AIR MATTRESS
An air mattress (10) has an upper face (11) forming a sleep surface, a lower face (12) and a plurality of side faces (13, 14, 15, 16) each extending between the upper face (11) and lower face (12). A generally planar sleep panel (20) defines the upper face (11). A peripheral skirt (30) is attached to the sleep panel (20) around a perimeter of the sleep panel (20). The skirt (30) defines the side faces (13, 14, 15, 16). A frame (40) is located within the skirt (30), and includes a plurality of frame elements (40). Each frame element (41) extends parallel and adjacent to one of the side faces (13, 14, 15, 16). The frame elements (41) together define a central cavity (42). A base cover (50) defines the lower face (11). The base cover (50) is attached to the skirt around a perimeter of the base cover (50). One or more inflatable bladders (60) are located within the cavity (42). An intermediate panel (70) is located between the sleep panel (20) and the bladder(s) (60). In one embodiment, the base cover (50) and intermediate panel (70) are low-stretch, and the intermediate panel (70) is attached to the frame (40) around a peripheral region of the intermediate panel (70). In one embodiment, the base cover (50) is detachably attached to the skirt (30), typically with a zipper (51).
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The present invention relates to a mattress. In particular, the present invention relates to an air fillable mattress.
BACKGROUND OF THE INVENTIONMany types of mattresses are known having various internal compositions and characteristics. The present market is moving away from traditional inner-spring mattresses which are heavy to transport and are known to wear unevenly over time.
Mattress trends in recent years have been towards construction from solid latex or solid viscoelastic foam. One disadvantage with latex and viscoelastic foam mattresses is that they do not readily permit different regions of the mattresses upper sleep layer to provide different firmness and support characteristics. Accordingly, when two people are sharing a mattress, a compromise is required between their individual preferences of firmness and support.
A further disadvantage with solid latex or viscoelastic foam mattresses is that they can provide excessive insulation which can be particularly problematic for people that generate large amounts of heat during sleep. The accumulation of heat during the night may cause discomfort and reduce the quality of sleep experienced by a user.
More recently air mattresses have been proposed. Existing air mattresses have a generally hollow mattress body defined by a base connected to four generally vertical side walls, defining a central cavity. One or more inflatable air bladders are typically located within the mattress cavity, and a padding and insulating layer is then placed over the air bladder(s). The padded layer is then covered with a tufted sleep layer which is fastened to the periphery of the side walls of the mattress with a zipper.
In the event that the user of the mattress desires a different mattress firmness or support level, the internal air pressure within the bladder can be selectively altered. In addition, different regions of the mattress sleep surface can be adjusted to different levels firmness by providing multiple air bladders within the mattress cavity. A disadvantage of existing air mattresses is that the zipper seam is highly visible and it may be difficult to match the zipper colour with the colour of the mattress fabric. This can result in the unsightly zipper seam being easily observed in the assembled mattress.
A further disadvantage of existing air mattresses is that the upper tufted sleep layer generally stretches and/or warps as the mattress ages. This permits the sleep layer to increase in area and the side walls may accordingly buckle outwardly. This may result in a deterioration of the quality and comfort provided by the upper sleep layer. The visual effect of the buckled side walls may also be unpleasant to some mattress users and the mattress may become unsuitable for use with fitted sheets and manchester.
A still further disadvantage of existing air mattresses is that the internal insulating layer is loose relative to the structural support components of the mattress, in order to provide access to the bladder when the sleep layer is removed. Accordingly, the insulating layer may move relative to the structural support components over time which can result in deterioration of the mattresses comfort and appearance.
OBJECT OF THE INVENTIONIt is the object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages, or at least to provide a useful alternative to existing air mattresses.
SUMMARY OF THE INVENTIONIn a first aspect, the present invention provides an air mattress having an upper face forming a sleep surface, a lower face and a plurality of side faces each extending between said upper face and said lower face, said air mattress comprising:
a generally planar sleep panel defining said upper face;
a peripheral skirt attached to said sleep panel around a perimeter of said sleep panel, said skirt defining said side faces;
a frame located within said skirt, said frame including a plurality of frame elements, each frame element extending parallel and adjacent to one of said side faces, said frame elements together defining a central cavity;
a low-stretch base cover defining said lower face, said base cover being attached to said skirt around a perimeter of said base cover;
one or more inflatable bladders located within said cavity; and
a low-stretch intermediate panel located between said sleep panel and said bladder(s), said intermediate panel being attached to said frame around a peripheral region of said intermediate panel.
In the context of the present specification, the term “low-stretch” in relation to a cover, panel, layer or other element, means that the element only has a very limited ability to be stretched beyond its original dimensions when subjected to typical service loads and envisages the use of materials known in the art as “non-stretch” materials.
Typically, said intermediate panel is bonded to said frame.
In a preferred embodiment, said intermediate panel comprises a compressible insulating layer and a low-stretch, non-tufted, woven or knitted fabric layer laminated to said compressible layer, said fabric layer being bonded to said frame around a peripheral region of said fabric layer.
The fabric layer of said intermediate panel may comprise yarns formed of one or more materials selected from the group consisting of cotton, polyester, polypropylene, viscose, cashmere, silk, bamboo, rayon and wool.
The base cover is typically detachably attached to said skirt, in one form with a zipper.
Preferably, said base cover comprises a low-stretch, non-tufted, woven fabric layer.
The skirt is typically bonded to said frame.
Preferably, said sleep panel is tufted.
In one form, said sleep panel is fixed to said intermediate panel around a peripheral region of said sleep panel.
The sleep panel may comprise multiple laminated layers.
The air mattress may further comprise one or more cushioning layers located between said intermediate panel and said sleep panel.
The air mattress may have two said bladders arranged in parallel side by side relation in said cavity. A rail member may be located in said cavity between said bladders.
Typically, said side faces, said upper face and said lower face define a rectangular prism.
In a second aspect, the present invention provides an air mattress having an upper face forming a sleep surface, a lower face and a plurality of side faces each extending between said upper face and said lower face, said air mattress comprising:
a generally planar sleep panel defining said upper face;
a peripheral skirt fixedly attached to said sleep panel around a perimeter of said sleep panel, said skirt defining said side faces;
a frame located within said skirt, said frame including a plurality of frame elements, each frame element extending parallel and adjacent to one of said side faces, said frame elements together defining a central cavity;
a base cover defining said lower face, said base cover being detachably attached to said skirt around a perimeter of said base cover;
one or more inflatable bladders located within said cavity; and
an intermediate panel, comprising an insulating compressible layer, located between said sleep panel and said bladder(s), said intermediate panel extending across said recess.
The intermediate panel is typically attached to said frame around a peripheral region of said intermediate panel.
Typically, said base cover is detachably attached to said skirt with a zipper.
The zipper is preferably located on said lower face.
The skirt may comprise a primary skirt portion defining said side faces and a flap depending from a lower edge of said primary skirt portion and extending at least partly across a lower face of said frame.
Preferably, said primary skirt portion and said flap are each bonded to said frame.
Preferably, said zipper is fixed to said flap.
Preferred embodiments of the present invention will now be described, by way of example only with reference to the accompanying drawings in which:
The air mattress 10 includes a generally planar sleep panel 20 which defines the upper face 11. A peripheral skirt 30 is attached to the sleep panel 20 around a perimeter of the sleep panel 20 and defines the side faces 13, 14, 15, 16. An internal frame 40 is located within the skirt 30. The frame 40 includes four frame elements in the form of elongate foam beams 41. Each foam beam 41 extends parallel and adjacent to one of the side faces 13, 14, 15, 16 and the foam beams 41 together define a rectangular enclosure having a central cavity 42. Depending upon the specific geometric configuration of the air mattress, varying numbers of foam beams may be utilised as required to form the desired shape, which will also be reflected in the shape of the central cavity 42. A base cover 50 defines the lower face 12 and is attached to the skirt 30 around a perimeter of the base cover 50.
Two inflatable bladders 60 are located in the cavity 42 in a side-by-side relation, providing separate sleep regions for two people sleeping side-by-side on the air mattress 10 when configured as, for example, a double, queen or king sized mattress. For single bed configurations, a single bladder 60 only would typically be provided. Each bladder 60 is separately fillable with air through an air valve 61 connected to an air compressor or pump (not shown). Accordingly, the air pressure within each bladder 60 can be set to a different level which permits a different firmness to be set in the two sleep regions of the mattress 10 associated with the two bladders 60. Each bladder 60 may include internal reinforcing walls or stiffening ribs as desired. The two bladders 60 will typically be separated by a centre rail 62 loosely located within the cavity 42.
Filling of the bladder 60 is typically controlled by a control unit (not shown) which may be fitted to bed furniture, (such as the bed frame) by way of a remote control unit operating on infra-red radio-frequency or other signal transmission system. The control system communicates with the valve and the pump or compressor. In configurations utilising more than one bladder 60, each bladder 60 may be controlled by a separate control unit, and a receiver control unit may be provided having settings for multiple bladders 60.
An intermediate panel 70 is located between the sleep panel 20 and the bladders 60 and extends across the cavity 42. A base panel 80 may also be provided between the bladders 60 and the base cover 50.
Construction of the air mattress 10 and specific features of each of the elements of the air mattress will now be described with reference to
In the arrangement depicted, the intermediate panel 70 is a laminated structure comprising a compressible insulating layer 71 and a low-stretch non-tufted, woven fabric layer 72. The compressible insulating layer 71 is laminated to the woven fabric layer 72 by bonding with a suitable adhesive. The compressible insulating layer 71 may be in the form of a polyurethane foam, latex, open woven fabric, or other such insulating compressible material which will typically be relatively stretchable in isolation. In the arrangement depicted, the compressible insulating layer 71 is formed of a 24 mm thick polyurethane foam. The compressible insulating layer provides both cushioning and insulating properties to the mattress 10. The compressible insulating layer 71 dissipates heat away from the user's body, and keeps the user insulated relative to the air within the bladders 60. Noise insulation is also provided to reduce transmission of noise, caused by filling/discharge of the bladders 60 and by either bladder 60 rubbing against the frame 40 and central rail 62.
The woven fabric layer 72 may comprise woven yams formed from one or more of any of various low-stretch materials, including cotton, polyester, polypropylene, viscose, cashmere, silk, bamboo, rayon, wool or the like. In the particular arrangement depicted, the woven fabric layer 72 is made from a blended yarn comprising 51.9% cotton, 27.6% polyester and 20.5% polypropylene with a weight of 200.6 gsm (g/m2). The fabric layer 72 might alternatively be knitted rather than woven. The woven fabric layer 72 provides structural rigidity to the mattress 10, retaining the structural shape of the frame 40.
The woven fabric layer 72 is slightly broader and longer than the compressible insulating layer 71, such that an edge region 73 of the woven fabric layer 72 overhangs the perimeter of the compressible insulating layer 71.
The foam beams 41 are typically formed of high density polystyrene foam, which may suitably have a density of the order of 31 kg/m3. The frame 40 is formed in situ on the intermediate panel 70 in an inverted position, specifically on the exposed face of the woven fabric layer 72, by positioning each of the foam beams 41 of the frame 40 adjacent an edge of the intermediate panel 70, with the overhanging edge region 73 of the woven fabric layer 72 projecting beyond the outer face 43 of each foam beam 41. Each foam beam 41 is attached to the intermediate panel 70, typically by adhesively bonding each foam beam 41 to the exposed face of the woven fabric layer 72. The foam beams 41 may alternatively be attached to the intermediate panel by stitching, welding or any other such permanent attachment. The edge region 73 of the woven fabric layer 72 is then folded over the outer face 43 of each foam beam 41 and adhesively bonded thereto. The frame 40 and intermediate panel 70 when assembled together define a structural mattress box.
Referring to
Referring to
Referring back to
The base panel 80 is typically formed of a compressible foam, for example, a polyurethane or polyester foam, with a thickness of the order of 25 mm so as to isolate the bladders 60 from the mattress foundation (such as a bed frame or ensemble base) on which the air mattress 10 would typically be located in use, thereby protecting the bladders 60 from any otherwise potentially damaging projections or the like in the foundation.
Referring next to
The base cover 50 may be fitted with straps, hooks or other such fasteners (not shown) in order to integrate the air mattress 10 with a strapping system for raising a portion of the air mattress 10 relative to a horizontal plane, for example to provide distinct sitting and laying modes of air mattress 10 inclination.
The partly assembled mattress is then turned over into the upright position and, as depicted in
The sleep panel 20 is designed to provide an aesthetically pleasing appearance and to provide a comfortable sleep surface. The sleep panel 20 will typically be a laminated structure, an example of which is depicted in
Referring to
The fully assembled air mattress 10 has a substantially identical appearance to other common forms of mattress, with only the sleep panel 20 and skirt 30 being readily visible by locating the zipper 51 (or other detachable attachment means) between the skirt 30 and base cover 50. The low-stretch characteristics of both the intermediate panel 70 and base cover 50, which are each attached to the frame and/or skirt, also provide for improved structural rigidity of the air mattress, with the low-stretch intermediate panel 70 particularly inhibiting deformation of the frame 40 as a result of stretching or warping of the sleep panel 20. The intermediate panel 70 also inhibits sinking of the sleep panel 20 into the cavity 42 when either bladder 60 is set at a low pressure which would otherwise deform the sleep surface of the air mattress 10.
In scenarios where the visibility of the zipper 51, or access to the cavity 42, is not of concern, it is envisaged that the sleep panel 20 and intermediate layer 70 may be secured to the frame 40 and/or skirt 30 by way of zippers, thereby providing access to the bladders 60 when the air mattress 10 is in the upright position.
Further, where structural rigidity of the air mattress 10 and displacement of the intermediate layer 70 is not of such concern, it is envisaged that the low-stretch non-woven fabric layer 72 of the intermediate panel 70 might be omitted, potentially with the compressible insulating layer 71 merely extending across the cavity 42 without being attached to the frame 40.
It is also envisaged that alternate versions of the air mattress 10 may be provided with pillowtop configurations and the like, for users desiring additional comfort/cushioning layers. Such an alternate air mattress 10′ is depicted in the fragmentary, cross-sectional view in
Although the invention has been described with reference to two specific embodiments, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.
Claims
1. An air mattress having an upper face forming a sleep surface, a lower face and a plurality of side faces each extending between said upper face and said lower 5 face, said air mattress comprising:
- a generally planar sleep panel defining said upper face;
- a peripheral skirt attached to said sleep panel around a perimeter of said sleep panel, said skirt defining said side faces;
- a frame located within said skirt, said frame including a plurality of frame elements, each frame element extending parallel and adjacent to one of said side faces, said frame elements together defining a central cavity;
- a low-stretch base cover defining said lower face, said base cover being attached to said skirt around a perimeter of said base cover;
- one or more inflatable bladders located within said cavity; and
- a low-stretch intermediate panel located between said sleep panel and said bladder(s), said intermediate panel being attached to said frame around a peripheral region of said intermediate panel.
2. The air mattress of claim 1, wherein said intermediate panel is bonded to said frame.
3. The air mattress of claim 1, wherein said intermediate panel comprises a compressible insulating layer and a low-stretch, non-tufted, woven or knitted fabric layer laminated to said compressible layer, said fabric layer being bonded to said frame around a peripheral region of said fabric layer.
4. The air mattress of claim 3, wherein said fabric layer of said intermediate panel comprises yarns formed of one or more materials selected from the group consisting of cotton, polyester, polypropylene, viscose, cashmere, silk, bamboo, rayon and wool.
5. The air mattress of claim 1, wherein said base cover is detachably attached to said skirt.
6. The air mattress of claim 5, wherein said base cover is detachably attached to said skirt with a zipper.
7. The air mattress of claim 1 wherein said base cover comprises a low-stretch, non-tufted, woven fabric layer.
8. The air mattress of claim 1, wherein said skirt is bonded to said frame.
9. The air mattress of claim 1, wherein said sleep panel is tufted.
10. The air mattress of claim 1, wherein said sleep panel is fixed to said intermediate panel around a peripheral region of said sleep panel.
11. The air mattress of claim 1, wherein said sleep panel comprises multiple laminated layers.
12. The air mattress of claim 1, further comprising one or more cushioning layers located between said intermediate panel and said sleep panel.
13. The air mattress of claim 1, having two said bladders arranged in parallel side by side relation in said cavity.
14. The air mattress of claim 13, further comprising a rail member located in said cavity between said bladders.
15. The air mattress of claim 1, wherein said side faces, said upper face and said lower face define a rectangular prism.
16. An air mattress having an upper face forming a sleep surface, a lower face and a plurality of side faces each extending between said upper face and said lower face, said air mattress comprising:
- a generally planar sleep panel defining said upper face;
- a peripheral skirt fixedly attached to said sleep panel around a perimeter of said sleep panel, said skirt defining said side faces;
- a frame located within said skirt, said frame including a plurality of frame elements, each frame element extending parallel and adjacent to one of said side faces, said frame elements together defining a central cavity;
- a base cover defining said lower face, said base cover being detachably attached to said skirt around a perimeter of said base cover;
- one or more inflatable bladders located within said cavity; and
- an intermediate panel, comprising an insulating compressible layer, located between said sleep panel and said bladder(s), said intermediate panel extending across said cavity.
17. The air mattress of claim 16, wherein said intermediate panel is attached to said frame around a peripheral region, of said intermediate panel.
18. The air mattress of claim 16, wherein said base cover is detachably attached to said skirt with a zipper.
19. The air mattress of claim 16, wherein said zipper is located on said lower face.
20. The air mattress of claim 19, wherein said skirt comprises a primary skirt portion defining said side faces and a flap depending from a lower edge of said primary skirt portion and extending at least partly across a lower face of said frame.
21. The air mattress of claim 20, wherein said primary skirt portion and said flap are each bonded to said frame.
22. The air mattress of claim 20, wherein said zipper is fixed to said flap.
Type: Application
Filed: Oct 15, 2007
Publication Date: Nov 18, 2010
Applicant:
Inventors: Allyn Beard (Gymea Bay), Rick Darnell Robinson (Pyrmont)
Application Number: 12/445,626
International Classification: A47C 27/08 (20060101);