inside the cover.

30. The futon mattress of claim 21 , wherein the closure device is a zipper coupled to the cover.

20 31. The futon mattress of claim 30, wherein the zipper is positioned along at least a portion of an interface between the top portion and the bottom portion.

32. The futon mattress of claim 21 , wherein the closure device is positioned along an interface between the top portion and the bottom portion to selectively allow the top

25 portion to be uncoupled from the bottom portion of the cover.

33. A futon mattress comprising: a cover having a top surface coupled to a bottom surface, the top and bottom surface of the cover each have a length and a width;

30 a zipper positioned along an interface between the top surface and the bottom surface of the cover to selectively allow the top surface to uncouple from the bottom surface; a first plurality of pockets positioned along an inside surface of the top of the cover and containing a first filler material accessible only from inside the cover, the first plurality of pockets positioned side-by-side along the length of the top of the cover; and a second plurality of pockets positioned along an inside surface of the bottom of the cover and containing a second filler material accessible only from inside the cover, the second plurality of pockets positioned side-by-side along the length of the bottom of the cover.