# US 6,295,674 B1 · Foldable sleeper sofa mattress and method of manufacturing

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- Number: US 6,295,674 B1
- Document ID: US6295674B1
- Status: Granted
- Kind: B1
- Application number: 09/488,545
- Filed: 2000-01-21
- Granted: 2001-10-02
- Earliest claimed: 2000-01-21
- Assignees: Sleeper Solutions
- Inventors: Sharon Lynne Smith-McKelvey; J. Scott Holliday
- Web page: https://patentgrep.com/patent/US6295674B1

## CPC

- A47C 27/15: consisting of two or more layers (A47C27/16 takes precedence)
- A47C 17/04: {Seating furniture, e.g.} sofas, couches, settees, or the like, with movable parts {changeable to beds}; Chair beds
- A47C 17/134: {by lifting or tilting}
- A47C 17/225: {with hidden separate full size mattress frame unfolded out of the base frame}
- A47C: CHAIRS; SOFAS; BEDS

## Abstract

A foldable springless mattress for a sleeper sofa has a hard but bendable bottom insulator pad, a first flexible foam layer adhered on top of the insulator pad, an all-natural latex rubber layer adhered on top of the first flexible foam layer, and a composite panel adhered on top of the rubber layer. The composite panel includes an intermediate layer of antimicrobial-treated fibers quilted together with a second flexible foam layer and a moisture-resistant damask fabric. This damask fabric covers all surfaces of the mattress. A process of making the foldable springless mattress includes the steps of providing the insulator pad, adhering the first flexible foam layer on top of the pad, adhering the rubber layer on top of the first flexible foam layer, and adhering the composite panel on top of the rubber layer. The composite panel is formed preliminarily by quilting the layer of antimicrobial-treated fibers together with the second flexible foam layer and the damask fabric.

## Claims

### Claim 1

A foldable mattress for a sleeper sofa, comprising:
a. a hard but bendable bottom insulator pad;
b. a first flexible foam layer adhered on top of the bottom insulator pad;
c. an all-natural latex rubber layer adhered on top of the first flexible foam layer; and
d. a composite panel adhered on top of the rubber layer.

### Claim 2 (depends on 1)

A foldable mattress, according to claim 1, wherein the mattress is springless.

### Claim 3 (depends on 1)

A foldable mattress, according to claim 1, wherein the bottom insulator pad is manufactured from fibers mixed with adhesive.

### Claim 4 (depends on 1)

A foldable mattress, according to claim 1, wherein the composite panel includes a top moisture-resistant damask fabric, a second flexible foam layer, and an intermediate layer of antimicrobial-treated fibers, all being quilted together.

### Claim 5 (depends on 4)

A foldable mattress, according to claim 4, wherein the damask fabric covers all surfaces of the mattress.

### Claim 6 (depends on 4)

A foldable mattress, according to claim 4, wherein the intermediate layer of antimicrobial-treated fibers includes synthetic polyester textile fibers.

### Claim 7 (depends on 2)

A foldable mattress, according to claim 2, wherein the intermediate layer of antimicrobial-treated fibers is composed of 80% synthetic polyester textile fibers, 10% silk and 10% blended wool.

### Claim 8

A process of making a foldable mattress for a sleeper sofa, comprising the steps of:
a. providing a hard but bendable bottom insulator pad;
b. adhering a first flexible foam layer on top of the insulator pad;
c. adhering an all-natural latex rubber layer on top of the first flexible foam layer; and
d. adhering a composite panel on top of the rubber layer.

### Claim 9 (depends on 8)

A process, according to claim 8, wherein the mattress in springless.

### Claim 10 (depends on 8)

A process, according to claim 8, further comprising the step of manufacturing the bottom insulator pad from fibers mixed with adhesive.

### Claim 11 (depends on 8)

A process, according to claim 8, further comprising the step of:
e. forming preliminarily the composite panel by quilting together a top moisture-resistant damask fabric, a second flexible foam layer, and an intermediate layer of antimicrobial-treated fibers.

### Claim 12 (depends on 11)

A process, according to claim 11, further comprising the step of:
f. covering all surfaces of the mattress with the moisture-resistant damask fabric.

### Claim 13 (depends on 11)

A process, according to claim 11, wherein the intermediate layer of antimicrobial-treated fibers includes synthetic polyester textile fibers.

### Claim 14 (depends on 11)

A process, according to claim 11, wherein the intermediate layer of antimicrobial-treated fibers is 80% synthetic polyester textile fibers, 10% silk and 10% blended wool.