EXTENDABLE AND/OR EXPANDABLE FOAM PANEL CONSTRUCTIONS

Abstract

By forming a plurality of separate, spaced, expansion zones in preselected areas of a foamed plastic product having a desired size and shape, a new foam plastic product is achieved which is capable of being expanded or extended in at least one direction during its use in order to accommodate dimensional changes or requirements. By forming the expansion zones in a precisely desired pattern which extends over a substantial portion of the foam plastic product, the resulting product is capable of being expanded, extended, or adjusted in at least one of its dimensions. In this way, the resulting product is quickly and easily expanded or extended in one direction to fit any desired application surface with ease and simplicity.

Description

RELATED APPLICATIONS

This application is related to U.S. Provisional Patent Application Ser. No. 61/125,986, filed Apr. 29, 2008 entitled “EXTENDABLE AND/OR EXPANDABLE FOAM PANEL CONSTRUCTIONS.”

TECHNICAL FIELD

This invention relates to enlarged, foam panel constructions and, more particularly, to enlarged foam constructions which are capable of being expanded or extended in at least one dimension whenever desired.

BACKGROUND ART

Throughout the years, an ever increasing variety of products and product areas have benefitted from the use of foam plastic materials. In this regard, product manufacturers, suppliers, and/or shippers have found that foam plastic products, materials, and profiles can be employed for improving the quality of the product being produced, as well as for substantially improving packing materials and product safety panels which are commonly used in product protection during shipment. Furthermore, due to the unique nature of foam plastic products and the ability of these products to be formed in various sizes, shapes, and configurations, these products have enjoyed increased acceptance and use.

As the abilities, capabilities, and versatility of foam plastic material became known to individuals and corporate entities, the popularity of foam plastic products substantially increased, along with the wide variety of product areas and purposes for which foam plastic products were employed. In this regard, foam plastic material has been used for protecting small fragile products such as those made from glass, as well as protecting large products made from metal or similar materials, such as refrigerators, stoves, and the like. In these large products, foam plastic panels are often employed to peripherally surround the product and protect the outer surfaces of the product.

In addition, foam plastic materials have also been employed in numerous other products as an integral components of the product. In this area, furniture, bedding, and mattresses have employed foam plastic materials as an integral component incorporated into the product structure itself. In this instance, foam plastic materials have proven to be effective in providing support and integrity to the product as a replacement for components which are more expensive and more difficult to employ.

In spite of the fact that foam plastic products have gained wide acceptance and use in a wide variety of applications, industries, and product areas, it has been recognized that the use of foam plastic products in many areas can be improved due to inherent physical characteristics of the foam plastic materials. In this regard, one of the principal difficulties encountered with the use of foam plastic materials is the difficulty in controlling the dimensions of the foam plastic material during production, in order to assure that precisely desired dimensions are attained. This problem has been found in the use of foam plastic panels for protecting large products, as well as in the use of foam plastic panels in furniture products, bedding, and mattresses.

In using large foam plastic panels for these products, the overall size and shape of the foam plastic product is critical in being used on a particular previously manufactured surface. However, during the production of the foam plastic panels, controlling a precise dimensional size has been found to be particularly difficult. As a result, foam plastic panels are often constructed in sizes larger than required, and then cut or trimmed to the dimension needed for a particular application. Although effective, this process is more expensive, since material is cut and thrown away, as well as being time-consuming and labor intensive.

Therefore, it is a principal object of the present invention to provide foam plastic products which are capable of being constructed in a manner which enables the product to possess an expandable or variable capability enabling the size or shape of the product to be flexible in at least one direction.

Another object of the present invention is to provide foam plastic products having the characteristic features described above which is capable of being produced with substantially no increase in manufacturing costs.

A further object of the present invention is to provide foam plastic products having the characteristic features described above wherein the resulting product is capable of being expanded to a desired dimension and automatically locked in that dimension.

Other and more specific objects will in part be obvious and will in part appear hereinafter.

SUMMARY OF THE INVENTION

By employing the present invention, all of the difficulties and drawbacks found in prior art constructions have been overcome and a new, unique, foam plastic product is achieved which is capable of being expanded or extended in at least one direction during its use in order to accommodate dimensional changes or requirements. In this way, foam plastic products of any size or configuration are capable of being employed for a wide variety of alternate purposes or applications due to the capability of the product to be expanded in at least one dimension. As a result, foam plastic products incorporating this construction achieve greater versatility and benefit in numerous industries, applications, and product areas, while also providing ease of use, speed and convenience during the installation process.

In accordance with the present invention, the desired foam plastic product is first produced using conventional manufacturing techniques with the overall configuration, size, and shape desired for the product. Thereafter, the foam plastic product is processed using a desired manufacturing method wherein a plurality of separate, spaced, expansion zones are formed in preselected areas of the product.

By forming the expansion zones in a precisely desired pattern which extends over a substantial portion of the foam plastic product, the resulting product is capable of being expanded, extended, or adjusted in at least one of its dimensions. As a result, without degradation of the integrity of the foam plastic product, the resulting product is quickly and easily expanded or extended in one direction to fit any desired application surface with ease and simplicity, without requiring any trimming, cutting, or laborious procedures for achieving a desired dimension.

Typically, each expansion zone is formed by cutting through the foam product in a predetermined length and pattern relative to adjacent cuts. In this way, predefined areas or cut-out zones are created whenever the foam product is moved in a particular direction.

Although the present invention can be implemented in a wide variety of forms and employed in numerous products and applications, one example of a product which is capable of experiencing substantial improvement in production and manufacture due to the application of the present invention is found in inner spring mattresses. In the production of inner spring mattresses, large foam panels are employed for improving support and longevity of the product. Typically, these large foam panels are placed on the surface of the inner spring assembly, positioned between the inner spring surface and the textile material cover which peripherally surrounds and defines the mattress assembly. In this regard, these large foam panels have been employed and have provided substantially improved mattress products.

Although the prior art foam panels have been successful in improving inner spring mattress assemblies, the construction of these enlarged, extruded foam panels are difficult to manufacture with accurate and repeatable dimensional tolerances. As a result, production difficulties and product installation problems presently exist.

By employing the present invention, all of these prior art difficulties are virtually eliminated and enlarged, extruded, foam panels are capable of being constructed having adjustable or variable dimensions, thereby enabling these panels to be employed as the top supporting panel or surface of a mattress, and placed on the surface of the inner spring and easily secured to the terminating edges of the inner spring assembly. Furthermore, using the enlarged extruded foam panels of the present invention, the panels are merely extended in one dimension in order to assure that the panels extend from one edge of the inner spring to the other edge, completely covering the desired surface and establishing the support for the mattress assembly.

In order to achieve this unique and previously unattainable goal, the enlarged extruded foam panels of the present invention are produced in the generally conventional manner and then exposed to a subsequent manufacturing operation which forms a plurality of zones in the foam panels, which enable the panel to expand and contract in at least one dimension. In this regard, it has typically been found that the expansion zones are formed in enlarged sections, extending from the top edge to the bottom edge of the foam panels. In addition, the width of each expansion zone can be varied and any desired number of expansion zones can be formed at spaced intervals to each other.

Once the expansion zone formation process has been completed, the resulting foam panel construction is capable of being expanded, extended, and contracted in at least one dimension. In particular, when a plurality of expansion zones are formed in the large foam panel extending from the top edge to the bottom edge of the panel, the side edges of the resulting panel are capable of being extended and contracted relative to each other.

As is fully detailed herein, the formation of numerous, separate, and independent expansion zones in spaced relationship to each other creates an elongated, expansion zone bearing section in the panel which is able to be extended and contracted in one dimension due to the ability of each expansion zone to have its size or shape easily increased or decreased. In this way, the enlarged foam panels of the present invention are positioned on the inner spring surface and easily adjusted in one dimension, such as its width, in order to completely extend from one side edge of the inner spring assembly to the other side edge thereof quickly and easily, while also being secured in the desired position. As a result, prior art problems and difficulties are completely eliminated.

In forming the expansion zones of the present invention in the foam panels, each expansion zone can be formed with any desired shape or configuration. In general, the only requirement is that each expansion zone is separate and independent from each adjacent expansion zone, thereby creating an interconnected lattice of foam material which peripherally surrounds the expansion zones and enables the resulting panel structure to be extendable in at least one dimension.

In one embodiment, the interconnected lattice of foam material which peripherally surrounds the expansion zones is formed with an inherent spring force which attempts to maintain each expansion zone in a substantially closed configuration. As a result, the resulting foam panel is normally maintained in a compact configuration, requiring the application of force to extend the foam panel in the desired direction.

When the extending force is applied, the foam panel extends or expands in the desired direction into an overall dimension sought by the user. Furthermore, the increase in the dimension of the foam panel causes each expansion zone to be enlarged as the dimension is increased. However, if the extending force is removed, the foam panel will return to its substantially original configuration due to the inherent spring force of the interconnected lattice of foam material.

In an alternate embodiment, the interconnected lattice of foam material is constructed with a particular configuration which enables the lattice of foam material to move between two specific alternate positions. In a first position, the lattice of foam material provides a spring force which attempts to return the foam panel to its original position. However, in a second position, the lattice of foam material becomes locked or substantially rigid in the second position, resulting in a foam panel which is maintained in a substantially stable overall expanded dimension.

This embodiment has been found to be particularly applicable for use on products or applications where the foam panels peripherally surround and protect a product being transported, and are not typically secured to the product along the edges of the panel. As a result, by achieving a foam panel which is fixed in its overall dimension, the panels are quickly and easily placed in position and maintained where desired, protecting a particular surface of the product.

In an alternate use of this embodiment of the present invention, the panel of foam material can be moved between its compact position and its extended position whenever desired. As a result, the foam panel can be used for various activities or recreational purposes, such as a pool float, with the panel being expanded for use, and contracted into a compact position for storage. In this way, a substantially increased benefit is provided to the consumer.

In producing the enlarged foam panels of the present invention, several alternative construction methods can be employed for forming the foam panel as well as the plurality of expansion zones in the panel member. Although any effective method can be employed, it has been found that the following methods are exemplary of the production systems that can be used to achieve the expandable or extendable foam panel of the present invention.

In this regard, the formation processes for creating the foam panel member preferably comprises one or more selected from the group consisting of extrusion injection molding, rotational molding, compression molding, expansion molding, and casting. In addition, the formation process for achieving the desired expansion zones in the foam panel preferably comprise one or more selected from the group consisting of water jet cutting, rotary die cutting, punch press cutting and laser cutting.

In order to fully understand the construction of the extendable foam panels of the present invention, one of the preferred manufacturing methods is further detailed herein. In this regard, the enlarged foam panel is produced in the normal manner well known in the industry. Once the foam panel has been produced, the foam panel is passed through a cutting die which forms the plurality of expansion zones in the panel member. Typically, these expansion zones are most easily created by forming slots or slits in the foam panel, extending from the top surface to the bottom surface thereof. Furthermore, as detailed above, the expansion zones are formed in the panel in predefined, desired sections of the panel, with each section preferably extending from one edge to the opposed edge thereof.

In a typical construction using this embodiment of the forming process, the cutting die comprises either a rolling cutting die or a flat cutting die which enables the enlarged foam panel to be continuously passed therethrough. In using a rolling cutting die, which has been found to be most efficient in a continuous production operation, a pair of die members are cooperatively associated with each other and constructed with a spaced zone therebetween through which the enlarged foam panel is capable of passing.

With at least one of the cooperating die members incorporating raised cutting elements, the desired slots or slits are formed in the foam panel as the panel passes between the cooperating rolling dies, with the area adjacent to the slots or slits being left intact. In this way, the expansion zones are easily formed along with the interconnected lattice of foam material surrounding the expansion zones.

Furthermore, using this production process, the desired expansion zones are quickly and easily formed in the enlarged foam panel in the precisely desired areas. Furthermore, once the elongated length of the foam panel has passed between the rolling dies, the resulting product is fully produced and ready for packaging and distribution to the user.

As is evident from this disclosure, as well as in the detailed discussion contained below, any desired configuration, shape, or orientation can be employed for forming slots, slits, and resulting expansion zones in the panel members. In one embodiment, the slot, slits and resulting expansion zones can be found randomly while in another alternate embodiment, the slots, slits and resulting expansion zones are formed in a cooperating pattern. However, regardless of the particular configuration employed, the slots, slits, and/or expansion zones are preferably staggered relative to each other in the desired direction in order to produce an integrated lattice of foam material peripherally surrounding the separate and independent expansion zones. In this way, the desired flexibility and expansion capabilities are most effectively achieved.

It has also been found that longitudinally extending, staggered straight slits/slots and/or longitudinally extending, staggered, arcuately curved slits/slots produce the most effective expansion zones and are easily manufactured in a controlled process. Furthermore, in the preferred embodiment, a first row of longitudinally extending staggered, slits/slots are offset relative to the second row of longitudinally extending, staggered slots/slits. If desired, further offset orientations can be employed for one or more additional rows. However, by employing at least two offset rows of slots/slits, a highly effective product is produced with an integrated lattice of foam peripherally surrounding each resulting expansion zone and providing the desired continuous spring force.

Finally, using an alternative construction process of the present invention, a greatly enlarged panel member can be achieved without required large, costly equipment to be employed. In this alternate method, foam panel members are constructed in the manner detailed above and then welded to each other along an adjacent side edge. If two panels are welded together, this resulting product is double the size or area of the original panel. Furthermore, by repeating this process, panels of any size or shape can be economically produced.

The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, as well as the article produced which possesses the features, properties, and relation of elements, which are exemplified in the following detailed disclosure, with the scope of the invention being indicated in the claims.

THE DRAWINGS

For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:

FIG. 1 is a top plan view of one embodiment of the readily extendable/expandable foam panel construction of the present invention;

FIG. 2 is a top plan view of an alternate embodiment of the readily extendable/expandable foam panel construction of the present invention;

FIG. 3 is a top plan view of a further alternate embodiment of the readily extendable/expandable foam panel construction of the present invention;

FIG. 4 is a perspective view of one embodiment of the readily extendable/expandable foam panel construction of the present invention forming an integral component of a mattress construction;

FIG. 5 is a perspective view of an alternate embodiment of the readily extendable/expandable foam panel construction of the present invention configured for use in an alternate mattress construction;

FIG. 6, which comprises FIGS. 6A, 6B, and 6C are all perspective views of an alternate embodiment of the readily extendable/expandable foam panel construction of the present invention, depicting the foam panel in two alternate configurations between a collapsed position and a fully extended position;

FIG. 7, which comprises FIGS. 7A, 7, 7C, and 7D, are perspective views of fragmentary portions of the readily extendable/expandable foam panel construction of the present invention depicting alternate configurations of the panel construction during its movement between a fully compact, collapsed position into a fully extended position;

FIG. 8, which comprises FIGS. 8A, 8B, and 8C are perspective views of various alternate constructions and configurations of a further alternate embodiment of the present invention.

FIG. 9 which comprises FIGS. 9A and 9B are perspective views of an elongated foam profile extrusion and cross-sectional panels cut therefrom depicting the foam panel construction of the present invention in both its fully collapsed position and its fully extended position;

FIG. 10 which comprises FIGS. 10A and 10B are perspective view of a further alternate embodiment of the foam panels of FIG. 12 shown in a collapsed, fully extended position; and

FIG. 11 which comprises FIGS. 11A and 11B are perspective views of an alternate embodiment of the foam panel construction of the present invention shown in a collapsed, fully extended position.

DETAILED DISCLOSURE

By referring to FIGS. 1-11, along with the following detailed description, the preferred construction of several alternate embodiments of the readily extendable/expandable foam panel construction of the present invention can best be understood. In this disclosure, although several alternate constructions and embodiment details are provided, further alternate configurations and constructions can be implemented without departing from the scope of the present invention. Consequently, it is to be understood that the following detailed disclosure is provided for exemplary purposes only and is not intended as a limitation of the present invention.

In FIGS. 1-3, three alternate configurations of readily extendable/expandable foam panel 20 of the present invention are shown. In each of these embodiments, readily extendable/expandable foam panel 20 comprises foam panel member 21 and a plurality of expansion zones or cutout zones 22 formed therein. As shown, each expansion zone 22 extends through foam panel 21, from the top surface thereof to the bottom surface.

In the constructions depicted, each foam panel member 21 comprises a generally rectangular shape defined by top edge 24, bottom edge 25, and side edges 26 and 27. In addition, for purposes of illustration, expansion zones 22 are depicted comprising substantially identical shapes in each of the alternate embodiments. In this regard, each expansion zone 22 comprises a substantially crescent or half moon shape. Although this shape is depicted in the Figures, this shape is provided for exemplary purposes only and, as fully detailed above, expansion zones 22 may comprise any desired size or shape.

As stated above, the only requirement is that each expansion zone 22 comprises a separate and independent zone positioned in spaced relationship to adjacent zones 22. Finally, when expansion zones 22 are formed in foam panel member 21, a fully interconnected lattice 23 of foam material is formed between expansion zones 22 in peripherally surrounding cooperating relationship therewith.

In the embodiments depicted in FIGS. 1 and 2, substantially the entire available surface of foam panel 21 comprises expansion zones 22. In FIGS. 1 and 2, side edges 26 and 27 do not incorporate expansion zones 22, while the embodiment in FIG. 1 also incorporates a plurality of additional longitudinally extending sections which are devoid of expansion zones 22. In addition, as clearly shown in FIGS. 1 and 2, expansion zones 22 are formed in foam panel member 21 extending completely from top edge 24 to bottom edge 25, regardless of the areas which are devoid of expansion zones 22.

In the embodiment depicted in FIG. 3, expansion zones 22 are formed in sections 31 and 32 of foam panel member 21, while the remainder of foam panel member is devoid of expansion zones 22. In addition, the cutout zones or expansion zones 22 formed in sections 31 and 32 extend from top edge 24 to bottom edge 25 directly adjacent side edges 26 and 27.

As is evident to one having ordinary skill in the art, any desired pattern of expansion zones 22 can be formed in foam panel 21 in order to achieve a desired readily extendable configuration. By incorporating expansion zones 22 which substantially cover foam panel 21 in its entirety, the expandability or extendibility of foam panel 20 is optimized. By employing a limited number of sections of expansion zones 22, as depicted in FIG. 3, the overall dimensional extendibility of foam panel 20 is more limited.

Regardless of the configuration employed, readily extendable/expandable foam panel 20 is capable of being dimensionally changed quickly and easily in order to accommodate any desired overall linear distance or dimension. In this regard, by applying a force to side edges 26 and 27 in an attempt to cause edges 26 and 27 to be spaced apart from each other, a user is able to quickly and easily increase the overall width of foam panel 20 to any desired dimension. As a result, by employing the present invention, foam panels are quickly and easily extended or expanded to accommodate any desired dimension for use with the particular product.

In FIG. 4, a typical mattress assembly 35 is depicted which incorporates the present invention. As shown, mattress assembly 35 comprises a support base 36 on which inner spring assembly 37 is positioned. As shown, inner spring assembly 37 comprises a plurality of helically coiled springs mounted in side to side, adjacent relationship with each other. In this embodiment, mattress assembly 35 is completed by placing extendable/expandable foam panel 20 on the top surface of spring assembly 37. Once this assembly is completed, the entire mattress is finalized by securing any desired additional components thereto and then peripherally surrounding the assembly with a cover of textile material to form the desired product.

As is evident from FIG. 4, the ease of constructing mattress assembly 35 using the present invention is readily achieved. As shown therein, extendable/expandable foam panel 20 is positioned on the top surface of spring assembly 37 for providing the top supporting surface of the finally constructed mattress. In completing the secure affixation of extendable/expandable foam panel 20 with spring assembly 37, any dimensional variations between the surface area defined by spring assembly 37 and extendable/expandable foam panel 20 are easily accommodated.

In this regard, once extendable/expandable foam panel 20 is placed on the top surface of spring assembly 37, side edge 26 of foam panel 20 is merely pulled to be coextensive with the terminating edge of spring assembly 37. Once in the desired position, a portion of edge 26 is affixed to the edge of spring assembly 37 by employing a fastener or clip 38. This process is repeated along the entire length of edge 26 until the entire edge is affixed to spring assembly 37. Thereafter, a similar process is employed with edge 27 in order to completely secure foam panel 20 to spring assembly 37.

As is evident from the foregoing detailed discussion by employing extendable/expandable foam panel 20 of the present invention foam panel 20 is quickly and easily securely affixed to spring assembly 37 with assurance that the entire top surface of spring assembly 37 is completely covered by foam panel 20. In addition, the complete coverage of spring assembly 37 is achieved with ease and simplicity in both the installation and manufacture of foam panel 20.

In FIG. 4, mattress assembly 35 is depicted incorporating the components detailed above. In addition to these components, namely foam panel 20, spring assembly 37, and support base 36, mattress assembly 35 also incorporates side edge guard/support number 39. In order to provide a final construction which achieves inherent strength and rigidity along the side edge of the mattress, for reducing buckling over long-term use and providing support for individuals when sitting on the edge of the mattress, most higher-quality mattress assemblies incorporate a side edge guard/support member 39. As depicted, side edge guard/support member 39 is mounted about spring assembly 37, peripherally surrounding the side edges thereof and being securely affixed thereto. In this way, the desired beneficial results are achieved.

In FIG. 5, an alternate embodiment of extendable/expandable foam panel 20 is depicted. In this embodiment, foam panel 20 is constructed in a manner similar to the embodiment detailed above and shown in FIG. 1. However, in this embodiment, side panels 40 and 41 are formed as an integral component of foam panel 20. By employing this embodiment of the present invention, side edge guard/support members 39 are not required and the material and labor needed to affix side edge guard/support members 39 to mattress assembly 35 is completely eliminated.

By employing the embodiment of the present invention depicted in FIG. 5, side panels 40 and 41 are automatically installed at the precisely desired location along the longitudinally extending side edges of spring assembly 37. In this way, by securely affixing expandable/extendable foam panel 20 to spring assembly 37, side panels 40 and 41 are automatically mounted in the precisely desired position, providing inherent support, rigidity, and longevity to the resulting product.

By referring to FIGS. 6-8, along with the following detailed discussion, further alternate embodiments of the present invention can best be understood. As is fully detailed below, in these embodiments of the present invention, expandable/extendable foam panel 20 is constructed in a manner which enables the foam panel to become locked in its opening position after it has been fully extended.

In this way, the panel members manufactured in accordance with this embodiment of the present invention achieve a fixed dimension when fully opened and extended, while also possessing a smaller, second dimension when compacted into its original position. By employing this embodiment of the present invention, the resulting foam panel can be opened to its fully extended position and then placed in cooperating association with a desired surface, without requiring affixation of the foam panel to the product in order to maintain the foam panel in the expanded configuration.

In FIG. 6, one configuration of extendable/expandable foam panel 20 of this embodiment of the present invention is depicted. In this embodiment, readily extendable/expandable foam panel 20 comprises foam panel member 21 and a plurality of expansion zones 22 formed therein. As shown, each cut of zone 22 extends through foam panel 21 from the top surface thereof to the bottom surface.

In this embodiment, each expansion zone 22 comprises a unique configuration which has been specially designed to achieve a uniquely configured lattice 23 of foam material which peripherally surrounds and defines each expansion zone 22. In this regard, lattice 23 of foam material is configured to enable panel member 21 to be extended or expanded in one direction in a manner which causes each cut of zone to become enlarged.

In this regard, this embodiment of the present invention operates in a manner similar to the embodiment detailed above. However, the unique aspect of this embodiment of the present invention provides lattice 23 of foam material with a unique configuration which causes the lattice to become rigid or fixed in its configuration once panel member 21 has been opened to a specific overall dimension. In this way, foam panel 20 is effectively locked in its open position.

In achieving this configuration, lattice 23 of foam material is constructed to possess a spring biasing force similar to the spring forces possessed by foam panel 20 detailed above. However, in this embodiment, lattice 23 is also constructed to automatically shift from providing a flexible, spring biasing force to being rigid, fixed, or locked in its open position, preventing foam panel 20 from automatically moving into a compact position.

Foam panels 20 manufactured in accordance with this embodiment of the present invention are fully depicted in FIGS. 6 and 7. As shown therein, two alternate configurations for expansion zones 22 are provided. However, in each of these alternate embodiments, lattice 23 of foam material is constructed to become fixed or rigid whenever panel 20 has been expanded beyond a particular dimension. As a result, extendable/expandable foam panels 20 are capable of being maintained in a fully compact position, as shown in FIGS. 6A and 7A, and extended or expanded to an open configuration, as shown in FIGS. 8B and 7D. However, whenever foam panel 20 has been opened to its substantially full extent, as depicted in FIG. 7C, lattice 23 of foam material becomes rigid or fixed in its configuration, maintaining panels 20 in a substantially rigid, open position.

In addition, as shown in FIG. 6C, foam panel 20 is preferably constructed for simultaneously providing both a locked and unlocked configuration. As depicted, the upper and lower portions of panel 20 have lattice 23 in its fully extended and locked position, while the middle portion of foam panel 20 is not fully extended. As a result, the side edges of foam panel 20 become arcuately curved.

Due to the ability of lattice 23 to become automatically locked in its fully extended position, the configuration depicted in FIG. 6C is maintained, until a force is applied to panel 20 to return panel 20 into its compact position. As a result, the dual locking, multi-purpose versatility nature of panel 20 is clearly evident.

When panel 20 is in the configuration depicted in FIG. 6C, lattice 23 of the foam material is effectively locked throughout panel 20. In this regard, whenever the foam elements forming lattice 23 are expanded sufficiently to cause the elements to pivot beyond 180°, the elements become locked. However, the amount of force required to reverse the locked configuration varies with the position of lattice 23, with the most force being required when the foam elements of lattice 23 are fully extended.

Although lattice 23 of foam material is constructed to maintain panel 20 in a fixed, rigid, open position when panel 20 is fully extended, lattice 23 of foam material is also configured to be reversible. Consequently, whenever desired, the side edges above foam panel member 21 can be advanced towards each other, causing lattice 23 of foam material to return to its original position, with expansion zones 22 returning to their substantially closed and collapsed configuration. In this way, readily extendable/expandable foam panel 20 of this embodiment of the present invention can be employed for a wide variety of alternate applications in its fully extended configuration, while also being quickly and easily returned to its small, compact configuration for storage or shipment.

This unique construction is fully depicted in FIG. 7, wherein foam panel portion 20 is depicted in four alternate extended positions in order to illustrate exactly how the “locking segments” operate. Once the lockable expansion segments are created in foam panel 20, regardless of the manufacturing process, these segments are considered “at rest” (or in a relaxed state) as shown in FIG. 7A. As the two ends of foam panel 20 are pulled apart in opposite directions, the lockable expansion segments begin to separate and open up. However, there is a spring force at work, which attempts to pull the segments back to a closed position (see FIG. 7B). As the two ends of the foam panel are pulled even further apart, the lockable expansion segments reach a postion where they have pivoted to a mid-way point and the spring force begins to decrease as the foam segments now begin to compress against each other with vertical force (see FIG. 7C). Now, as the expansion segments pivot past the mid-way point, the vertical force of the foam segments pressing against one another and begins to force the segments into a subsequently open position (see FIG. 7D) and completely removes the original spring force that was present in FIG. 7B. The expansion segments are now “locked” into an open configuration (see FIG. 7D).

Another unique aspect of this embodiment of the present invention is the substantial expansion distance that can be achieved using the present invention. As diagrammatically depicted in FIG. 7, extendable/expandable foam panel 20 is capable of being altered from a compact configuration (FIG. 7A) to an elongated, substantially enlarged configuration (FIG. 7D). In addition, a plurality of alternate expansion distances can be achieved between the two extremes.

In this regard, it has been found that expansion distances ranging between every one foot width of foam panel 20, panel 20 can be expanded to a width ranging between about 2.25 and 2.8 feet in width. As a result, one extendable/expandable foam panel 20 is capable of being employed for use with a wide variety of various products having different dimensions. Although the dimensions of the product may vary, the capability of foam panel 20 of the present invention to be adjusted to accommodate numerous alternate dimensions enables a single foam panel to be used with a wide variety of differently sized end products.

In FIG. 8, several alternate views are provided of a further alternate foam panel product which is capable of enjoying the benefits achieved by extendable/expandable foam panel 20. In this embodiment, a water toy or float construction 50 is attained wherein extendable/expandable foam panel 20 incorporates longitudinally extending, cylindrically shaped foam tubes 51 and 52 intergrally formed along the side edges of the panel 20. By employing this construction, a float configuration is realized which is capable of being quickly and easily converted from a small compact configuration into an enlarged, fully extended, body supporting configuration for use as a pool water float.

As shown in FIG. 8, extendable/expandable foam panel 20 incorporates a plurality of expansion zones 22 forming lattice 23 of foam material therebetween. As detailed above, the size and shape of expansion zones 22 are configured to establish lattice 23 of foam material which enables foam panel 20 to possess two separate and distinct properties or physical characteristics.

One of the properties possessed by foam panels 20 of this embodiment of the present invention is a spring biasing force which actively attempts to return foam panel 20 to its original compact position during its initial stages of being extended or expanded. However, whenever foam panel 20 has been extended or expanded to a pre-defined dimension, the configuration of lattice 23 of foam material created by expansion zones 22 causes foam panels 20 to become locked, fixed, or rigid in its fully extended or expanded position. In this way, the float construction 50, or any other resulting product, maintains a specific dimension whenever panel 22 has been fully extended.

As a result, the float construction 50 can be used in the desired manner with complete assurance that the overall width of the product will be maintained throughout its use. Furthermore, when use has been completed, float construction 50 is returned to its original collapsed position by merely exerting a closing pressure on the side edges of foam panel 20. In this way, expansion zones 22 return from a fully open position to their collapsed, closed configuration, enabling float construction 50 to be storable in its small, compact configuration.

By referring to FIG. 9, along with the following detailed discussion, an alternate method for manufacturing extendable/expandable foam panels 20 can best be understood. In this manufacturing method, an elongated foam profile 60 is extruded using generally conventional foam profile extrusion equipment. In addition, in this embodiment, cuts, slits, or open areas 61 are formed in foam profile 60 as an integral part of the extrusion process by forming the extrusion die in a desired manner. By incorporating cuts, slits, or open areas 61 in foam profile 60, the entire foam profile 60 is capable of being extended or expanded in at least one direction, since cuts, slits, or open areas 61 create or form the desired expansion zones whenever foam profile 60 is extended or expanded.

If desired, elongated foam profile 60 can be employed in the configuration achieved from the extrusion process. However, it has been found that this manufacturing method can be most effectively employed by forming a plurality of segments 65 from an elongated foam profile 60. In this regard, segments 65 are quickly and easily created by merely cutting elongated foam profile 60 perpendicularly to the central axis thereof, effectively achieving a cross-sectional segment 65 having a desired thickness.

As depicted in FIG. 9B, each cross-sectional segment 65 is easily produced and is capable of being quickly and easily extended or expanded by merely pulling the side edges thereof in opposite directions. In this way, the overall width of section 65 is extended or expanded, while cuts, slits, or open zones 61 formed therein are converted into expansion zones 67, with lattice 68 of foam material peripherally surrounding expansion zones 67. In the configuration depicted in FIG. 9, cuts, slits, or open zones 61 are constructed with the design detailed above which achieves expansion zones 67 that are automatically converted from a construction having an inherent spring biasing return force to a construction which when fully extended becomes locked In its open position.

In FIG. 10, a further alternate embodiment of the present invention is depicted. In this embodiment, elongated foam profiles 60 are constructed as detailed above and shown in FIG. 12, and then subsequently welded in adjacent, side to side relationship with a cooperating elongated foam profile 60. The resulting product is depicted in FIG. 10, wherein three separate elongated foam profiles 60 have been welded to each other.

Thereafter, in an alternative embodiment of the present invention, elongated sections of the resulting welded profile are formed, effectively achieving an elongated foam cross-section having three sections 65 welded to each other. In this way, a final structure is realized which possesses any desired length. As a result, an enlarged longitudinally extending product is achieved having virtually any desired dimension which is able to be manufactured both expeditiously and economically.

Finally, in FIG. 11, a further alternate embodiment of expandable/extendable foam panel 20 is depicted. In this embodiment, foam panel 20 is constructed with cuts, slits, and open zones 70 formed in foam panel 20 extending both horizontally and vertically. By employing this construction, foam panel 20 can be extended or expanded in two mutually exclusive directions, depicted in FIG. 11 as both horizontal expansion and vertical expansion. Although FIG. 11 depicts cuts, slits, and open zones 70 being formed perpendicular to each other, any desired angular relationship can be employed without departing from the scope of this invention.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently obtained and, since certain changes may be made in the above article without departing from the scope of the invention, all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limited sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Claims

1. A mattress, comprising:

an innerspring having a perimeter;

one or more foam panels adjacent to at least a portion of the perimeter of the innerspring, each of the one or more foam panels comprising: an elongated member disposed along a longitudinal axis; and at least one expansion zone integrally formed in the one or more foam panels; wherein the at least one expansion zone is configured to expand in the direction of the longitudinal axis of the at least one foam panel to allow a length of the foam panel to be expanded up to an expansion distance of the at least one expansion zone and contracted.

2. The mattress of claim 1, further comprising one or more channels disposed through the elongated member.

3. The mattress of claim 1, wherein the at least one expansion zone is comprised of a plurality of expansion zones integrally formed in the foam panel and forming a plurality of openings in the foam panel.

4. The mattress of claim 1, wherein the plurality of expansion zones are comprised of a plurality of apertures.

5. The mattress of claim 4, wherein a first aperture among the plurality of apertures is disposed on a top edge of the foam panel, and a second aperture among the plurality of apertures is disposed on a bottom edge of the foam panel.

6. The mattress of claim 4, wherein the plurality of apertures form apertures along length axes of the elongated member between a top edge and a bottom edge of the foam panel.

7. The mattress of claim 4, wherein the plurality of apertures are disposed along the longitudinal axis of the foam panel.

8. The mattress of claim 4, wherein the plurality of apertures are disposed along a plurality of longitudinal axes of the foam panel.

9. The mattress of claim 4, wherein the plurality of apertures are comprised of a plurality of cuts.

10. The mattress of claim 4, wherein the plurality of apertures are comprised of a plurality of slits.

11. The mattress of claim 1, wherein the at least one expansion zone is comprised of a plurality of expansion zones.

12. The mattress of claim 11, wherein each of the one or more foam panels further comprises at least one interconnected lattice of foam disposed between adjacent expansion zones among the plurality of expansion zones.

13. The mattress of claim 1, wherein the one or more foam panels each comprises a substantially flat planar body including a top surface and a bottom surface, and defined by a top edge, a bottom edge, a first side edge, and a second side edge.

14. The mattress of claim 3, wherein the plurality of expansion zones comprises a first expansion zone adjacent to a second expansion zone, each of the plurality of expansion zones extending from one edge to an opposite edge of the planar body.

15. The mattress of claim 14, wherein the first expansion zone comprises a first portion of the plurality of apertures in a first pattern of apertures, the first portion separately expandable and contractible in a direction orthogonal to a first geometric line, at least a portion of each of the first portion disposed within the first geometric line when the first portion is fully contracted, the first geometric line extending from the one edge to the opposite edge of the planar body.

16. The mattress of claim 15, wherein the second expansion zone comprises a second portion of the plurality of apertures in a second pattern of apertures, the second portion separately expandable and contractible in a direction orthogonal to a second geometric line, at least a portion of each of the second portion disposed within the second geometric line when the second portion is fully contracted, the second geometric line extending from the one edge to the opposite edge of the planar body.

17. The mattress of claim 16, wherein the first pattern of apertures comprises a different aperture shape than the second pattern of apertures, and the first geometric line and the second geometric line are parallel to each other and parallel to the top surface.

18. The mattress of claim 4, wherein the plurality of apertures is further defined as being formed in a planar body in juxtaposed, spaced, adjacent relationship to each other, effectively forming at least one expansion zone which enables the foam member to be expandable and contractible in the expansion zone.

19. The mattress of claim 4, wherein the plurality of apertures are further defined as being formed in a planar body in juxtaposed, spaced, adjacent relationship to each other substantially throughout the entire planar body.

20. The mattress of claim 4, wherein the plurality of apertures are further defined as comprising a shape or configuration comprising at least one selected from the group consisting of circles, slits, half moon shapes, quarter moon shapes, triangles, trapezoids, rectangles, ovals, and ellipses.

21. The mattress of claim 13, wherein the planar body is a product of any desired width produced by employing continuous roll forming.