US3873388A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Mattress pad and method and apparatus for constructing the same
Assignee: HUNTER MILDRED B
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Filing: 1972-04-21
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Granted: 1975-03-25
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Expires: 1992-04-21
Abstract
Abstract Method and apparatus for forming a pad used to cover a spring assembly in the construction of a support, such as a mattress or seating means. The pad is constructed to include a resilient, single density layer of fiber elements and a firm, double density layer of fiber elements, with the outside surface of the double density layer being provided with a synthetic backing. The pad is constructed from fabric scraps, wherein the scraps are shredded to form a plurality of fiber elements. Some of the fiber elements are supplied to a first carding station operable for carding the fiber elements to form two lengths of fiber roping which are reciprocally fed over each other and onto the upper surface of a conveyor to form the double density layer of fiber material which is then subjected to a needle punching operation to cause certain of the fiber elements to vertically engage each other. Additional amounts of the shredded fiber elements are supplied to a second carding station operable for forming a third length of fiber material which is reciprocally applied to the upper surface of the double density layer to form a single density layer, both layers of which are subjected to a second needle punching operation to cause certain of the fiber elements of the two layers of fiber material to vertically engage each other. After the two layers of fiber material leave the second needle punching operation, synthetic material is applied to selected portions of the outside surface of the double density layer of fiber material. The pad is then advanced through oven means where the synthetic material is cured. The fiber material leaving the curing oven can be selectively cut into predetermined widths and can be selectively cut into predetermined lengths or can be wound onto reel means for storage.
Inventors
- 👤 Evandow W Hunter
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 01:39
CPC Classifications
A; A47; A47C; A47C27/00; A47C27/04; A47C27/05; D; D04; D04H; D04H1/00; D04H1/40; D04H1/44; D04H1/46
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
397 words
A method of forming a pad for use in covering a spring assembly used in the construction of a support, such as a mattress or seating means utilizing spring constructions, including the steps of: a. forming a first web or batt of fiber material having a plurality of fiber elements; b. reciprocally feeding said first web or batt of fiber material along equal opposite first and second directions a predetermined distance while advancing said material in a third angularly disposed direction along a predetermined path to form a first layer of fiber material having overlapping fiber elements; c. forming a second web or batt of fiber material having a plurality of fiber elements; d. reciprocally feeding said second web or batt of fiber material along said equal opposite first and second directions said predetermined distance while applying said second web or batt of fiber material to the upper surface of said first layer of fiber material moving said predetermined path to form a second layer of fiber material supported on said first layer of fiber material, each having a plurality of overlapping fiber elements; e. needle punching said two layers of fiber material moving along said predetermined path so as to vertically engage certain of the fiber elements of said first and second layers whereby a single layer of more dense fiber material is formed; f. forming a third web or batt of fiber material having a plurality of fiber elements; g. reciprocally feeding said third web or batt of fiber material along Equal opposite first and second directions a predetermined distance while applying said third web or batt of fiber material to the upper surface of said layer of more dense fiber material to form a first more dense layer of fiber material and a second resilient less dense layer of fiber material with said single resilient less dense layer supported on said more dense layer; h. needle punching said two layers of fiber materials moving along said predetermined path so as to vertically engage certain of the fiber elements of said resilient less dense layer with certain of the fiber elements of said more dense layer; i. applying synthetic backing forming material to at least a portion of an outer surface of said more dense layer of fiber material for forming a synthetic backing along said surface; and j. curing said synthetic backing forming material.
Claim 2
Independent Claim
397 words
A method of forming a pad for use in covering a spring assembly used in the construction of a support, such as a mattress or seating means utilizing spring constructions, including the steps of: a. forming a first web or batt of fiber material having a plurality of fiber elements; b. reciprocally feeding said first web or batt of fiber material along equal opposite first and second directions a predetermined distance while advancing said material in a third angularly disposed direction along a predetermined path to form a first layer of fiber material having overlapping fiber elements; c. forming a second web or batt of fiber material having a plurality of fiber elements; d. reciprocally feeding said second web or batt of fiber material along said equal opposite first and second directions said predetermined distance while applying said second web or batt of fiber material to the upper surface of said first layer of fiber material moving said predetermined path to form a second layer of fiber material supported on said first layer of fiber material, each having a plurality of overlapping fiber elements; e. needle punching said two layers of fiber material moving along said predetermined path so as to vertically engage certain of the fiber elements of said first and second layers whereby a single layer of more dense fiber material is formed; f. forming a third web or batt of fiber material having a plurality of fiber elements; g. reciprocally feeding said third web or batt of fiber material along Equal opposite first and second directions a predetermined distance while applying said third web or batt of fiber material to the upper surface of said layer of more dense fiber material to form a first more dense layer of fiber material and a second resilient less dense layer of fiber material with said single resilient less dense layer supported on said more dense layer; h. needle punching said two layers of fiber materials moving along said predetermined path so as to vertically engage certain of the fiber elements of said resilient less dense layer with certain of the fiber elements of said more dense layer; i. applying synthetic backing forming material to at least a portion of an outer surface of said more dense layer of fiber material for forming a synthetic backing along said surface; and j. curing said synthetic backing forming material.
Claim 3
Dependent Claim
25 words
A method of forming a pad as defined in claim 1 including a further step of cutting said layers of fiber material into predetermined lengths.
Claim 4
Dependent Claim
26 words
A method of forming a pad as defined in claim 2 including a further step of cutting said layers of fiber material into a predetermined width.
Claim 5
Dependent Claim
29 words
A method of forming a pad as defined in claim 1 including a further step of winding said layers of fiber material with said synthetic backing onto reel means.
Claim 6
Dependent Claim
45 words
A method of forming a pad as defined in claim 1 further characterized in that said synthetic material is selectively applied to predetermined portions of the outer surface of said more dense layer of fiber material, as said material is moved along said predetermined path.
Claim 7
Dependent Claim
40 words
A method of forming a pad as defined in claim 1 further characterized in that said more dense layer of fiber material is angularly advanced along a second predetermined path prior to receiving said less dense layer of fiber material.
Claim 8
Dependent Claim
32 words
A method of forming a pad as defined in claim 6 further characterized in that said more dense layer of fiber material is inverted for movement along said second angularly disposed path.
Claim 9
Dependent Claim
48 words
A method of forming a pad as defined in claim 1 further characterized in that said lengths of fiber material are formed by disintegrating scraps of material and with the fiber element obtained from said scraps of material processed to form said web or batt of fiber material.
Claim 10
Dependent Claim
36 words
A method of forming a pad as defined in claim 8 further characterized in that said fiber elements obtained from said scraps of material are carded to form said said web or batt of fiber material.
Claim 11
Independent Claim
341 words
A method of forming a pad for use in covering a spring assembly used in the construction of a support, such as a mattress or seating means utilizing spring constructions, including steps of: a. forming a first web or batt of fiber material having a plurality of fiber elements; b. reciprocally feeding said first web or batt of fiber material along equal opposite first and second directions a predetermined distance while advancing said material in a third angularly disposed direction along a predetermined path to form a first layer of fiber material having overlapping fiber elements; c. forming a second web or batt of fiber material having a plurality of fiber elements; d. reciprocally feeding said second web or batt of fiber material along said equal opposite first and second directions said predetermined distance while applying said second web or batt of fiber material to the upper surface of said first web or batt of fiber material moving along said predetermined path to form a second layer of fiber material supported on said first layer, each having a plurality of overlapping fiber elements; e. needle punching said two layers of fiber material moving along said predetermined path so as to vertically engage certain of the fiber elements of said first and second layers to form a layer of dense fiber material; f. forming a third web or batt of fiber material having a plurality of fiber elements; g. reciprocally feeding said third web or batt of Fiber material in opposite directions an equal predetermined distance while applying said third web or batt of fiber material to the upper surface of said more dense layer of fiber materials moving along said predetermined path to form a number of layers of fiber material, one layer being of more dense fiber elements and a second layer being of more resilient, less dense fiber elements; h. needle punching said two variable density layers of fiber materials moving along said predetermined path so as to vertically engage certain of the fiber elements of said two layers.
Claim 12
Independent Claim
341 words
A method of forming a pad for use in covering a spring assembly used in the construction of a support, such as a mattress or seating means utilizing spring constructions, including steps of: a. forming a first web or batt of fiber material having a plurality of fiber elements; b. reciprocally feeding said first web or batt of fiber material along equal opposite first and second directions a predetermined distance while advancing said material in a third angularly disposed direction along a predetermined path to form a first layer of fiber material having overlapping fiber elements; c. forming a second web or batt of fiber material having a plurality of fiber elements; d. reciprocally feeding said second web or batt of fiber material along said equal opposite first and second directions said predetermined distance while applying said second web or batt of fiber material to the upper surface of said first web or batt of fiber material moving along said predetermined path to form a second layer of fiber material supported on said first layer, each having a plurality of overlapping fiber elements; e. needle punching said two layers of fiber material moving along said predetermined path so as to vertically engage certain of the fiber elements of said first and second layers to form a layer of dense fiber material; f. forming a third web or batt of fiber material having a plurality of fiber elements; g. reciprocally feeding said third web or batt of Fiber material in opposite directions an equal predetermined distance while applying said third web or batt of fiber material to the upper surface of said more dense layer of fiber materials moving along said predetermined path to form a number of layers of fiber material, one layer being of more dense fiber elements and a second layer being of more resilient, less dense fiber elements; h. needle punching said two variable density layers of fiber materials moving along said predetermined path so as to vertically engage certain of the fiber elements of said two layers.
Claim 13
Dependent Claim
27 words
A method of forming a pad as defined in claim 10 including a further step of winding said layers of variable density fiber material onto reel means.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-03-24 | 1978-09-23 | 1979-03-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-03-24 | 1982-09-23 | 1983-03-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-03-24 | 1986-09-23 | 1987-03-25 | $7700.00 | Window Closed / Lapsed |