Abstract:
A molded mattress having a one piece seamless cover with a ventilation plug mounted in a tamper resistant recess formed surrounding a ventilation hole. The one piece seamless cover may have a plurality of airways formed in the cover to allow air circulation between the user and the mattress cover. The one piece seamless cover is integrally rotomolded to form a rugged comfortable mattress for intensive use environments. An RFID communication chip may be inserted in the cover for information management. The cover may be formed from solid color, translucent or transparent material.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to intensive use furniture specifically a one piece molded mattress for use in intensive use environments as a sleeping surface. 
       BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a one piece molded mattress having no seams, no stitches and no strings used in the assembly. The one piece molded cover may be provided with a filtered vent to allow air to escape to prevent ballooning when a user lies on the mattress. Sealed seam mattresses have been used for air beds, camping mattresses, water floats and beds where hygienic contamination is a concern. Traditionally, sealed seam mattresses have a resilient inner mattress pad formed of a fibrous material or foam, depending on the environment and building regulations. A cover is formed over the pad by wrapping a sheet of material around the pad and welding or sealing the edges to surround the pad. Prior art mattresses teach attaching the material by stitching, seams or strings to hold the mattress cover around the pad. 
         [0003]    The prior art teaches placing a pillow on the mattress inside the cover or attached to a covered mattress. The prior art teaches the pillow may be layered on the mattress pad at one end or may be disposed adjacent the head end. The prior art further teaches disposing the pillow on the top side of the mattress or using a sleeve to connect the pillow to the mattress pad. The pad is then covered with a sheet material that is welded on the seams to seal the pad therein. 
         [0004]    Prior art seamed or welded mattresses may be adapted with ventilation to allow air exchange between the inside of the mattress cover and the ambient air. The opening may cause issues in an intensive use environments. In intensive use environments, furniture and fixtures must be tamper resistant to prevent hiding contraband and creating loose pieces of material. The ventilation plug must be secured to prevent its removal and use as a weapon or contraband. Further, the ventilation hole must be covered to prevent insertion of contraband for hiding in the mattress cover. 
         [0005]    Further, prior art plastic mattresses do not allow air circulation between the user and the cover. This lack of air circulation makes the use of the prior art mattress hot and uncomfortable for the user to lie on for long periods. Lack of air circulation between the plastic cover and the user&#39;s body may also cause sweating or irritation. 
         [0006]    Accordingly, it is desirable to provide a one piece molded mattress cover that is molded without seams or stitches and filled with a resilient foam to provide support. The one piece molded mattress cover may have a plurality of air channels formed on the surface and a ventilation plug that is recessed into the body of the mattress and fixed there I a tamper resistant attachment to prevent removal. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention may comprise a one piece molded mattress comprising a molded hollow seamless cover having a top, bottom surfaces, and an inside cavity and outside skin. The top having a corrugated top outside surface forming a plurality of air circulation channels along the surface of the mattress cover. A vent hole in the molded cover extending from the inside to the outside and adapted to receive a ventilation plug. The vent hole having a recess configured to receive an outer perimeter edge of a ventilation plug. The ventilation plug having an outer lip that snaps into the recess whereby the outer lip of the ventilation plug is captured inside the ventilation hole recess. 
         [0008]    The ventilation plug may be fixed in the vent hole using an adhesive, welding or the like. The ventilation plug may have an plug inside surface, a plug outside surface, a plug perimeter wall and a plurality of vent apertures extending through the plug from the plug outside surface to the plug inside surface. The plug perimeter wall extends between the plug inside surface and the plug outside surface. The apertures formed in the plug or provided by a screen material over the vent hole held in place by the ventilation plug to prevent the travel of organisms and contraband into the one piece molded mattress cover. An edge between the plug perimeter wall and the plug outside surface is completely covered when the plug is fixed in the recess to make the attachment tamper resistant by not providing access to the plug perimeter wall from the ventilation hole. 
         [0009]    The one piece molded mattress cover may be rotomolded to provide a seamless hollow construction having side walls, end walls and a top and bottom surfaces. The side walls, end walls and a top and bottom surfaces are integrally molded together to form a seamless one piece molded mattress cover. A hollow inside cavity in the one piece molded mattress cover is filled with foam for support. The foam material may be inserted into the hollow cavity at the ventilation hole thereby filling the hollow cover and urging the one piece mattress to retain a shape. The foam material filling the one piece molded mattress cover to provide support for the user. The foam filling also resisting the insertion of contraband into the mattress cover. 
         [0010]    The shape of the one piece molded mattress cover may be molded to provide pillow arrangement at a head end. Drainage holes or peripheral drainage retention may be formed integral to the cover. The one piece molded mattress cover may have support portions adapted to support a users shoulders, hips or knees. The one piece molded mattress cover may be flat, undulated or wedge shaped depending on the user requirements. 
         [0011]    The above description sets forth, rather broadly, a summary of one embodiment of the present invention so that the detailed description that follows may be better understood and contributions of the present invention to the art may be better appreciated. Some of the embodiments of the present invention may not include all of the features or characteristics listed in the above summary. There are, of course, additional features of the invention that will be described below and will form the subject matter of claims. In this respect, before explaining at least one preferred embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the following description or as illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a side elevation view of a first embodiment of the one piece seamless molded mattress. 
           [0013]      FIG. 2 . is a foot end elevation view of a first embodiment of the one piece molded mattress. 
           [0014]      FIG. 3  is a top plan view of the first embodiment of the one piece molded mattress. 
           [0015]      FIG. 4  is a bottom plan view of the first embodiment of the one piece molded mattress. 
           [0016]      FIG. 5  is a section view taken at approximately  5 - 5  of  FIG. 3  of the of a first embodiment of the one piece molded mattress. 
           [0017]      FIG. 6  is an opposite side elevation view of the first embodiment of the one piece molded mattress of  FIG. 1 . 
           [0018]      FIG. 7  is a head end elevation view of the first embodiment of the one piece molded mattress. 
           [0019]      FIG. 8  is a section view of the one piece molded mattress illustrating the attached ventilation plug taken at approximately  7 - 7  of  FIG. 6 . 
           [0020]      FIG. 9  is a top plan view of the ventilation plug. 
           [0021]      FIG. 10  is a perspective view of the ventilation plug in the ventilation hole in the one piece molded mattress 
           [0022]      FIG. 11  is a perspective view of the first embodiment of the one piece molded mattress. 
           [0023]      FIG. 12  is a foot end elevation view of a second embodiment of the one piece molded mattress. 
           [0024]      FIG. 13  is a bottom plan view of the second embodiment of the one piece molded mattress. 
           [0025]      FIG. 14  is a side elevation view of the second embodiment of the one piece molded mattress. 
           [0026]      FIG. 15  is a top plan view of the second embodiment of the one piece molded mattress. 
           [0027]      FIG. 16  is a bottom plan view of view of a third embodiment of the one piece molded mattress. 
           [0028]      FIG. 17  is a top plan view of the third embodiment of the one piece molded mattress. 
           [0029]      FIG. 18  is a foot end elevation view of the third embodiment of the one piece molded mattress. 
           [0030]      FIG. 19  is a perspective view of the third embodiment of the one piece molded mattress. 
           [0031]      FIG. 20  is a bottom plan view of a fourth embodiment of the one piece molded mattress. 
           [0032]      FIG. 21  is a side elevation view of the fourth embodiment of the one piece molded mattress 
           [0033]      FIG. 22  is a top plan view of the fourth embodiment of the one piece molded mattress. 
           [0034]      FIG. 23  is a foot end elevation view of the fourth embodiment of the one piece molded mattress. 
           [0035]      FIG. 24  is a top plan view of a fifth embodiment of the one piece molded mattress. 
           [0036]      FIG. 25  is a section view taken at approximately  25 - 25  of  FIG. 21  of the fourth embodiment of the one piece molded mattress. 
           [0037]      FIG. 26  is a section view taken at approximately  26 - 26  of  FIG. 22  of the fourth embodiment of the one piece molded mattress. 
           [0038]      FIG. 27  is a section view taken at approximately  27 - 27  of  FIG. 24  of the fifth embodiment of the one piece molded mattress. 
           [0039]      FIG. 28  is a bottom plan view of a sixth embodiment of the one piece molded mattress. 
           [0040]      FIG. 29  is a side elevation view of the sixth embodiment of the one piece molded mattress 
           [0041]      FIG. 30  is a top plan view of the sixth embodiment of the one piece molded mattress. 
           [0042]      FIG. 31  is a foot end elevation view of the sixth embodiment of the one piece molded mattress. 
           [0043]      FIG. 32  is a perspective view of the sixth embodiment of the one piece molded mattress. 
           [0044]      FIG. 33  is a section view taken at approximately  33 - 33  of  FIG. 29  of the sixth embodiment of the one piece molded mattress. 
           [0045]      FIG. 34  is a section view taken at approximately  34 - 34  of  FIG. 30  of the sixth embodiment of the one piece molded mattress. 
           [0046]      FIG. 35  is a side elevation view of a seventh embodiment of the one piece molded mattress. 
           [0047]      FIG. 36  is a foot end elevation view of the seventh embodiment of the one piece molded mattress. 
           [0048]      FIG. 37  is a perspective view of the seventh embodiment of the one piece molded mattress. 
           [0049]      FIG. 38  is a side elevation view of an eighth embodiment of the one piece molded mattress. 
           [0050]      FIG. 39  is a foot end elevation view of the eighth embodiment of the one piece molded mattress. 
           [0051]      FIG. 40  is a perspective view of the eighth embodiment of the one piece molded mattress. 
           [0052]      FIG. 41  is a side elevation view of a ninth embodiment of the one piece molded mattress. 
           [0053]      FIG. 42  is a foot end elevation view of the ninth embodiment of the one piece molded mattress. 
           [0054]      FIG. 43  is a perspective view of the ninth embodiment of the one piece molded mattress. 
           [0055]      FIG. 44  is a side elevation view of a tenth embodiment of the one piece molded mattress. 
           [0056]      FIG. 45  is a foot end elevation view of the tenth embodiment of the one piece molded mattress. 
           [0057]      FIG. 46  is a perspective view of the tenth embodiment of the one piece molded mattress. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0058]    In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part of this application. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. 
         [0059]    The present invention comprises a one piece molded mattress having a cover formed by plastic molding without stitching, seams or strings to hold the mattress together. Referring to  FIG. 1 , the one piece molded mattress referred to generally by the numeral  10  comprises a one piece molded seamless cover  12  having a mattress top surface  14 , a mattress bottom surface  16 , a head end  18 , a foot end  19 , a foot end wall  20 , a first side wall  22  and a pillow portion  24 . The one piece molded cover  12  may be formed of plastic having a color or transparent or translucent quality. Where the cover  12  is transparent contraband (not shown) hidden in the mattress cover  12  may be visible. The pillow portion  24  may further comprise a top pillow  26  and a bottom pillow  28 . The top surface  14  and bottom surface  16  may have a corrugated design  38  comprising a plurality of ridges  40  and troughs  42  formed therein. 
         [0060]    Referring to  FIGS. 2, 3, 4 and 6 , head end  18  may comprise a top pillow surface  32 , a bottom pillow surface  34  and a head end wall  36 . The mattress cover  12  may further comprise a second side wall  44 . The corrugated surface  38  may dispose the ridges  40  and troughs  42  to extend from the first side wall  22  to the second side wall  44 . Pillow portion  24  may be integrally molded adjacent the head end  18  on mattress top surface  14 . Foot end wall  20  may join the mattress top surface  14  and mattress bottom surface  16 . Side wall  22  is attached to mattress top surface  14  and mattress bottom surface  16 . Head end  18  may comprise head end wall  19  joining mattress top surface  14  and mattress bottom surface  16 . 
         [0061]    Referring to  FIG. 5 , the one piece molded cover  12  may be hollow having an inside cavity  46  defined by inner surface  48 . A foam material  50  may be inserted into the one piece molded cover  12 . The foam material  50  may fill the inside cavity  46  including the pillow portion  24 . An identification RFID chip  51  may be inserted in foam material  50  in the inside cavity  46 . 
         [0062]    Referring to  FIG. 7 , the foot end wall  20  may have a ventilation hole  52  formed therein. The ventilation hole  52  may have a ventilation plug  56  fixed therein. The foam material  50  ( FIG. 5 ) may be sprayed or poured into the inside cavity  46  through the ventilation hole  52 . The ventilation hole  52  may be sealed by the ventilation plug  56 . 
         [0063]    Referring to  FIGS. 8 and 9 , ventilation plug  56  is fixed in ventilation hole  52 . The ventilation hole  52  extends from the outer surface  54  of the molded cover  12  to the inner surface  48 . Ventilation hole  52  may have a lip  58  surrounding opening  60  and a sloping shoulder  62  extending from lip  58  into inside cavity  46 . Plug recess  64  is formed surrounding opening  60 . Plug recess  64  has a recess outside surface  65 , a recess landing  66  and a recess inside surface  68 . Ventilation plug  56  has a plug outside surface  70 , a plug inside surface  72  and a plug perimeter wall  74 . Plug perimeter wall  74  is attached to and extends from plug outside surface  72  at outside plug edge  73 . Plug perimeter wall  74  may have a circular shape with a diameter sized to bear against the landing  66 . Sloping shoulder  62  has a diameter smaller than plug perimeter wall  74 . Sloping shoulder  62  is formed integrally in the one piece molded cover  12  and may deform when ventilation plug  56  is inserted therein to allow ventilation plug  56  to seat in the plug recess  64 . Ventilation plug  56  is adapted and sized to snap into plug recess  64  having ventilation plug outside surface  70  bear against recess outside surface  65 . Ventilation plug  56  is further adapted to snap into plug recess  64  having ventilation plug inside surface  72  bear against recess inside surface  68 . Sloping shoulder  62  extends over and covers ventilation plug perimeter wall  74  at overlap  75  when ventilation plug  56  is in ventilation hole  52  whereby the plug perimeter wall  74  is surrounded by the plug recess  64  having edge  73  in recess  64  and covered by sloping shoulder  62  at overlap  75 . Ventilation plug  56  may have ventilation holes  53  formed therein by cutting or drilling or molding to allow air passage through ventilation holes  53 . Ventilation plug  56  may be fixed in the ventilation hole  52  using an adhesive  75  or welding similar permanent attachment. RFID chip  51  may inserted adjacent ventilation plug  56 . RFID chip  51  may have memory  53 , a transmitter  55 , a receiver  57  and an antenna  59 . Memory  53  may have storage of identification information such as date of service, location assignment, personnel assignment and manufacturing information. The RFID chip  61  adapted for wireless communication to a communication portal  61 . 
         [0064]    Referring to  FIGS. 10 and 11 , ventilation plug  56  may be mounted in ventilation hole  52  having sloping shoulder  62  extending over ventilation plug  56  perimeter wall  74 . Ventilation plug outside surface  70  may be recessed into the inside cavity  46  from the outer surface  54  of the molded one piece cover  12 . One piece molded mattress  10  may have a plurality of ventilation holes  52  formed therein. 
         [0065]    Referring to  FIGS. 12-15 , a second embodiment of the one piece molded mattress  100  may comprise a one piece molded cover  112  having a mattress top surface  114 , a mattress bottom surface  116 , a head end  118 , a foot end  120 , a first side wall  122 , a second side wall  144  and a pillow portion  124 . The pillow portion  124  may further comprise a single pillow  126  integrally molded adjacent the head end  118  on mattress top surface  114 . Foot end  120  may comprise a foot end wall  126  joining the mattress top surface  114  and mattress bottom surface  116 . Side wall  122  is attached to mattress top surface  114  and mattress bottom surface  116 . Head end  118  may comprise head end wall  119  joining mattress top surface  114  and mattress bottom surface  116 . 
         [0066]    Referring to  FIGS. 16-19 , the one piece molded mattress  200  may comprise a one piece molded cover  212  having a mattress top surface  214 , a mattress bottom surface  216 , a head end  218 , a foot end  220 , and a first side wall  222  and second side wall  244 . Foot end  220  may comprise a foot end wall  226  joining the mattress top surface  214  and mattress bottom surface  216 . Side walls  222 ,  244  are attached to mattress top surface  214  and mattress bottom surface  216 . Head end  218  may comprise head end wall  219  joining mattress top surface  214  and mattress bottom surface  216  to form inside cavity  246 . The top surface  214  and bottom surface  216  may have a corrugated design  238  comprising a plurality of air circulation indentations  242  formed therein. The one piece molded mattress cover  212  may further comprise a second side wall  244 . The corrugated surface  238  may dispose the air circulation indentations  242  extending from first side wall  222  to second side wall  244 . 
         [0067]    Referring to  FIGS. 20-27 , the one piece molded mattress  300  may comprise a one piece molded cover  312  having a sloped mattress top surface  314 , a mattress bottom surface  316 , a head end  318 , a foot end  320 , and a first side wall  322  and second sidewall  344 . Foot end  320  may comprise a foot end wall  326  joining the mattress top surface  314  and mattress bottom surface  316 . Side walls  322 ,  344  are attached to sloped mattress top surface  314  and mattress bottom surface  316 . Head end  318  may comprise head end wall  319  joining sloped mattress top surface  314  and mattress bottom surface  316  to form inside cavity  346 . The sloped top surface  314  may have a liquid retention slope  347  surrounding the sloped mattress top surface  314 . Drainage holes  349  may be formed at sloped mattress top apex  341  approximately midway between side walls  322 ,  344  extending from the mattress top surface  314  to mattress bottom surface  316 . Liquid retention slope  347  is formed higher at the side walls  322 ,  344  and lower at drainage holes  349  allowing gravity to urge liquid  345  to migrate from sidewalls  322 ,  344  toward drainage holes  349 . Likewise, liquid retention slope  347  is higher at the foot end wall  326  and head end wall  319  and lower at drainage holes  349  allowing gravity to urge liquid  345  to migrate to drainage holes  349 . 
         [0068]    Referring to  FIGS. 28-34 , the one piece molded mattress  400  may comprise a one piece molded cover  412  having a surrounded mattress top surface  414 , a mattress bottom surface  416 , a head end  418 , a foot end  420 , and a first side wall  422  and second sidewall  444 . Foot end  420  may comprise a foot end wall  426  joining the surrounded mattress top surface  414  and mattress bottom surface  416 . Side walls  422 ,  444  are attached to surrounded mattress top surface  414  and mattress bottom surface  416 . Head end  418  may comprise head end wall  419  joining surrounded mattress top surface  414  and mattress bottom surface  416  to form inside cavity  446 . The surrounded mattress top surface  414  may have a liquid retention lip  447  surrounding the mattress top surface  414 . Liquid retention lip  447  extends upward as an extension of first and second side walls  422 ,  444  and, head end wall  419  and foot end wall  426 . Foam material  450  may be inserted inside the a one piece molded cover  412  to fill the inside cavity  446 . 
         [0069]    Referring to  FIGS. 35-37 , the one piece undulated molded mattress  500  may comprise a one piece molded cover  512  having a undulated mattress top surface  514 , a mattress bottom surface  516 , a head end  518 , a foot end  520  and a first side wall  522  and second sidewall  544 . Foot end  520  may comprise a foot end wall  526  joining the mattress top surface  514  and mattress bottom surface  516 . Side walls  522 ,  544  are attached to undulated mattress top surface  514  and mattress bottom surface  516 . Head end  518  may comprise head end wall  519  joining mattress top surface  514  and mattress bottom surface  516 . Top surface  524  may have an undulating shape  525  wherein a head portion  527  is higher relative to the bottom surface  516  than a hip portion  529 . A knee portion  531  may be elevated higher than hip portion  529  with respect to bottom surface  516 . The undulated top surface  514  may have a corrugated design  538  comprising a plurality of air passages  542  formed therein. The corrugated surface  538  may dispose the air passages  542  extending from first side wall  522  to second side wall  544 . 
         [0070]    Referring to  FIGS. 38-40 , the one piece molded mattress  600  may comprise a one piece molded cover  612  having a mattress top surface  614 , a mattress bottom surface  616 , a head end  618 , a foot end  620  and a first side wall  622  and second sidewall  644 . Foot end  620  may comprise a foot end wall  626  joining the mattress top surface  614  and mattress bottom surface  616 . Side walls  622 ,  644  are attached to mattress top surface  614  and mattress bottom surface  616 . Head end  618  may comprise head end wall  619  joining mattress top surface  614  and mattress bottom surface  616 . one piece molded mattress  600  may have an upright shape  625  wherein head portion  627  is higher relative to the bottom surface  616  with mattress top surface sloping downward from a head portion to hip portion  629 . Hip portion, knee portion  631  and foot end portion  620  are at the same elevation with respect to mattress bottom surface  616 . may be elevated higher than hip portion  629  with respect to bottom surface  616 . The top surface  614  may have a corrugated design  638  comprising a plurality of air passages  642  formed therein. The corrugated surface  638  may dispose the air passages  642  extending from first side wall  622  to second side wall  644 . 
         [0071]    Referring to  FIGS. 41-46 , one piece molded mattress  700  may comprise a one piece wedge shaped molded cover  712  having a mattress top surface  714 , a mattress bottom surface  716 , a head end  718 , a foot end  720  and a first side wall  722  and second sidewall  744 . Foot end  720  may comprise a foot end wall  726  joining the mattress top surface  714  and mattress bottom surface  716 . Side walls  722 ,  744  are attached to mattress top surface  714  and mattress bottom surface  716 . Head end  718  may comprise head end wall  719  joining mattress top surface  714  and mattress bottom surface  716 . Wedge shaped one piece molded mattress cover  712  may have a wedge shape  725  wherein a head portion  727  is higher relative to bottom surface  716  than foot end  720 . Top surface  714  may have a wavy design  738  comprising a plurality of airways  742  formed therein. The wavy design surface  738  may dispose the airways  742  extending from first side wall  722  to second side wall  744 . 
         [0072]    While the invention has been described with reference to exemplary embodiments, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. For example, certain ranges, limits, settings, and other such parameters may be modified to further implement the teachings herein. In addition, many modifications may be made to adapt a particular situation or substance to the teachings of the invention without departing from the scope thereof.