LONG LIFE COMPRESSED CUSHION AND/OR MATTRESS WITH COVER
A method for reducing a cushion footprint for long-term storage may include inserting a foam core into a plastic cover, subsequently applying a vacuum to the plastic cover, and, while under the vacuum effect, sealing the plastic cover, and its contents. A device providing the vacuum effect may include a surface having protruding sections connected to non-protruding sections via tapered sections. A cushion may include an at least 20 density high resiliency foam core, and a fabric cover that includes (a) a combination of polyester and spandex and/or lycra, (b) nylon to which a thin water resistant material coating is applied, and/or (c) polyester fabric including raised anti-slip polyvinyl chloride dots, other portions of the polyester fabric at which the dots are not positioned having applied thereto a polyvinyl chloride coating. The device may compress the foam core while housed in a fabric cover, housed in the plastic cover.
This application is a divisional of U.S. patent application Ser. No. 12/985,591, filed Jan. 6, 2011, which claims the benefit, under 35 U.S.C. §119(e), of U.S. Provisional Patent Application No. 61/335,643, filed Jan. 7, 2010, and of U.S. Provisional Patent Application No. 61/335,793, filed Jan. 11, 2010, the entire contents of each of which is hereby incorporated by reference.
FIELD OF THE INVENTIONThe present invention relates to a system and method for providing cushions and/or mattresses in a compressed state for an extended period of time, and to a cushion and/or mattress arrangement by which the cushion and/or mattress may be stored long-term in a compressed state.
BACKGROUNDShipping and storing of cushions and mattresses are often difficult, expensive, and require large spaces due to their large size. Many such cushions and mattresses sold in the marketplace include a foam core with a fabric case that covers the foam core and is designed to be used in conjunction with the foam core. The cover is used to protect the foam core, make the product more attractive, allow for easy cleaning, and for comfort.
For the mattress to be used as a medical mattress, e.g., for use in a nursing home, hospital, or patient-home-care setting, such that a patient who purchases the mattress and is covered by a Medicare plan may be reimbursed for the purchase, the Medicare system requires the product to contain a water resistant cover, presumably to prevent fluids soaking the foam core.
Medical mattress covers typically have a vinyl slip resistant surface on at least one side of the cover, particularly at the bottom surface of the mattress opposite the surface on which the patient lies when the mattress is used, which non-slip surface may avoid slippage of the mattress with respect to a bed-frame on which the mattress lies.
SUMMARYThe present invention is directed to cushions and/or mattresses configured for long-term compression, thereby allowing for their storage and shipment with a small footprint, reducing cost and maximizing efficiency of such storage and/or shipment. The present invention is also directed to a method of compressing, storing, and/or decompressing cushions and/or mattresses in a manner that provides for their storage and/or shipment with a small footprint. The present invention is also directed to an apparatus and/or system for compressing cushions and/or mattresses in a manner that provides for their storage and/or shipment with a small footprint.
In particular, the noted mattresses and/or cushions may be suitable as medical mattresses and may meet requirements of the Medicare system, such as those described above.
An example method, according to the present invention, for providing a cushion in condition for storage includes: inserting a foam core into a plastic cover; subsequent to the insertion of the fabric covered foam core into the plastic cover, applying a vacuum to the plastic cover; and, while the plastic cover is under the vacuum effect, sealing the plastic cover, and its contents.
In an example, the method may further include: inserting the foam core into a fabric cover prior to the insertion of the foam core into the plastic cover, the step of inserting the foam core into the plastic cover including inserting the foam core with its fabric cover into the plastic cover.
The method may further include: folding and/or rolling the sealed plastic covered, fabric covered, foam core into a small footprint object having a shape.
The method may further include (a) preserving the shape by at least one of taping and sealing the footprint object, and/or (b) inserting the small footprint object into an outer sleeve.
The method may further include inserting the small footprint object into an outer cover that has a zipper, and constraining the small footprint object within the outer cover by zippering the zipper.
The outer cover may be formed of a non-woven material of fibers bonded together by at least one of chemical treatment, mechanical treatment, heat treatment, and solvent treatment.
The method may further include applying an adhesive to the small footprint object to preserve the shape, wherein the adhesive includes non-stick tabs at an outer-exposed edge of the adhesive.
The method may further include inserting the small footprint object into an outer sleeve that includes a pre-cut perforation.
The method may further include inserting the small footprint object into an outer sleeve, and subsequently puncturing holes into the plastic cover while the small footprint object is contained in the outer sleeve.
The fabric cover may include a cloth made by at least one of weaving, knitting, and felting fibers.
The plastic cover may include a polyethylene material.
The plastic cover may include four edges. Prior to the step of inserting the fabric covered foam core into the plastic cover, three of the edges may be sealed and the fourth edge may remain unsealed for the insertion of the fabric covered foam core into the plastic cover via the unsealed fourth edge, and the sealing step may include sealing the fourth edge.
The applying of the vacuum may include compressing the combination of the foam core, fabric cover, and plastic cover.
A top side of the combination and an opposite bottom side of the combination may be pressed towards each other by the compressing step.
During the compressing step, the bottom side may remain stationary while the top side is pressed towards the bottom side.
The compression may be performed by a movable surface of a compression machine pressing down on the top side.
The movement of the movable surface may be implemented mechanically, hydraulically, and/or electrically.
In an example, at least one edge of the movable surface includes at least a part of a heat sealing apparatus via which the sealing step is performed.
The compressing step may include applying a compressive force of approximately 2,624,790 Pa to the combination.
In an example, in the compressing step, at least one outer edge of the foam core is compressed to a lesser degree than at least one inner portion of the foam core. For example, a compressing apparatus presses against the foam core for performing the compressing, the compressing apparatus including a block that includes a thin portion by which the at least one outer edge is compressed, a thick portion by which the at least one inner portion of the foam core is compressed, and a tapered portion by which the thick and thin portions are connected.
In an example embodiment, in the compressing step, at least one outer edge of the foam core and a center of the foam core are compressed to a lesser degree than at least one inner portion of the foam core that lies between the center and the at least one outer edge.
An example cushion arrangement according to an example embodiment of the present invention includes: an at least 20 density high resiliency foam core; and a fabric cover, where the fabric cover includes: (a) a combination of polyester and at least one of spandex and lycra; (b) nylon to which a thin water resistant material coating is applied; and/or (c) a polyester fabric including raised anti-slip polyvinyl chloride dots, other portions of the polyester fabric at which the dots are not positioned having applied thereto a polyvinyl chloride coating.
In an example, the foam core includes at least one of an ethylene based foam and a urethane based foam.
In an example, the fabric cover includes the nylon to which the coating is applied, the coating including a polyvinyl chloride material.
In an example embodiment, at least one side of the fabric cover includes a slip resistant vinyl material, and (a) the slip resistant vinyl material includes holes plugged by a waterproof material and/or (b) the slip resistant vinyl material overlays a waterproof material.
An example cushion arrangement according to an example embodiment of the present invention includes: a foam core; a plastic cover; a fabric cover housed by the plastic cover and housing the foam core; and an outer cover housing the plastic cover while the plastic cover houses the fabric cover and the fabric cover houses the foam core. The foam core may be compressed while maintained in the plastic and fabric covers.
In an example, the plastic cover is heat sealed while housing the fabric cover and foam core.
In an example, the plastic cover is initially heat sealed while housing the compressed foam core, prior to insertion into the outer cover, and unsealed while maintained in the outer cover.
An example compressing device, according to an example embodiment of the present invention, includes two surfaces configured for relative movement towards and away from each other. In an example, at least one of the surfaces includes at least one protruding section and at least one non-protruding section, each of the at least one protruding section being connected to at least one respective one of the at least one non-protruding section by a respective tapered section.
In an example, at least one edge of at least one surface includes at least a part of a heat sealing apparatus.
Example embodiments of the present invention provide a system and method which allow for compression of a cushion and/or mattress, such that the cushion and/or mattress is in a compressed state for an extended period of time, which may allow for the cushion and/or mattress to be shipped, stored, and sold in the compressed state. Further, example embodiments of the present invention provide a system and method in which the cushion and/or mattress may be fully assembled prior to said compression, so the product is ready for use by the consumer upon decompression, e.g., after purchase, with no other modifications. For example, the cushion and/or mattress would not have to be fit with a cover or positioning strap or other product parts after decompression.
The inventors have discovered that there are many advantages to having a cushion and/or mattress that can be shipped, stored, and sold in a compressed state in which it remains for an extended period of time, and/or to fully assembling the cushion and/or mattress prior to such compression.
Some of these advantages include the following: more economical shipping and delivery; “greener” transportation by increasing units per truck/container load; greener packaging; and economical storage. For example, the compression proposed by the present invention helps retailers maximize precious shelf space in order to sell maximum amount of products per square inch of shelf. Medical equipment companies, similarly, may make deliveries with smaller vehicles. Further, the product is more easily stored by “stacking” the product. “Greener packaging” is provided because the compressed product requires less packaging materiel than if in an uncompressed form. Because of its small size, the product might not be classified as “over-size” by national carriers, so that shipping via national carriers may be at a cheaper rate.
To realize all these benefits, example embodiments of the present invention provide for the cushion and/or mattress product to remain in a compressed state for an extended period of time, and yet still regain its pre-compression properties after its decompression. In this regard, embodiments of the present invention provide said compression and materials for the cushion and/or mattress in a manner that allows the product to retain its viability and good condition from compression of the foam in the factory to a desired compressed size, which compression partially breaks down some of the internal structure of the foam, to its ultimate decompression, e.g., by the consumer, and finally for an extended subsequent period of use post-decompression.
As noted above, and referring to
In order for the product to be able to maintain its form and other specifications after prolonged compression, example embodiments of the present invention provide for use of a particular foam as the foam core 105 of the cushion and/or mattress 100. In an example embodiment, a 20 density (or higher) high resiliency (also referred to as high-rebound) foam is used, where the density measurement refers to the number of pounds the foam weighs per cubic foot. The foam may be any ethylene and/or urethane based foam, e.g., a polyethylene or polyurethane foam. Such foam is soft enough to be significantly compressed, while being resilient enough to decompress to a high percentage of its original pre-compression size after many months of being in its compressed state.
In an example embodiment, the foam-based cushion and/or mattress product 100 is compressed with its case 110 already placed on the foam core 105, and the materials used for the case are tailored to allow for maintaining such encasement with the case 110 during compression. In an example embodiment, the case is made from a “breathable” fabric, which allows for proper air flow for a compression and a vacuum effect created for the foam core 105, and which is wrinkle resistant to avoid wrinkles and creases to the fabric case 110 which may be caused by the compression. The compressive state may be maintained despite the use of breathable material, by a plastic film or bag 115 which is heat-sealed, as described below. Accordingly, in an example embodiment of the present invention, a wrinkle resistant yet breathable fabric, e.g., a combination textile material of polyester and spandex or Lycra, is used for the case 110. For example, a Poly-Lycra blend may be used as the wrinkle resistant and breathable foam core case 110.
For the mattress 100 to be used as a medical mattress, e.g., for use in a nursing home, hospital, or patient-home-care setting, example embodiments provide materials which allow for the mattress to be coded for the Medicare system, such that a patient who purchases the mattress and is covered by a Medicare plan may be reimbursed for the purchase. Currently, in order to be coded for reimbursement, the Medicare system requires the product to contain a water resistant cover, presumably to prevent fluids soaking the foam core. Accordingly, an example embodiment of the present invention provides for the cushion and/or mattress case 110 to be water resistant. Use of the water resistant material creates a challenge to performing the compression and the decompression with the case 110 already on the mattress 100 as compression may include air flow out from the foam core 105 in one or more, and preferably all, directions, and, similarly, decompression may include air flow into the foam core 105, while most water resistant materials do not allow for significant, if any, air flow.
Accordingly, in an example embodiment, in order to achieve proper compression and decompression for the cushion and/or mattress product 100 when the case 110 is already covering the foam core 105, a water resistant, yet air permeable material is used, as the case 110. Referring to
Medical mattress covers typically have a vinyl slip resistant surface on at least one side of the cover, particularly at the bottom surface of the mattress opposite the surface on which the patient lies when the mattress is used, which non-slip surface may avoid slippage of the mattress with respect to a bed-frame on which the mattress lies. Such a vinyl slip resistant surface, for example, which is more slip-resistant than a breathable fabric treated with a thin water resistant coating, may inhibit air flow, which may be less than optimal even if the non-slip material is used at only one side of the cover.
Accordingly, referring to
Alternatively, referring to
In an example embodiment, a slip-resistant material as described above may be used, whether waterproofed or not, on one side of a cushion, the other sides having the wrinkle-resistant yet breathable fabric described above. For example, the other sides may have the described combination textile material of polyester and spandex or Lycra, e.g., a Poly-Lycra blend.
Referring to
In an alternative example embodiment, instead of a zipper 500, a breathable material, e.g., a strip of breathable material, may be used to separate the portions of the cover 110 having non-breathable material. For example, the breathable material may be positioned where the zipper 500 would be positioned in the cover 110 shown in
Referring to
The method may further include, at step 610, applying vacuum to the covered foam core after it has been inserted into the plastic bag. In an example embodiment, the vacuum may be applied via vertical compression processing. For example, a compression machine 700, e.g., as shown in
The inventors have discovered that it may occur that a center region of the cushion/mattress decompresses at a faster rate than the edges of the cushion/mattress, and may even occur that the edges never decompress to the same extent as do other portions of the cushion/mattress. For example the center region may decompress to 6 inches while the edges may only decompress to 5.6 inches.
The inventors have also discovered that it may be desirable for certain parts of the cushion/mattress, e.g., a mid-section that usually would bear the bulk of a person's weight, to be more firm than other parts of the cushion/mattress. This may be very beneficial for medical cushions or mattresses where pressure prevention with different firmness zones on a cushion or mattress is desirable.
Therefore, according to an example embodiment of the present invention, a staged compression may be performed, whereby the edges and/or other predetermined parts, e.g., the mid-section, of the cushion/mattress may be compressed to lesser degree that other parts of the cushion/mattress. In an example embodiment, the staged compression may include placing blocks of a hard substance, such as wood, metal, or extremely dense foam, on those parts of the cushion/mattress that are to be more compactly compressed, e.g., those parts other than the edges and/or the center of the cushion/mattress, prior to compression by the compression machine. For example,
Alternatively, as shown in
If the edges of the blocks 800 are straight such that they extend perpendicular to the top surface of the cushion/mattress 100, the differences in the compression stages may be noticeable on the finished product. Accordingly, in an example embodiment of the present invention, the blocks 800 may have tapered edges 805 extending from the bottom surface 710 of the pressing board 715 to a bottom surface 820 of the blocks 800 that face and are parallel to a top surface of the cushion/mattress 100 that is placed on the surface 705 of the bottom section of the compression machine 700. The differences in the compression stages may thereby be more gradual and less noticeable. The blocks 800 placed on the top surface of the mattress 100 shown in
Referring again to
In an example embodiment of the present invention, the method further includes, at step 620, rolling the compressed covered foam core into a tubular shape, or otherwise folding the compressed covered foam core, which may make the covered foam core more manageable for storage, shipping, and sale. In order to keep the product in this tubular shape, or other folded or rolled state, the product may be taped, sealed, and/or, at step 625, placed in an additional outer plastic bag or sleeve, as is typically done for compressed cushions without long-life compression.
Leaving the cushion/mattress in the rolled state over a long period of time contributes to wrinkles on both the outer fabric covering and the inner foam core. However, the portion of the cushion/mattress that is facing inside of the roll will be much more wrinkled than the portion of the cushion/mattress facing the outside of the rolling, because the portion on the outside of the rolling is stretched by the rolling action. Therefore, according to an example embodiment of the present invention, where different materials are used for the side of the cushion/mattress upon which one is intended to lie and the opposite side, e.g., where the opposite side includes the non-stick material, the rolling may be performed such that the top portion of the cushion/mattress on which it is intended for the consumer to sit or lie is positioned on the exterior with respect to the direction of the rolling.
In an example embodiment of the present invention, the method may further include, at step 630, after insertion into the additional outer sleeve, puncturing holes in the heat sealed plastic film. The cushion may then slightly decompress due to the passage of air through the holes, to the extent allowed by the space limitations of the interior of the additional outer sleeve. The decompression causes the cushion and plastic cover to fill in extra space within the outer sleeve. For example,
The puncturing of the holes allowing passage of air through the foam core may extend the life of the ability of the foam core to decompress. Otherwise, if the foam core remains sealed in the airtight inner plastic film over a prolonged time span, the firmness and rebound capabilities of the foam core may be negatively affected. Additionally, the nature of foam is such that generally the more foam is compressed the longer it will take for the foam to rebound. The decompression allowed by the puncturing of the holes in the plastic film may therefore cause the cushion to later fully decompress at a quicker rate.
Because the covered foam core is in a compressed state and/or because of the covered foam core's rolled state, the outer plastic sleeve or tape may be under tremendous pressure, due to a natural tendency of the foam to exert forces in a decompression direction and/or to unroll, and push heavily against the plastic sleeve. Because of such pressure, manual opening of the outer sleeve or tape, without an instrument, may be difficult, which may lead to the use, e.g., by the consumer/customer or delivery personnel, of a sharp object to cut open the plastic sleeve, which may result in damage to the product, e.g., cutting of the cover, for example, the polyester, vinyl, and/or Poly-Lycra blend of the cover, which cover is to remain over the cushion and/or product during its use. (For cushions and/or mattresses compressed without a cover and which are covered after decompression, this is not as great a concern since, even if the sharp object pierces the product, only the foam core, and not its subsequently placed cover, would be pierced. However, particularly in an instance where the mattress/cushion is compressed with a cover, the sharp object may pierce the fabric cover, resulting in an unacceptable gash.)
In order to overcome this challenge, in an example embodiment of the present invention, the outer sleeve is designed such that is does not require (nor prompt) the usage of a sharp object for the removal of the sleeve. For example, an embodiment provides for use of an outer sleeve with a zipper, so the user only has to unzip the outer sleeve for its removal. As a zipper might not work optimally when incorporated in a plastic, the outer sleeve may instead be made from non-woven fabric, for example, a fabric-like material including fibers bonded together by chemical, mechanical, heat, or solvent treatment.
Especially for a large cushion and/or mattress, whose size would require a large amount of material for the outer sleeve, the non-woven fabric might not be an economical choice for the outer sleeve. Therefore, an example embodiment provides for elimination of the outer sleeve and use of tape to roll the compressed mattress into the tubular shape. In order to eliminate piercing with a sharp object, the example embodiment provides non-stick tabs at an outer edge of each strip of tape, allowing for easy removal of the tape by pulling at the tabs, eliminating the need for any sharp object.
Alternatively, one or more Velcro or other straps may be used instead of or around the outer sleeve, the Velcro or other strap being wound about a circumference of the tube formed by the rolled covered foam core.
In an example embodiment, buckles and/or hooks may be used for straps about the folded or rolled covered foam core. For example a buckle(s) and/or hook(s) may be used to connect to ends of straps, and maybe easily unfastened.
Alternatively, a plastic sleeve with a pre-cut perforation is used as the outer sleeve, which perforation may be used to easily split open the outer sleeve without use of a sharp object. For example, the outer sleeve housing the covered foam core may form a tubular shape and the pre-cut perforation may extend along the entire length or approximately the entire length of the tube.
Alternatively, the compressed covered foam core may be rolled (or otherwise folded) into the tubular shape and then inserted into a box, e.g., without an outer sleeve, the box being of such structural soundness that it withstands the pressure of the compressed foam trying to “unroll” from its tubular form.
For using the product after it has been placed in its compressed and covered state and in the outer sleeve, box, tape, and/or straps, a person may remove the compressed covered foam core from the outer sleeve, box, tape, and/or straps, and then un-roll (or otherwise unfold) the compressed covered foam core from its tubular shape (to the extent natural forces have not already done so). The inner airtight plastic bag, which had been previously hot-sealed, may be opened causing air to flow through the vapor permeable cover, thereby exposing the foam core to the air, which may cause decompression. The high resiliency foam core may then recover its original characteristics and return to its original size or nearly its originally size, prior to the compression.
The above description is intended to be illustrative, and not restrictive. Those skilled in the art can appreciate from the foregoing description that the present invention may be implemented in a variety of forms, and that the various embodiments may be implemented alone or in combination. Therefore, while the embodiments of the present invention have been described in connection with particular examples thereof, the true scope of the embodiments and/or methods of the present invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.
Claims
1-22. (canceled)
23. A cushion arrangement, comprising:
- an at least 20 density high resiliency foam core; and
- a fabric cover comprising at least one of: (a) a combination of polyester and at least one of spandex and lycra; (b) nylon to which a thin water resistant material coating is applied; and (c) a polyester fabric including raised anti-slip polyvinyl chloride dots, other portions of the polyester fabric at which the dots are not positioned having applied thereto a polyvinyl chloride coating.
24. The cushion arrangement of claim 23, wherein the foam core comprises at least one of an ethylene based foam and a urethane based foam.
25. The cushion arrangement of claim 23, wherein the fabric cover comprises the nylon to which the coating is applied, the coating including a polyvinyl chloride material.
26. The cushion arrangement of claim 23, wherein at least one side of the fabric cover includes a slip resistant vinyl material, and at least one of (a) the slip resistant vinyl material includes holes plugged by a waterproof material and (b) the slip resistant vinyl material overlays a waterproof material.
27. A cushion arrangement, comprising:
- a foam core;
- a plastic cover;
- a fabric cover housed by the plastic cover and housing the foam core; and
- an outer cover housing the plastic cover while the plastic cover houses the fabric cover and the fabric cover houses the foam core;
- wherein the foam core is compressed while maintained in the fabric and plastic covers.
28. The cushion arrangement of claim 27, wherein the plastic cover is heat sealed while housing the fabric cover and foam core.
29. The cushion arrangement of claim 27, wherein the plastic cover is initially heat sealed while housing the compressed foam core, prior to insertion into the outer cover, and unsealed while maintained in the outer cover.
30. A compressing device, comprising:
- two surfaces configured for relative movement towards and away from each other;
- wherein at least one of the surfaces includes at least one protruding section and at least one non-protruding section, each of the at least one protruding section being connected to at least one respective one of the at least one non-protruding section by a respective tapered section.
31. The compressing device of claim 30, wherein at least one edge of at least one surface includes at least a part of a heat sealing apparatus.
Type: Application
Filed: Feb 13, 2014
Publication Date: Jun 12, 2014
Inventors: Moshe KLERER (Brooklyn, NY), Stuart SIMONOVITS (Brooklyn, NY)
Application Number: 14/179,776
International Classification: A47C 20/00 (20060101); B65B 63/02 (20060101);