LONG LIFE COMPRESSED CUSHION AND/OR MATTRESS WITH COVER

• US 20110162148A1
• Filed: 01/06/2011
• Published: 07/07/2011
• Est. Priority Date: 01/07/2010
• Status: Active Grant

• Current Assignee: K2 Health Products, LLC
• Original Assignee: K2 Health Products, LLC
• Inventors: Klerer, Moshe, Simonovits, Stuart
• Granted Patent: US 8,650,687 B2
• Time in Patent Office: Days
• US Class Current: 5/655.9
• CPC Class Codes: A47C 20/00 Head -, foot -, or like rests for beds, sofas or the like book rests or bed tables A47B23/00; bed-rests specially adapted for nursing A61G7/065
• CPC Class Codes: B65B 63/02 for compressing or compacting articles or materials prior to wrapping or insertion in containers or receptacles

Abstract

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.

Claims

1. A method for providing a cushion in condition for storage, the method comprising:

inserting a foam core into a plastic cover;

subsequent to the insertion of the 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.

2. The method of claim 1, further comprising:

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.

3. The method of claim 2, further comprising:

at least one of folding and rolling the sealed plastic covered, fabric covered, foam core into a small footprint object having a shape.

4. The method of claim 3, further comprising:

at least one of (a) preserving the shape by at least one of taping and sealing the footprint object, and (b) inserting the small footprint object into an outer sleeve.

5. The method of claim 3, further comprising:

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.

6. The method of claim 5, wherein the outer cover is formed of a non-woven material of fibers bonded together by at least one of chemical treatment, mechanical treatment, heat treatment, and solvent treatment.

7. The method of claim 3, further comprising:

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.

8. The method of claim 3, further comprising:

inserting the small footprint object into an outer sleeve that includes a pre-cut perforation.

9. The method of claim 3, further comprising:

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.

10. The method of claim 2, wherein the fabric cover includes a cloth made by at least one of weaving, knitting, and felting fibers.

11. The method of claim 2, wherein the plastic cover includes a polyethylene material.

12. The method of claim 2, wherein:

the plastic cover includes four edges;

prior to the step of inserting the fabric covered foam core into the plastic cover, three of the edges are sealed and the fourth edge remains unsealed for the insertion of the fabric covered foam core into the plastic cover via the unsealed fourth edge; and

the sealing step includes sealing the fourth edge.

13. The method of claim 2, wherein applying the vacuum includes compressing the combination of the foam core, fabric cover, and plastic cover.

14. The method of claim 13, wherein a top side of the combination and an opposite bottom side of the combination are pressed towards each other by the compressing step.

15. The method of claim 14, wherein, during the compressing step, the bottom side remains stationary while the top side is pressed towards the bottom side.

16. The method of claim 15, wherein the compression is performed by a movable surface of a compression machine pressing down on the top side.

17. The method of claim 16, wherein the movement of the movable surface is implemented at least one of mechanically, hydraulically, and electrically.

18. The method of claim 15, wherein 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.

19. The method of claim 14, wherein the compressing step includes applying a compressive force of approximately 2,624,790 Pa to the combination, and the foam core comprises an at least 20 density high resiliency foam.

20. The method of claim 13, wherein, 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.

21. The method of claim 20, wherein 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.

22. The method of claim 13, wherein, 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.

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.