METHOD OF MANUFACTURING A CUSTOMIZED MATTRESS

Abstract

The method of manufacturing a hybrid mattress discloses a novel molding process to embed springs into foam, comprising the following steps: (1) creating a mold board with a number of pegs positioned in a specific configuration; (2) placing springs around the pegs positioned on the mold board; (3) placing the mold board on a pouring table with the pegs and springs facing upward; (4) pouring liquid foam around the pegs onto the mold board; (5) waiting for the liquid foam to mature; and (6) removing the mold from the mature foam with now embedded springs. The result is a mattress with dual support provided from the springs and foam. Embedding the springs into foam enhances the elasticity and durability of the spring itself, thereby extending the useful life of the mattress. Embedding the springs into the foam reduces the common coiling noises that are very common in the prior art.

Claims

1. A method of manufacturing a hybrid mattress, comprising the steps of: creating a mold board with a number of pegs adjustably positioned in a specific configuration; placing a corresponding number of springs around each of the number of pegs positioned on the mold board; placing the mold board on a pouring table with the pegs and the corresponding number of springs facing upward; pouring a liquid foam around the pegs onto the mold board so that the liquid foam surrounds the number of pegs so as to embed the liquid foam between wires of the number of springs; waiting a set time for the liquid foam to mature; and removing the mold board with the number of pegs from the mature foam with a number of embedded springs.

2. The method of claim 1, further comprising the step of determining the number of pegs and the corresponding number of springs to be utilized based on the specific needs of a customer.

3. The method of claim 1, further comprising the step of determining the specific configuration of the number of pegs and the corresponding number of springs based on the specific needs of a customer.

4. The method of claim 3, wherein the specific configuration of the number of pegs and the corresponding number of springs is either a tight configuration, intermediate configuration, or loose configuration.

5. The method of claim 1, further comprising the step of determining the type of corresponding number of springs to be utilized based on the specific needs of a customer.

6. The method of claim 5, wherein the type of corresponding number of springs utilized is either Bonnell springs or offset springs.

7. The method of claim 5, wherein the type of corresponding number of springs utilized is a combination of Bonnell springs and offset springs.

8. The method of claim 1, further comprising the step of determining the type of liquid foam to be utilized based on the specific needs of a customer.

9. The method of claim 8, wherein the type of liquid foam utilized is either polyurethane foam, memory foam, or latex foam.

10. The method of claim 1, further comprising the step of pouring a top layer of liquid memory foam and waiting for the top layer of liquid memory foam to mature.

11. The method of claim 1, wherein the mold board has either the dimensions of a twin mattress, a full mattress, a queen mattress, or a king mattress, depending on the specific needs of a customer.

12. The method of claim 1, wherein the number of pegs are metal.

13. The method of claim 1, wherein the number of pegs are removably attachable to the mold board.

14. A method of customizing a hybrid mattress based on a preference of a customer, comprising the steps of: determining a size of the hybrid mattress and of a corresponding mold board; determining a number of springs; determining a specific configuration of the number of springs; and determining a type of liquid foam.

15. The method of claim 14, wherein the size of the hybrid mattress is either a twin, full, queen, or king.

16. The method of claim 14, wherein the specific configuration of the number of springs is either a tight configuration, an intermediate configuration, or a loose configuration.

17. The method of claim 14, wherein the type of liquid foam is either polyurethane foam, memory foam, or latex foam.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1 depicts a flow-chart of the improved mattress manufacturing method embodying the principles of the present invention;

[0032] FIG. 2 depicts a top view of a twin sized mold board with a relatively large quantity of pegs positioned tightly together embodying the principles of the present invention;

[0033] FIG. 3 depicts a top view of a twin sized mold board with an intermediate quantity of pegs positioned closer together embodying the principles of the present invention;

[0034] FIG. 4 depicts a top view of a twin sized mold board with a relatively small quantity of pegs positioned loosely together embodying the principles of the present invention;

[0035] FIG. 5 depicts a perspective view of a mold board embodying the principles of the present invention;

[0036] FIG. 6 depicts an exemplary spring embodying the principles of the present invention;

[0037] FIG. 7 depicts a perspective view of a cut-out of an improved mattress embodying the principles of the present invention;

[0038] FIG. 8 depicts another perspective view of a cut-out of an improved mattress embodying the principles of the present invention;

[0039] FIG. 9 depicts a close up view of foam embedded around springs in a cut-out of an improved mattress embodying the principles of the present invention;

[0040] FIG. 10 depicts an aerial via of a cut-out of an improved mattress embodying the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0041] To promote an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described herein. The embodiments disclosed herein are not intended to be exhaustive or to limit the scope of the invention to the precise form disclosed. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. Therefore, no limitation of the scope of the claimed invention is thereby intended. The present invention includes any alterations and further modifications of the illustrated devices and described methods and further applications of principles in the invention which would normally occur to one skilled in the art to which the invention relates.

[0042] FIG. 1 depicts a flow-chart of the improved hybrid mattress manufacturing method embodying the principles of the present invention. The disclosed method of manufacturing an improved hybrid mattress comprises at least the following basic steps: step 100 creating the mold board with a number of pegs positioned in specific configurations; step 200 placing the springs around the pegs positioned on the mold board; step 300 placing the mold board on a pouring table with the pegs and coils facing upward; step 400 pouring liquid foam around the pegs onto the mold board; step 500 waiting for the liquid foam to mature; and step 600 removing the mold from the mature foam with embedded springs.

[0043] FIGS. 2-4 depict exemplary mold boards with differing number of adjustably attachable pegs positioned in various configurations. For example, FIG. 2 depicts a twin sized mold board 20 with a relatively large quantity of pegs 21 positioned tightly together, thereby maximizing firmness and longevity. FIG. 3 depicts a twin sized mold board 30 with an intermediate quantity of pegs 31 positioned closer together, resulting in a medium-firm mattress with improved longevity. FIG. 4 depicts a twin sized mold board 4 with a relatively small quantity of pegs 41 positioned loosely, resulting in a softer mattress with improved longevity.

[0044] FIG. 5 depicts a mold board 50 may be a metal board with the dimensions of the common mattress sizes, i.e., twin, full, queen, king, etc. The pegs 51 may also be made of metal or another similar material. The minimum number of pegs 51 needed per mold board 50 to achieve a desired firmness will vary depending on the size of the mattress. The pegs 51 are removably attachable to the mold board 50 by commonly known and simple methods such as a removable screw or the like. The pegs 51 may be adjustably positioned on the mold board 50 in various configurations, depending on the specific needs and desires of the customer. For example, a firmer mattress requires pegs and corresponding springs positioned tightly together (FIG. 2), while a softer mattress requires pegs and corresponding springs positioned in a looser configuration (FIG. 4). The pegs 51 may also be positioned in various geometric shapes so as to maximize support. Similarly, various numbers of pegs 51 may be utilized depending on the needs of the customer. For example, a customer who calls for a firmer mattress may elect to have a relatively large quantity of pegs and corresponding springs to maximize support (FIG. 2), or a smaller number of springs for a softer mattress (FIG. 4). In this regard, the positioning and number of pegs and corresponding springs can be fully customized into a myriad of iterations on a standard or customer-by-customer basis.

[0045] For simplicity and exemplary purposes, image a metal board 50 with three configurations: firm, medium-firm, and soft. The firm configuration utilizes the greatest number of pegs 51 and corresponding springs 60 generally positioned tight together, exemplified in FIG. 2. The medium-firm configuration utilizes an intermediate number of pegs 51 and corresponding springs 60 generally positioned loser, exemplified in FIG. 3. The soft configuration utilizes the smallest number of pegs 51 and corresponding springs 60 generally positioned loosely together, exemplified in FIG. 4. Similar mold board configurations can be applied to the common mattress sizes.

[0046] Once the quantity and positioning of the pegs is determined, then the springs 50 are placed around the pegs 51. Each peg 51 corresponds to a spring 60. FIG. 6 depicts an exemplary spring 60 that can be positioned around a peg 51 of a sample mold board 50. Various types of springs 50 known in the industry may be utilized, such as bonnell springs and offset springs. Bonnell springs are the oldest and most common type of coil used in mattresses. They are hourglass-shaped, with a rounded top and bottom, and are connected together with wire. Bonnell springs are durable and provide good support, but they may not conform as well to the body as other types of springs. Offset springs are similar in shape to Bonnell springs but have a flat top and bottom that is angled to create a hinging effect. This allows the springs to conform more closely to the body, providing better support and reducing pressure points. Again, the type of spring 50 utilized depends on the specific needs of the customer. The specific type of spring 50 used in a mattress can affect its overall comfort, support, and durability. A combination of different types of springs 50 may be utilized to provide a more customized level of support and comfort.

[0047] Next, the mold board 50 is placed on a pouring table with the pegs 51 and springs 60 facing upward. Liquid foam 71 is then poured around the pegs 51 onto the mold board 50. Different types of foam 71 may be utilized, such as polyurethane, memory, or latex foam.

[0048] Polyurethane foam is a type of synthetic foam that is widely used in a variety of applications, including furniture cushions, insulation, and packaging materials. The foam can be molded into various shapes and densities, depending on the desired application. Polyurethane foam can be classified into two main types: flexible foam and rigid foam. Flexible foam is used in furniture cushions, mattresses, and car seats, among other applications. It is soft, lightweight, and conforms well to the body. Polyurethane foam is known for its durability, resistance to compression, and ability to retain its shape over time. It is also resistant to moisture and mildew.

[0049] Memory foam, also known as viscoelastic foam, is a type of polyurethane foam that is designed to contour to the body in response to heat and pressure. It was originally developed by NASA in the 1970s to improve the safety of aircraft cushions. Memory foam is made from a combination of polyurethane foam and additional chemicals that give it its unique properties. It is dense and supportive, but also soft and pliable, which allows it to conform closely to the body's shape. When weight is applied to the foam, it responds by sinking in and molding to the body's curves. When the pressure is released, the foam slowly returns to its original shape. One of the key benefits of memory foam is its ability to distribute weight evenly across the surface of the mattress or pillow. This can help to reduce pressure points and alleviate discomfort in areas like the hips, shoulders, and back. Memory foam is also known for its motion isolation properties, which can be beneficial for couples who are sensitive to their partner's movements during the night. Memory foam is available in a range of densities and firmness levels, allowing you to choose the right level of support and comfort for your needs. However, it can also be associated with a sleeping hot sensation, as it tends to retain body heat more than other types of foam. Some newer formulations of memory foam include cooling technologies designed to address this issue. Overall, memory foam is a popular choice for mattresses, pillows, and other sleep products due to its ability to provide customized support and comfort.

[0050] Latex foam is a type of foam made from the sap of the rubber tree. It is a natural and eco-friendly alternative to synthetic foam materials like polyurethane foam. Latex foam has several benefits over synthetic foams like polyurethane foam. It is naturally hypoallergenic, resistant to dust mites, and antimicrobial, making it a good choice for people with allergies or sensitivities. It is also durable and long-lasting, with a lifespan of up to 20 years or more. Latex foam is also known for its breathability, which helps to regulate body temperature and prevent overheating during sleep. It is available in a range of firmness levels, from soft to firm, making it a good choice for a variety of sleep preferences. Overall, latex foam is a high-quality and eco-friendly foam material that provides excellent support, comfort, and durability. Again, the type of foam 61 utilized depends on the specific needs of the customer. Further, a top layer of memory foam may be added for improved comfort.

[0051] Since the springs 60 are wrapped around the pegs 51, when the liquid foam 71 is poured, the liquid foam 71 settles around the pegs 51 and is embedded between the wires of the springs 60. The liquid foam 71 must then mature and cool down into its hardened form. FIGS. 6, 7, 8, and 9 depict exemplary cut-outs 70 of an improved mattress with foam 71 embedded within the springs 60. Once the liquid foam 71 has matured, the mold 50 is removed from the foam 71 and the customized mattress is ready to be quilted and packaged for use.