Compressible foam foundation for mattress support

• US 9,756,951 B1
• Filed: 04/27/2017
• Issued: 09/12/2017
• Est. Priority Date: 11/01/2016
• Status: Active Grant

• Current Assignee: Mattress Angel, LLC
• Original Assignee: James O. Stewart Jr
• Inventors: Stewart, Jr., James O.
• Primary Examiner(s): KURILLA, ERIC J
• Application Number:
  US15/499,077
• Time in Patent Office: 138 Days
• CPC Class Codes: A47C 19/025 Direct mattress support frames, Cross-bars
• CPC Class Codes: A47C 19/12 Folding bedsteads travelling or camp beds A47C17/64
• CPC Class Codes: A47C 23/005 foldable or dismountable
• CPC Class Codes: A47C 27/16 reinforced with sheet-like or rigid elements, e.g. profiled
• CPC Class Codes: A47C 31/001 Fireproof means

Abstract

A foundation for a mattress is formed from a foam block and supports that extend across the bottom side of the foam block. The supports are preferably secured within channels in the bottom side of the foam block and can be attached to the foam block by an adhesive. The foam block is made of foam rigid enough to support a mattress and is compressible so it has a compressed configuration and an expanded configuration. In the compressed configuration, the foundation may be folded into a compact form and vacuum-sealed in a plastic membrane which easies in storage, shipping, and delivery of the foundation. When the foundation is delivered to its place of use, the compressed foundation can be removed from its packaging, allowing the foam block to return to its expanded configuration and placed onto a standard bed frame with the supports providing crosswise support across the frame.

Claims

1. A foundation for a mattress, comprising:

a foam block comprised of a top side, a bottom side, a head side, a foot side, a pair of side edges, a lateral width, and a foundation length, wherein the head side and the foot side are separated by the foundation length, wherein the pair of side edges are separated by the lateral width, wherein the foam block is further comprised of a unitary, flexible foam block with a plurality of channels recessed into the unitary foam block at its bottom side at spaced apart locations, wherein the foam block has a compressed configuration and an expanded configuration, wherein the top side and the bottom side are separated by a first thickness in the compressed configuration and a second thickness in the expanded configuration, and wherein the second thickness is greater than the first thickness; and

a plurality of crosswise supports connected to the foam block at its bottom side, wherein the crosswise supports are rigid and span the lateral width between the pair of side edges, wherein the crosswise supports are connected to the bottom side of the foam block by at least one of an adhesive and a friction fit, wherein each one of the plurality of crosswise supports has a plurality of sides respectively contacting walls of the channels and an outer-facing side not in contact with the walls of the channels, wherein the crosswise supports are separated from each other by a distance, wherein no rigid connection extends between adjacent pairs of the crosswise supports, and wherein the distance has a range that is greater than the first thickness of the foam block and is less than the lateral width of the foam block.

2. The foundation of claim 1, wherein the adjacent pairs of the crosswise supports are flexibly connected to each other through contiguous portions of the foam block.

3. The foundation of claim 1, wherein the spaced apart locations of the plurality of channels correspond with the distance between the crosswise supports, wherein the channels span the entire lateral width between the pair of side edges.

4. The foundation of claim 3, wherein the outer-facing side is substantially flush with a surface of the bottom side of the foam block.

5. The foundation of claim 1, further comprising a cover comprised of a flame retardant material, wherein the cover envelops the foam block and the crosswise supports.

6. The foundation of claim 5, further comprising a vacuum-seal plastic membrane encasing the foam block, the crosswise supports, and the cover forming a packaged foundation assembly.

7. The foundation of claim 6, wherein the foam block has an opened arrangement and a folded arrangement, wherein portions of the foam block bend between the adjacent pairs of the crosswise supports in the folded arrangement, and wherein the head side of the foam block and the foot side of the foam block overlap a center section of the foam block in the folded arrangement.

8. The foundation of claim 7, wherein the foam block is in a planar form in the opened arrangement and is in the compressed configuration in the folded arrangement.

9. The foundation of claim 7, further comprising a shipping material surrounding the packaged foundation assembly when the foam block is in the folded arrangement.

10. The foundation of claim 1, wherein the foam block is further comprised of a flexible and compressible polyurethane foam material having an indentation force deflection between thirty-nine and ninety-five pounds per cubic foot.

11. A foundation for a mattress, comprising:

a foam block comprised of a top side, a bottom side, a head side, a foot side, a pair of side edges, a thickness, a lateral width, and a foundation length, wherein the head side and the foot side are separated by the foundation length, wherein the pair of side edges are separated by the lateral width, wherein the foam block has a compressed configuration and an expanded configuration, wherein the entire foam block is further comprised of a foam material having an indentation force deflection between thirty-nine and ninety-five pounds per cubic foot, wherein the top side and the bottom side are separated by a first thickness in the compressed configuration and a second thickness in the expanded configuration, and wherein the second thickness is greater than the first thickness;

a cover enveloping the foam block;

a vacuum-seal plastic membrane encasing the foam block and the cover when the foam block is in the compressed configuration forming a packaged foundation assembly, wherein the packaged foundation assembly has an opened arrangement and a folded arrangement, wherein the foam block has a planar form in the opened arrangement, and wherein the head side and the foot side of the foam block overlap a center section of the foam block in the folded arrangement; and

a plurality of crosswise supports connected to at least one of the cover and the foam block at its bottom side, wherein the foam block is further comprised of a unitary, flexible foam material, wherein portions of the foam block connect and bend between adjacent pairs of the crosswise supports when in the folded arrangement, wherein the crosswise supports are rigid with a rigidity greater than the foam block, and wherein no rigid connection extends between the adjacent pairs of the crosswise supports, wherein the foam block is further comprised of a plurality of channels recessed into the foam block at its bottom side at spaced apart locations corresponding with the distance between the crosswise supports, wherein the channels span the entire lateral width between the pair of side edges, wherein each one of the plurality of crosswise supports has a plurality of sides respectively contacting walls of the channels and an outer-facing side not in contact with the walls of the channels, and wherein the plurality of the crosswise supports fit within the channels and are attached to the channels by at least one of an adhesive and a friction fit.

12. The foundation of claim 11, wherein the crosswise supports are separated by a distance, and wherein the distance has a range that is greater than the first thickness of the foam block and less than the lateral width of the foam block.

13. The foundation of claim 11, further comprising a shipping material surrounding the packaged foundation assembly in the folded arrangement, and a shipping container holding the packaged foundation assembly within the shipping material.

14. The foundation of claim 11, wherein the cover is comprised of a flame retardant material.

15. The foundation of claim 11, wherein the foam block has an indentation force deflection greater than thirty-nine pounds per cubic foot.

16. A foundation for a mattress, comprising:

a foam block comprised of a top side, a bottom side, a head side, a foot side, a pair of side edges, a lateral width, a foundation length, and a plurality of channels recessed into the bottom side, wherein the head side and the foot side are separated by the foundation length, wherein the pair of side edges are separated by the lateral width, wherein the foam block has a compressed configuration and an expanded configuration, wherein the top side and the bottom side are separated by a first thickness in the compressed configuration and a second thickness in the expanded configuration, wherein the second thickness is greater than the first thickness, wherein the channels span the entire lateral width between the pair of side edges, wherein the channels are at locations spaced apart by a distance, and wherein the distance has a range that is greater than the first thickness of the foam block and is less than the lateral width of the foam block;

a plurality of crosswise supports connected to the foam block within the channels, wherein the crosswise supports span the lateral width between the pair of side edges, wherein each one of the plurality of crosswise supports has an outer-facing side not in contact with walls of the channels, wherein the outer-facing side of each of the plurality of crosswise supports is substantially flush with a surface of the bottom side of the foam block, and wherein each one of the plurality of crosswise supports has a plurality of sides respectively contacting the walls of the channels;

a cover enveloping the foam block and the plurality of crosswise supports; and

a plastic membrane encasing the foam block and the cover when the foam block is in the compressed configuration, wherein the foam block and the cover in the plastic membrane have an opened arrangement and a folded arrangement, wherein the foam block has a planar form in the opened arrangement, and wherein the head side and the foot side of the foam block overlap a center section of the foam block in the folded arrangement.

17. The foundation of claim 16, wherein the plurality of crosswise supports are connected to the bottom side of the foam block within the channels by at least one of an adhesive and a friction fit.

18. The foundation of claim 16, wherein the foam block is further comprised of a unitary, flexible foam material, and wherein portions of the foam block bend between adjacent pairs of the crosswise supports when in the folded arrangement.