WO2025050164A1

WO2025050164A1 - A mattress construction system and method of manufacture thereof

Info

Publication number: WO2025050164A1
Application number: PCT/AU2024/050940
Authority: WO
Inventors: George Giannopoulos
Original assignee: Futuresleep Pty Ltd
Current assignee: Futuresleep Pty Ltd
Priority date: 2023-09-05
Filing date: 2024-09-03
Publication date: 2025-03-13
Anticipated expiration: 2026-03-05

Abstract

The present disclosure is directed to a mattress comprising a bottom layer defining the bottom of a spring encasement cavity, a top layer defining the top of the spring encasement cavity, side walls defining the sides of the spring encasement cavity, an array of coils arranged within the spring encasement cavity, wherein the bottom layer, top layer and side walls are mechanically secured together in an adhesive free manner.

Description

A MATTRESS CONSTRUCTION SYSTEM AND METHOD OF MANUFACTURE

THEREOF

TECHNICAL FIELD

[0001] The invention is broadly directed to a mattress encasement system. In particular embodiments, the invention provides a natural and recyclable mattress and method of manufacture therefore.

BACKGROUND

[0002] There exists a considerable demand for the production and commercialisation of a mattress which is made from natural and recyclable materials. Most mattresses on the market can take over one hundred years before they fully decompose. The estimates for memory foam mattresses exceed one thousand years.

[0003] Currently, the United States throw an average of eighteen million mattresses a year into landfill, however as of 2020, there were less than one hundred recycling facilities. In addition to this is the requirement of large volumes of adhesive for the manufacture of the mattresses globally. Many of the adhesives used in the industry comprise environmentally harmful components such as methylene chloride, n-propyl bromide, acetone and solvents. The use of adhesives also renders many mattresses unrecyclable due to the inability to separate the internal parts into starting materials in a recycling facility due to damage or tearing of the materials during the process.

[0004] These requirements for mattress manufacture, and the lack of recyclable material at the end of the product lifecycle create a space where considerable investment is required.

[0005] People are becoming more environmentally aware, and are seeking greener processes and mattresses, without sacrificing quality and comfort to produce the same.

[0006] In contrast, a mattress made of easily recyclable materials which can be disassembled readily in a recycling facility would be advantageous. It may be an advantage to both the environment, and to consumer health, to provide a mattress which does not require the use of adhesive, but is still able to be manufactured in a manner that does not forfeit comfort.

[0007] The present invention was conceived with these shortcomings in mind. [0008] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein.

SUMMARY OF THE INVENTION

[0009] In a first aspect of the present invention there is provided a mattress comprising an array of coils affixed to a support structure, at least one side wall arrangement on at least one side of the array of coils, and, the at least one side wall arrangement comprising at least one flexible apron secured to the support structure, to thereby secure the at least one side wall relative to the array of coils.

[0010] Preferably, the support structure extends around the perimeter of the array of coils

[0011] Preferably, the support structure is flat, round, or triangular.

[0012] In another aspect, there are one or more additional arrays of coils.

[0013] Preferably, the the support structure is an edge rail.

[0014] Preferably, the the array(s) of coils comprise a first and second support structure, where the first support structure extends around the upper perimeter of the array of coils, and the second support structure extends around the lower perimeter of the array of coils

[0015] Preferably, each of the coils is individually encased.

[0016] Preferably, the at least one side wall arrangement is secured within a flexible case.

[0017] Preferably, at least one flexible apron extends from the flexible case.

[0018] Preferably, the at least one flexible apron is secured to the support structure reversibly. [0019] Preferably, the at least one flexible apron is secured to the support structure with a plurality of spring clips.

[0020] Preferably, no adhesive is used or present in the construction of the mattress.

[0021] Preferably, the at least one side wall arrangement is secured to the support structure in an adhesive free manner.

[0022] Preferably, the at least one side wall arrangement comprises three flexible aprons.

[0023] In a second aspect of the present invention there is provided a mattress comprising at least one side wall, an array of coils, where the at least one side wall comprises at least one flexible apron, and wherein the at least one side wall is secured to the array of coils through the at least one flexible apron in an adhesive free manner.

[0024] Preferably, the at least side wall is formed from latex blocks.

[0025] Preferably, the array of coils are secured together with a plurality of spring clips

[0026] Preferably, the array of coils is comprised of a plurality of pocket springs.

[0027] In yet another aspect of the invention, there is provided a mattress comprising an array of coils encased by a top layer, a bottom layer, and a plurality of sidewalls, wherein the top layer, bottom layer and sidewalls are secured relative to the array of coils in an adhesive free manner.

[0028] Preferably, in yet another aspect of the present invention there is provided a method of manufacturing a coil mattress wherein the method of manufacturing does not involve the use of an adhesive.

[0029] Various features, aspects, and advantages of the invention will become more apparent from the following description of embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Embodiments of the invention are illustrated by way of example, and not by way of limitation, with reference to the accompanying drawings, which are briefly described below.

[0031] Figure 1 is a schematic view of a cross-section of a mattress according to an embodiment of the present invention.

[0032] Figure 2 is a perspective view of a mattress according to an embodiment of the present invention, wherein the top layer has been retracted to expose the internal arrangement for illustrative purposes.

[0033] Figure 3 is a side view of the mattress according to the embodiment of the present invention of Fig. 1 , wherein the mattress has been disassembled to show the internal arrangement for illustrative purposes.

[0034] Figure 4 is a top view of the mattress according to the embodiment of the present invention of Fig. 2 and Fig. 3, wherein the internals are covered.

[0035] Figure 5 is a perspective view of the mattress according to the embodiment of the present invention of Fig. 2, Fig. 3 and Fig. 4, wherein the mattress is arranged in a complete manner before it may be inserted in a conventional mattress case.

[0036] Embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments, although not the only possible embodiments, of the invention are shown. The invention may be embodied in many different forms and should not be construed as being limited to the embodiments described below.

DETAILED DESCRIPTION

[0037] With reference to Figure 1 , there is provided a schematic cross-sectional view of the mattress according to an embodiment of the present invention. The side wall (10) is shown inside a flexible case (12) and extending down at least one side of the array of coils (20). In this particular embodiment, there are two arrays of coils (18, 18') stacked upon one another for purposes of providing comfort. Appended or extending off of the flexible case (12) are three flexible aprons (16). These flexible aprons may be secured to the support structure (not shown) on the upper and lower surface of each of the arrays of coils (18, 18'). It will be appreciated to those skilled in the art that the number of flexible aprons is not limited, and may be one, two, three, four and so on, so as to encompass any number or series of stacked arrays of coils (18, 18'). [0038] With reference once again to Figure 1 , it could be envisaged in another embodiment that there would be one array of coils (18), wherein the side wall (10) is still inside a flexible case (12) extending down at least one side of the array of coils (18). In this embodiment, there may be two flexible aprons (16) to be secured to a support structure (not shown) on the upper and lower surface of the single array of coils (18). It will be appreciated by those skilled in the art that this arrangement is by no means limited within reason.

[0039] The support structure (not shown) will be shown in later figures and embodiments. It will be appreciated to those skilled in the art when referring to an array of coils (18) that the support structure is generally referred to as an edge rail. This rail may be made of metal, plastic, resin or natural materials, and for every array of coils there is provided two support structures, generally equivalent in size, nature and function. For every array of coils there is first support structure on the upper face of the array of coils, and a second support structure on the lower face of the array of coils. These edge rails, or support structures provide a structure to the array of coils.

[0040] In an embodiment of the present invention, the support structure or edge rails may be further utilised in order to provide a surface to which a flexible apron extending from a flexible case of a side wall may be secured to reversibly. In the prior art, the side walls are generally glued to the array of coils or the support structure which renders the mattress very hard to recycle at the end of its lifecycle. By securing the side walls to the support structure reversibly, for example, through the use of spring clips, the recyclability of the mattress is improved dramatically, and negates the need for any chemical adhesives during manufacture.

[0041] Furthermore, the use of spring clips or another reversible securing means in combination with either i) and environmentally friendly side wall material, such as latex or ii) a readily recyclable synthetic material, the mattress then becomes 100% recyclable with the appropriate recycling facilities.

[0042] It will be appreciated to those skilled in the art that the material which is used as a side wall and encased in the flexible casing is by no means limited. Latex foam may be used as a side wall material, a natural material made from rubber tree sap. Latex foam is antibacterial and antifungal. The abundance of microscopic air chambers in latex foam ensures good heat insulation, optimal evaporation of transpiration fluid and constant air circulation. In other embodiments, memory foam, standard foam, or recyclable foam-like material made from plastic bottles may be utilised to provide the side wall materials.

[0043] The array of coils may be comprised of an array of encased coils, commonly referred to as pocket springs. Encased coils are individually wrapped coil systems that are stitched into individual fabric units during manufacture.

[0044] With reference to Figure 2, there is provided a view of the mattress (100) according to a preferred embodiment of the present invention. The top layer (110) has been removed in order to expose the internal arrangement of the mattress (100). In this embodiment, the coils (102) are formed into an array via a plurality of securing means (104, 114'). In this embodiment, there is provided a bottom layer (not shown). The coils (102) which are formed into an array via securing means (104, 104') is secured to a support structure or frame (108) both at the top of array and the bottom of the array such that the support structure or frame (108) provides an encasement cavity to which the array of coils (102) is arranged within. Furthermore, there is provided four side walls (106) (only one shown in this aspect), which extend around the perimeter of the support structure or frame (108). Each side wall (106) may be inserted into a flexible case (as shown) to which at least one flexible apron (see 112) extends from. The at least one flexible apron (112), which extends from the side walls (106) can be affixed to the support structure or frame (108) under tension to hold the side walls (106) against the coils (102) which have been formed into an array. The top layer (110) can then be used to cover the internal arrangement as described and form a complete mattress or mattress insert. Other layers, for example the top layer (110), may also be secured to the support structure or frame (108), using the spring clips. It will be appreciated as mentioned that there may be a plurality of flexible aprons extending from the flexible case which houses the side walls (106), which may assist in securing or affixing the side walls (106) to the support structure or frame (108). This may be used to affix the side walls to the top and bottom of each array of coils via the support structure (also referred to throughout as an edge rail) as discussed.

[0045] The mattress provided by this, or any further embodiment may be inserted into a conventional mattress casing as appreciated by those skilled in the art.

[0046] Referring now to Figure 3, there is provided a side-view of the embodiment shown in Fig. 3. The mattress (100) is here shown disassembled with the side walls (106) flaring outward as a result of them not being secured to the support structure of the array of coils by the flexible apron (112). The arrays of coils (102) are shown from a side view, affixed to the lower support structure or frame (108) through a securing means (114). The side walls (106) are shown in this embodiment in latex. It will be appreciated by those skilled in the art that this is by no means limiting, and that the side walls (106) could be comprised of any other suitable material such as foam. The top layer (110) is shown fitted in this figure. The flexible apron (112) which is also referred to as a flexible securing layer is shown unfixed to the support structure (108), as will be illustrated in later figures, which serves the purpose of securing the side walls (106) to the perimeter of the support structure (108).

[0047] Referring now to Figure 4, there is provided a top view of the mattress (100) as described in Fig. 2 and Fig 3. Fig. 4 shows the mattress in an assembled form, with the top layer (110) covering the internal arrangement, the side walls (106) firmly against the support structure (not visible) through the securing of the flexible apron (112) to the support structure, or referred to as the flexible securing layer. The plurality of flexible aprons (112), although only one shown, is tensioned and affixed to the support structure (108) via a plurality of securing means (200). The person skilled in the art would appreciate that the securing means (200) shown in this figure are spring clips, but that any suitable metal securing means, plastic securing means or recycled material-based securing means could be readily used and adapted in the same or identical manner to form a similar embodiment as that shown in Fig. 4.

[0048] Referring now to Figure 5 is a perspective view of Figure 4, where there is provided a top view of the mattress (100), with the top layer (110) covering the internal arrangement of the mattress. The flexible apron (112) is tensioned to arrange the side walls (106) firmly against the support structure (not visible). The flexible apron (112) is tensioned by pulling taut and fixing the flexible apron to the support structure (not shown) via a plurality of securing means (200). This is also the method generally employer internally and on the other side of the mattress, as discussed with reference to Figure 1 .

[0049] In an embodiment, the coils may be encased coils. Encased coils are formed into an array via securing means between each individual coil. These wire form springs are individually encased in fabric, and are also known as "pocketed" or Marshall-type coils and have been manufactured for many years for use as spring cores for mattresses by arranging the encased coils into rows or columns within a perimeter. The person skilled in the art will appreciate that many different encased coils may be used within the mattress. The coil count and configuration may be changed to support various body types, body weights, and comfort.

[0050] In an embodiment, there may be provided an arrangement wherein there are two, three or four separate arrays of coils stacked upon one other, with a support structure (108) on the top layer and bottom layer respectively. It may be an advantage to stack the array of coils to provide a mattress with high malleability hence improving comfort for the user. Additionally, the stacking of arrays of coils may be required to give enough rise to the mattress so that it can be appropriately inserted into a mattress case, and fills the rise between a platform of a bed frame and bed frame head.

[0051] As previously discussed, the support structure (108) is preferably an edge rail. Edge rails are commonly employed within mattresses to provide a spring encasement perimeter and therefore secure the array of coils into a preferred shape. The edge rails may be flat, round or triangular depending on preference. In an embodiment of the present invention, it may be advantageous to use a flat rail to reduce the feel of the support structure when a user lies upon the top layer (110) of the mattress.

[0052] In a preferred embodiment, the coils (102) are encased coils which are formed into an array via a plurality of securing means (104). In the embodiment depicted in the figures, the securing means is a spring clip which is formed from metal. These metal clips are crimped onto the fabric of each of the encased coils to form a mechanical fixing means between at least one other encased coil in order to form an array. A person skilled in the art would appreciate that the encased coils can be affixed to one another through other known methods, such as glue, plastic clips, non-metal clips or a hot press method. Hot pressing is commonly used in mattress manufacture as a densification process during which pressure and temperature are applied simultaneously to a mattress comprised of fibres and resin to mould the final product.

[0053] In most embodiments of the present invention, the flexible apron (112) is adapted to serve the purpose of being a method of affixing of securing the side wall, which is generally inside a flexible case to the support structure. A person of ordinary skill may consider these to be 'flaps' or 'extensions' of the flexible case which serve this primary purpose. These terms, as discussed, have been used interchangeably throughout, however a person skilled in the art would appreciate that the flexible apron does serve this purpose in the present invention. The flexible apron is adapted to extend from the flexible case which encases the side wall (106), and be secured on the support structure reversibly. The top layer (110) is then used to cover the securing means and provide an insulating layer between the user and the exposed securing means for purposes of providing comfort to the user.

[0054] Any reference throughout the specification to a support structure may be considered in the industry and art to be an edge rail, which is present in most arrays of coils.

[0055] Whilst the flexible case and flexible aprons are referred to separately, and in some embodiments the flexible aprons may be sewn to the case, it will be appreciated to those skilled in the art that these may be formed from an integral piece of flexible material. The material may be any conventional material which is flexible, including but not limited to cotton, wool, polyester or polyurethane.

[0056] Whilst the embodiment of the present invention as referred to in the figures uses a flat edge wire as the support structure, it could be envisaged that the support structure may include a round edge wire, or other supporting structures may be used if there is an absence of an edge wire. Furthermore, the coil arrangement may not be limited in any referenced embodiment to an array of coils, and could include other coils or commercial springs as desired. This may include, but is not limited to, open coils, continuous springs or offset springs.

[0057] The person skilled in the art will appreciate that the mattress as formed by any embodiment of the present invention may be inserted into a mattress cover or encasement. These are commonly referred to as a zippered mattress encasement and assist in providing comfort by preventing exposure of a user to any of the internal componentry of the mattress as formed. This may further increase the recyclability of the mattress, as a person skilled in the art may appreciate that the mattress could be removed from the cover or encasement and repaired as needed. This may include, but is not limited to, the replacement of a the array of encased coils (102) due to failure or weakness, replacement of the top layer (110), a rejuvenation and recalibration of the bottom layer in order to re-tension the arrangement to improve the formation of the mattress when worn over time.

[0058] It will be appreciated by persons skilled in the art that numerous variations and modifications may be made to the above-described embodiments, without departing from the scope of the following claims. The present embodiments are, therefore, to be considered in all respects as illustrative of the scope of protection, and not restrictively.

[0059] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein.

[0060] As used herein and in the appended claims, the singular form of a word includes the plural, unless the context clearly dictates otherwise. Thus, the references "a," "an" and "the" are generally inclusive of the plurals of the respective terms. For example, reference to "a feature" includes a plurality of such "features." The term "and/or" used in the context of "X and/or Y" should be interpreted as "X," or "Y," or "X and Y.

[0061] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

[0062] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. LEGEND

Claims

1. A mattress comprising: an array of coils affixed to a support structure; at least one side wall arrangement on at least one side of the array of coils; and the at least one side wall arrangement comprising at least one flexible apron secured to the support structure, to thereby secure the at least one side wall relative to the array of coils.

2. The mattress of claim 1 , wherein the support structure extends around the perimeter of the array of coils.

3. The mattress of claim 1 or 2, wherein the support structure is flat, round, or triangular.

4. The mattress of any one of claims 1 to 3, further comprising an additional array of coils.

5. The mattress of any one of claims 1 to 4, wherein the support structure is an edge rail.

6. The mattress of any one of claims 1 to 5, wherein the array(s) of coils comprise a first and second support structure, where the first support structure extends around the upper perimeter of the array of coils, and the second support structure extends around the lower perimeter of the array of coils.

7. The mattress of any one of the preceding claims, wherein each of the coils is individually encased.

8. The mattress of claim 1 , wherein the at least one side wall arrangement is secured within a flexible case.

9. The mattress of claim 9, wherein the at least one flexible apron extends from the flexible case.

10. The mattress of any one of the preceding claims, wherein the at least one flexible apron is secured to the support structure reversibly.

11. The mattress of claims 1 or 2, wherein the at least one flexible apron is secured to the support structure with a plurality of spring clips.

12. The mattress of any of the preceding claims, wherein no adhesive is used or present in the construction of the same.

13. The mattress of any of the preceding claims, wherein the at least one side wall arrangement is secured to the support structure in an adhesive free manner.

14. The mattress of any of the preceding claims, wherein the at least one side wall arrangement comprises three flexible aprons.

15. A mattress comprising: at least one side wall; an array of coils; wherein the at least one side wall comprises at least one flexible apron; wherein the at least one side wall is secured to the array of coils through the at least one flexible apron in an adhesive free manner.

16. The mattress of any of the preceding claims, wherein the at least side wall is formed from latex blocks.

17. The mattress of any of the preceding claims, wherein the array of coils are secured together with a plurality of spring clips.

18. The mattress of any of the preceding claims, wherein the array of coils is comprised from a plurality of pocket springs.

19. A method of manufacturing a coil mattress wherein the method of manufacturing does not involve the use of an adhesive.

0. A mattress comprising an array of coils encased by a top layer, a bottom layer, and a plurality of sidewalls, wherein the top layer, bottom layer and sidewalls are secured relative to the array of coils in an adhesive free manner.