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  Systems and methods relating to a corner block for a mattressRelated Patent Categories: Beds, Mattress (for Whole Body), Having Substantial Means To Form Or Strengthen The Edge, Border, Or Corner Of The MattressThe Patent Description & Claims data below is from USPTO Patent Application 20070220680. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The invention relates generally to mattresses. More particularly, in various embodiments, the invention relates to a corner block for providing a reinforced square corner on a mattress, mattresses made with such corner blocks, and methods of manufacturing mattresses employing such corner blocks. BACKGROUND OF THE INVENTION [0002] Conventionally, mattresses generally have unreinforced, rounded corners. When installed into a crib frame, conventional mattress corners make it possible for an infant to injure him/herself by lodging an extremity, such as an arm or leg, between the crib frame and the corner of the crib mattress. [0003] Various prior art approaches have been employed to reduce the likelihood of this occurring. In some instances, crib bumpers are employed. Typically, crib bumpers are affixed along the periphery of a crib mattress and extend upward and between the mattress and the crib sides. A disadvantage to bumpers is that they often pull away from the corners of the mattress and leave a gap between a mattress corner and a corner of the crib frame. Another prior art approach employs mattresses that extend upward along their periphery to provide an integrated bumper. However, such mattresses can be significantly more complicated to manufacture. [0004] Accordingly, there is a need for an improved structure for a crib mattress. SUMMARY OF THE INVENTION [0005] The invention addresses the deficiencies in the prior art by, in various embodiments, providing a corner block for squaring a corner of a mattress. In other embodiments, the invention provides mattresses employing the corner block of the invention and methods of manufacturing such mattresses. In some embodiments, a mattress of the invention may be employed as a crib mattress. An advantage of such crib mattresses is that they better fit within the corners of a crib frame to inhibit an infant from lodging an extremity between a corner of the mattress and a corner of the crib frame. [0006] According to one aspect, the invention provides a corner block formed from a shape resilient polymer material, such as, polyurethane foam, visco-elastic foam, latex, polyethylene foam, polystyrene, or from cardboard, wood, metal, wire, plastic molded part, polypropylene, and acrylonitrile butadiene styrene (ABS). In one implementation, the polymer material has a density of about 23 kilograms/meter.sup.3. In other implementations, the polymer material has a density of between about 18 kilograms/meter.sup.3 and about 28 kilograms/meter.sup.3. In other implementations, the polymer material has a density of between about 20 kilograms/meter.sup.3 and about 26 kilograms/meter.sup.3. In other embodiments, the corner block of the invention may be formed from any suitable material depending on the desired application. [0007] The corner block includes first and second legs, which extend from a vertex at an angle to each other. Each leg includes an inner (e.g., frame contacting) surface and an outer surface. In one configuration, the outer surfaces of the first and second legs intersect at a substantially right angle. In one embodiment, each leg is about 41/2 inches long, as measured from the intersection of the outer surfaces of the first and second legs to terminal ends of each respective leg. According to a further embodiment, the first and second legs are about 41/2 inches high. According to an alternative embodiment, each leg is about 5 inches high. In other configurations, the legs of the corner block are between about 4 inches and about 10 inches long and between about 4 inches and about 10 inches high. In alternate configurations, the legs of the corner block are between about 4 inches and about 6 inches long. In further configurations, the legs of the corner block are between about 4 inches and about 6 inches high. [0008] According to another feature, the legs are between about 1/4 inch and about 11/2 inches thick as measured from the inner surface to the outer surface. In some embodiments, the outer surfaces of the first and second legs each include first and second sections. The first section of each leg extends from the vertex at approximately a right angle to each other, and the second section of each leg extends from a terminal end of a respective first section of each leg along an axis angled inward relative to a respective axis of the respective first section. [0009] According to some configurations, the inner surfaces of the first and second legs intersect at a transition section. According to one feature, the transition section is sized and shaped to interfit around a corner of a coil spring mattress frame. According to another feature, the transition section may be curved to further facilitate such interfitting. In one embodiment, the distance between the vertex of the angle of intersection of the outer surfaces and the apex of the curve of the transition section is between about 3/4 inch and about 11/2 inches. [0010] In some embodiments, a portion of the inner surfaces of the first and second legs may be carved out to receive a corner of a coil spring mattress frame. According to one feature of these embodiments, the carve out may be sized and shaped such that upper and lower parts of the legs may overlap upper and lower sides of a mattress frame, when interfitted onto a corner of the frame to facilitate attaching the corner block to the frame. [0011] According to another aspect, the invention is directed to a mattress employing a corner block of the invention. In one embodiment, the mattress includes a coil spring frame, in which the coil springs may or may not be pocketed. The corner blocks are attached to each corner of the frame, either prior or subsequent to attachment of polymer foam material to short ends of the frame. The mattress of the invention may then be further assembled by any suitable approach. According various constructions, the mattress may be of any size, including without limitation, single, double, full, queen, king, California king, or crib size. [0012] According to a further embodiment, subsequent to attachment of a fire retardant material, the mattress is placed in a compression bag. With the mattress so placed, the compression bag is evacuated to compress it, including compressing the coil springs of the mattress frame. With the mattress so compressed, it is inserted into a final mattress cover. The cover may then be closed by any suitable mechanism. Optionally, the compression bag may be removed prior to closing the mattress cover. In some instances, the compression bag may be made from a water resistant polymer and left on the mattress to shield inner portions of the mattress from inadvertent exposure to fluids during use. [0013] Other features and advantages of the invention are described below with regard to various illustrative embodiments. BRIEF DESCRIPTION OF THE DRAWINGS [0014] The invention may be better understood with reference to the appended illustrative drawings in which like reference designations refer to like parts, the various views may not be drawn to scale; and in which: [0015] FIG. 1A is a top view of a corner block for providing a reinforced square corner on a mattress according to an illustrative embodiment of the invention; [0016] FIG. 1B is an outside perspective view of the corner block of FIG. 1A; [0017] FIG. 1C is an inside perspective view of the corner block of FIG. 1A; [0018] FIG. 1D is an inside perspective view of the corner block of FIG. 1A including an optional cutout according to another illustrative embodiment of the invention; [0019] FIGS. 2A-2H depict an illustrative process for making a mattress that includes a corner block of the invention; [0020] FIG. 3 depicts an alternative embodiment of the invention; and Continue reading... Full patent description for Systems and methods relating to a corner block for a mattress Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Systems and methods relating to a corner block for a mattress patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Systems and methods relating to a corner block for a mattress or other areas of interest. ### Previous Patent Application: Perimeter stiffening system for a foam mattress Next Patent Application: Garment processing with biological inspection procedures Industry Class: Beds ### FreshPatents.com Support Thank you for viewing the Systems and methods relating to a corner block for a mattress patent info. 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