Mattress retention assembly and radiofrequency weld in surface covers

A hospital bed includes a sleep deck having an upper portion, a middle portion, and a lower portion each defining a support surface and an underbody that defines a notch. An opening is defined by and extends through the upper portion. A space is defined between the upper portion and the middle portion. A mattress is disposed on the sleep deck. An outer mattress shell encases the mattress and includes a fold defined by a weld. A mattress retention assembly is coupled to the outer mattress shell. The mattress retention assembly includes at least one of a first magnet and a second magnet selectively coupling the mattress to the sleep deck, a portion of the mattress retention assembly extends between the outer mattress shell and the sleep deck, an affixing member disposed on the outer mattress shell, and a retention ridge extending through the sleep deck.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a mattress retention assembly and a radiofrequency weld on a surface cover. More specifically, the present disclosure relates to a mattress retention assembly and welds in surface covers for a hospital bed.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, a hospital bed includes a sleep deck that has an upper portion, a middle portion, and a lower portion that each define a support surface and an underbody that defines a notch. An opening is defined by and extends through the upper portion. A space is defined between at least the upper portion and the middle portion. A mattress is disposed on the support surface of the sleep deck. An outer mattress shell encases the mattress. The outer mattress shell includes a fold that is defined by a weld extending through the outer mattress shell. A mattress retention assembly is operably coupled to the outer mattress shell. The mattress retention assembly includes at least one of a first magnet and a second magnet that selectively couples the mattress and the outer mattress shell to the sleep deck. A portion of the mattress retention assembly extends between the outer mattress shell and the sleep deck. An affixing member is disposed on the outer mattress shell. A retention ridge extends through the space that is defined by the sleep deck.

According to another aspect of the present disclosure, a mattress assembly includes a mattress and an outer mattress shell that is covering the mattress and has a patient support portion and a sleep deck portion. The outer mattress shell defines an interior surface and an exterior surface. A bonding strip is coupled to the interior surface of the outer mattress shell. A fastening strip is coupled to the exterior surface of the outer mattress shell. A weld extends through the exterior surface and through the interior surface of the outer mattress shell. A clasp locker is operably coupled to the fastening strip and detachably couples the patient support portion to the sleep deck portion of the outer mattress shell.

According to yet another aspect of the present disclosure, a method for manufacturing a mattress includes forming the mattress that has an outer mattress shell that includes a patient support portion and a sleep deck portion. The outer mattress shell defines an interior surface and an exterior surface. The method further includes applying at least one bonding strip to the interior surface of the outer mattress shell. The method further includes coupling a clasp locker to detachably couple the patient support portion of the outer mattress shell to the sleep deck portion that is proximate the bonding strip. The method further includes applying electromagnetic energy to the outer mattress shell and the at least one bonding strip at an attachment site to operably couple the outer mattress shell with the at least one bonding strip. The method further includes applying pressure to the outer mattress shell and the at least one bonding strip at the attachment site.

DETAILED DESCRIPTION

Referring toFIGS.1A-10, reference numeral10generally designates a hospital bed that includes a sleep deck12that defines an opening14. A mattress18is coupled to the sleep deck12, and an outer mattress shell20is coupled to the mattress18. The hospital bed10further includes a mattress retention assembly22having a first magnet24and a second magnet26that function to operably couple the mattress18with the sleep deck12.

Throughout its use, the hospital bed10and the sleep deck12may be repositioned to suit the needs of the caregiver and/or user. For example, the caregiver may adjust the hospital bed10so that the user is in a seated or upright position. Traditionally, such repositioning may cause the mattress18to slip or shift relative to the sleep deck12of the hospital bed10. The mattress retention assembly22minimizes sliding or shifting of the mattress18relative to the sleep deck12, such that the caregiver can adjust the position of the hospital bed10as needed. In addition, the mattress retention assembly22also allows the caregiver to secure and/or detach the mattress18to the sleep deck12, allowing a caregiver to easily clean and sterilize the hospital bed10between users, thereby decreasing the risk of infection or contamination and lengthening the functional life of the mattress18.

With reference again toFIGS.1A and1B, in addition to the sleep deck12, the illustrated hospital bed10also includes a footboard28, a headboard30, and supports32. The supports32may be movable or stationary to ease potential repositioning or relocation of the hospital bed10. In some instances, the footboard28may reposition along with the potential repositioning of the mattress18and sleep deck12. Comparatively, the headboard30of the hospital bed10will typically remain stationary during repositioning of the mattress18and the sleep deck12. Thus, the caregiver will use the mattress retention assembly22to secure the mattress18during such articulations where the headboard30remains stationary.

As illustrated, between the headboard30and the footboard28, the sleep deck12includes an upper portion34, a middle portion36, and a lower portion38. The upper portion34, middle portion36, and lower portion38collectively define a support surface40and an underbody42of the sleep deck12. The upper portion34, as shown, is configured to support the head and torso of the user. The middle and the lower portions36,38, as shown, are configured to support the lower back, buttocks, and leg regions of the user. It is generally contemplated that the sleep deck12may define spaces44at least partially separating the upper portion34, the middle portion36, and the lower portion38. These spaces44allow for a generally hinged movement of the upper portion34of the sleep deck12relative to the middle portion36and the lower portion38relative to the middle portion36. In addition, it is also contemplated that the underbody42of the sleep deck12may define notches46(FIG.2A). As depicted, the notches46are used to further secure the mattress18to the sleep deck12by allowing the caregiver to fit the mattress retention assembly22within the notches46to prevent unwanted movement of the mattress18during repositioning.

With reference again toFIGS.1A and1B, the mattress18includes a top surface48and a bottom surface49, and the outer mattress shell includes an interior surface50and an exterior surface52, described in more detail below. The top and bottom surfaces48,49of the mattress18further include a head portion54, configured to support a head and torso of the user, a medial portion56, configured to support a lumbar and buttocks of the user, and a foot portion58, configured to support legs of the user, which correspond respectively with the upper, middle, and lower portions34,36,38of the sleep deck12. Similarly, the head portion54, the medial portion56, and the foot portion58correspondingly identify portions of the outer mattress shell20. Thus, specific portions (e.g., the upper and head portions34,54) of the sleep deck12and the mattress18can be adjusted to accommodate the needs of the user. Further, the mattress18and the outer mattress shell20include corner portions60discussed in more detail below with respect toFIGS.9A and9B. Proximate the corner portions60, the outer mattress shell20includes a handle62(FIGS.1A,1B, and4A) coupled to the outer mattress shell20. The handle62may be configured to receive the mattress retention assembly22, as illustrated. The caregiver may utilize the handle62along with the mattress retention assembly22to secure the position of the mattress18during various articulations.

With reference now toFIGS.2A-2C, the mattress retention assembly22may include a retention feature72in the form of a hook that, as illustrated, includes a raised portion74and a planar portion75that together at least partially define a recessed portion76. The recessed portion76is further defined by a clasping portion78, described in further detail below. The retention feature72couples the mattress18to the sleep deck12during repositioning and articulation of the hospital bed10. Stated differently, the retention feature72may prevent the mattress18from significant movement while the mattress18and the sleep deck12are adjusted. The recessed portion76of the retention feature72is configured to fit around an end of the sleep deck12, while the raised portion74is configured to brace against the sleep deck12to maintain the functionality of the mattress retention assembly22by limiting significant shifting of the mattress18during repositioning.

As shown inFIG.2A, the clasping portion78and the planar portion75couple the retention feature72to the sleep deck12via compressive force. The clasping portion78engages the underbody42of the sleep deck12, and the planar portion75engages the support surface40of the sleep deck12. Stated differently, the planar portion75extends between the outer mattress shell20and the sleep deck12. Additionally or alternatively, the clasping portion78may fit within one of the notches46defined by the sleep deck12to at least partially couple the retention feature72, and the mattress18, to the sleep deck12. The retention feature72may be, by way of example not limitation, a rigid polymeric material, such as plastic, or a flexible yet rigid metal, such as steel, and may include any one of an arcuate, triangular, rectangular, etc. geometries as the clasping portion78. As described below, the retention feature72is flexibly adjusted to manipulate the retention feature72around the sleep deck12, such that the planar portion75extends along the support surface40.

The planar portion75of the retention feature72is fixedly coupled to the mattress18by a fastener portion80, which is disposed within the outer mattress shell20. Coupling members82extend through outer mattress shell20and the fastener portion80to securely couple to the retention feature72to the outer mattress shell20. The coupling members82may be, by way of example not limitation, bolts which are secured with nuts in the outer mattress shell20. The coupling members82extend through the planar portion75of the retention feature72, which includes a contact plate84disposed between the coupling members82and the sleep deck12. The contact plate84provides a buffer between the coupling members82and the sleep deck12to minimize abrasive contact on the sleep deck12by the coupling members82. The retention feature72allows the caregiver to secure the mattress18on the sleep deck12while also being able to selectively uncouple the retention feature72and the mattress18from the sleep deck12to provide access to the bottom surface49of the mattress18for repair and/or cleaning while the retention feature72remains coupled to the sleep deck12.

With further reference toFIGS.2A-2C, the raised portion74is integrally formed with the planar portion75and the clasping portion78to define the recessed portion76. Additionally or alternatively, the raised portion74and the planar portion75can be individual pieces that are then coupled to one another, along with the clasping portion78to define the recessed portion76. The recessed portion76generally allows the retention feature72to be flexible, such that the raised portion74can bend to create an increased separation between the planar portion75and the clasping portion78. Stated differently, the size of the recessed portion76that is defined between the raised portion74and the planar portion75increases so that the retention feature72can clamp onto the sleep deck12. The raised portion74and the planar portion75are coupled at a flex corner86of the retention feature72, such that there is a high degree of flexion at the flex corner86. This flexion allows the fit of the retention feature72on the sleep deck12to be tight, as the retention feature72can be bent and manipulated at the flex corner86to fit the retention feature72on the edge of the sleep deck12. A plurality of ridges88may provide additional structural support for the retention feature72around the flex corner86. The plurality of ridges88strengthen the retention feature72around the flex corner86to minimize the effects of repeated flexing of the retention feature72around the sleep deck12. The raised portion74may provide additional leverage for a user when bending the retention feature72at the flex corner86before connection to the sleep deck12.

With reference now toFIGS.3A and3B, in another aspect of the present disclosure, the mattress retention assembly22includes a locking flap100coupled to the outer mattress shell20via a flat portion101of the locking flap100. The flat portion101of the locking flap100extends between the outer mattress shell20and the sleep deck12to couple the outer mattress shell20to the sleep deck12. The locking flap100may also be coupled to a post102of the footboard28ultimately coupling the mattress18to the sleep deck12. It is also contemplated that the footboard28may include multiple posts102to which the locking flap100may be coupled. The locking flap100includes a cutout portion104defined by at least one securing member106that may allow the locking flap100to be used with sleep decks that have projections or obstructions. As illustrated inFIG.3B, the cutout portion104is arcuate in shape and is defined by two securing members106coupled to the posts102of the footboard28, such that each of the posts102may be received within each of the securing members106, respectively. Thus, the locking flap100is configured to couple the mattress18with the sleep deck12via the posts102of the footboard28, such that upon repositioning of the hospital bed10, the locking flap100may resist potential sliding movement of the mattress18.

It will be understood by one having ordinary skill in the art that a variety of different materials may be used to construct the locking flap100. The locking flap100may extend the width of the sleep deck12. Alternatively, the locking flap100may extend across only a portion of the width of the sleep deck12while still preventing the mattress18from significantly repositioning relative to the sleep deck12. It is generally contemplated that the locking flap100may be directly coupled to the mattress18and/or the outer mattress shell20. As stated above, attaching the locking flap100to either the mattress18or the outer mattress shell20allows the caregiver to minimize the shifting of the mattress18relative to the sleep deck12.

With reference now toFIGS.4A-4C, the mattress retention assembly22includes a first strap110and a second strap112. Additionally or alternatively, the mattress retention assembly22may include a loop strap114that has a single strap116configured to couple to an attachment portion118of the handle62. The mattress retention assembly22illustrated inFIGS.4A-4Cincludes a first clasp portion122and a second clasp portion124, which have a first groove126and a second groove128, respectively, described below. As illustrated inFIG.4A, the first strap110is coupled to the head portion54of the mattress18. In addition, the second strap112may be coupled to the medial portion56of the mattress18, as well as coupled to the sleep deck12through the opening14defined by the sleep deck12. The first strap110and the second strap112are configured to selectively couple to each other and retain the mattress18on the sleep deck12. As depicted inFIG.4A, the second strap112is coupled to the sleep deck12by looping the second strap112through the opening14defined by the sleep deck12, such that the second strap112encircles a portion of the sleep deck12. Additionally or alternatively, the second strap112may be coupled to the sleep deck12by directly fastening the second strap112to the sleep deck12. The second strap112may be adhered, fastened, welded, or otherwise coupled to the sleep deck12via known detachment methods. The caregiver may detach the first strap110from the second strap112when cleaning the sleep deck12or removing the outer mattress shell20of the mattress18.

As shown inFIGS.4B and4C, the mattress retention assembly22may include the loop strap114, which includes a single strap116configured to pass through the opening14defined by the sleep deck12such that the loop strap114encircles at least a portion of the sleep deck12. Additionally, as depicted inFIGS.1A and1B, the loop strap114may couple to the mattress18through the handle62on the outer mattress shell20. In this instance, the caregiver may couple the loop strap114to the mattress18by attaching a restraint120on the loop strap114to the attachment portion118on the handle62. The loop strap114may be coupled to the handle62at an attachment portion118by, for example, a snap or other fastener known in the art. In either construction, the caregiver may then tighten the loop strap114to secure the mattress18to the sleep deck12.

The first groove126and the second groove128, mentioned above, are configured to slidably couple the first and second clasp portions122,124, respectively. The first and second grooves126,128assist the caregiver in facilitating the coupling of the first and second clasp portions122,124to secure the mattress18to the sleep deck12. Moreover, it is contemplated that the first and second magnets24,26of the mattress retention assembly22may be disposed upon the first and second clasp portions122,124, respectively. For example, as shown inFIG.4B, the first magnet24is disposed on the first clasp portion122and the second magnet26is disposed on the second clasp portion124, wherein the first magnet24includes a polarity opposite that of the complementary second magnet26of the mattress retention assembly22. Stated differently, the first strap110is operably coupled with the first magnet24and the second strap112is operably coupled with the second magnet26, such that the second magnet26of the second strap112is selectively coupled with the first magnet24of the first strap110. The first and second magnets24,26may further assist the caregiver in securing the mattress18with the sleep deck12using the mattress retention assembly22, while also allowing the caregiver to more easily uncouple the first and second clasp portions122,124. To secure the mattress18, the caregiver can tighten the loop strap114and/or the first and second straps110,112to ensure the mattress18remains stabilized during articulation of the sleep deck12.

With reference now toFIG.5A, in yet another aspect of the present disclosure, it is contemplated that the first magnet24is disposed on the head portion54of the outer mattress shell20and the second magnet26is disposed on the foot portion58of the outer mattress shell20. The first and second magnets24,26of the mattress retention assembly22can correspond to a top mattress magnet140and a bottom mattress magnet142, respectively. It is generally contemplated that the top mattress magnet140and the bottom mattress magnet142are embedded in the mattress18, such that the outer mattress shell20conceals the top mattress magnet140and the bottom mattress magnet142. Alternatively, the top and the bottom mattress magnets140,142may be operably coupled with the exterior surface52of the outer mattress shell20, such that the top mattress magnet140and the bottom mattress magnet142are exposed to the sleep deck12. An upper magnetic portion144and a lower magnetic portion146of the sleep deck12, are configured to couple the mattress18to the sleep deck12via the top mattress magnet140and bottom mattress magnet142, respectively. It is generally contemplated that the top mattress magnet140and bottom mattress magnet142include a polarity opposite that of the complementary upper magnetic portion144and lower magnetic portion146, respectively.

With reference again toFIG.5A, when the top and the bottom mattress magnets140,142are disposed on the exterior surface52of the outer mattress shell20, the top and bottom mattress magnets140,142are coated with a layer of material148having a coefficient of friction exceeding at least 0.3μ to facilitate the shear resistance between the top and the bottom mattress magnets140,142and the upper and lower magnetic portions144,146during repositioning of the hospital bed10. It is also contemplated that the coefficient of friction may be as low as 0.1p. In addition, the upper and lower magnetic portions144,146, as illustrated, include the material148to frictionally, as well as magnetically, engage the top and bottom mattress magnets140,142, respectively. Accordingly, the layer of material148may assist the overall retention of the mattress18by keeping the mattress magnets140,142in line with the magnetic portions144,146. Stated differently, the coupling force between the upper and the lower magnetic portions144,146and the top and the bottom mattress magnets140,142remains stable during various articulations of the sleep deck12and the mattress18as a result of both the magnet force and the frictional force. The top mattress magnet140and the bottom mattress magnet142may be coupled to the outer mattress shell20, such that each mattress magnet140,142can be adhered, fastened, and/or embedded within the outer mattress shell20. Similarly, the upper and lower magnetic portions144,146can be adhered, fastened, and/or embedded within the sleep deck12. The secure attachment of each of the mattress magnets140,142and the magnetic portions144,146defines the secure attachment and coupling of the mattress18with the sleep deck12.

As shown inFIG.5B, the mattress retention assembly22may include an affixing member150coupled to the outer mattress shell20. The affixing member150has a generally high coefficient of friction to minimizes significant movement of the mattress18in relation to the sleep deck12. The coefficient of friction of the affixing member150is generally contemplated to exceed at least 0.3μ in order to securely grip the mattress18to the sleep deck12. It is also contemplated that the coefficient of friction may be as low as 0.1μ. Thus, the caregiver can adjust the hospital bed10while maintaining the selected position of the mattress18. The affixing member150, as depicted, is located at the head portion54and the foot portion58of the mattress18. However, the affixing member150may also be located at the medial portion56of the mattress18independently of, or in combination with, the other portions of the mattress18. Alternatively, it will be understood that there may be multiple affixing members150each located at the head portion54, the medial portion56, and/or the foot portion58of the mattress18. Additionally, the affixing member150may span the entire width and height of the bottom surface49of the mattress18. Alternatively, the affixing member150may span a width sufficient to retain the mattress18in the desired position. In either configuration, the caregiver can reposition the hospital bed10and the mattress18will simultaneously reposition while remaining with the sleep deck12.

In such an embodiment, the weight of the user may further assist in the coupling between the affixing member150and the sleep deck12through pressure forces. The coefficient of friction, although sufficient independently, may be enhanced by pressure forces exerted by the weight of the user on the mattress18. Accordingly, the caregiver may adjust the mattress18and the sleep deck12of the hospital bed10while the hospital bed10is in use and the affixing member150will minimize significant movement of the mattress18relative to the sleep deck12.

With reference now toFIGS.6A-6D, the mattress retention assembly22may also include a retention ridge152that may be coupled to the mattress18. It is generally contemplated that the retention ridge152can be coupled to the interior surface50of the outer mattress shell20and be covered by the outer mattress shell20. Alternatively, the retention ridge152may be coupled to the exterior surface52of the outer mattress shell20. It is also contemplated that at least one retention ridge152may be used; however, the use of more than one retention ridge152is further contemplated. The retention ridge152is configured to fit within at least one of the spaces44defined by the sleep deck12. For example, the retention ridge152may be received in the space44defined between the upper portion34and the middle portion36of the sleep deck12. Additionally or alternatively, the retention ridge152may be received in the space44defined between the middle portion36and the lower portion38of the sleep deck12. The depicted interlocking configuration of the retention ridge152within one of the spaces44allows the caregiver to reposition the hospital bed10, while the retention ridge152minimizes the likelihood that the mattress18will downwardly and/or upwardly shift along the sleep deck12. When multiple retention ridges152are used, each retention ridge152abuts the sleep deck12to prevent significant movement of the mattress18. The retention ridge152may extend at least partially along the width of the sleep deck12and the mattress18. Additionally or alternatively, the retention ridge152may extend the entire width of the sleep deck12and the mattress18. In either aspect, the retention ridge152interfaces with the sleep deck12such that when a caregiver adjusts the position of the sleep deck12and the mattress18, the mattress18moves with the sleep deck12to the caregiver selected position.

As depicted inFIGS.6C and6D, the retention ridge152includes a flange154and a projection156that has a first surface158and a second surface160. Additionally, as shown, a cavity162is defined by the projection156, discussed further below. The retention ridge152may be generally rigid or solid, and the projection156, as shown, is generally rectangular. It will also be understood, however, that the projection156may take on a variety of other geometric constructions. The rectangular shape of the projection156may result in the first and second surfaces158,160having larger contact surface areas with the sleep deck12when compared with alternative shapes of the projection156. The larger contact surface areas of the first and second surfaces158,160provide a greater surface of engagement with the sleep deck12.

A port164is defined by the projection156and provides access to cavity162. The port164is configured to receive a cord166(FIG.6B), which may be at least one of a power cord or a data cord from the mattress18. The cord166(FIG.6B) can be disposed within the cavity162to generally conceal the cord166while retaining any potential excess slack of the cord166(FIG.6B), which may be extracted when the mattress18is repositioned. The port164may be located at lateral portions168of the retention ridge152. Alternatively, the port164may be located at any other suitable portion of the retention ridge152, for example, at a midway portion170. The positioning of the port164may depend upon where the cord166is positioned relative to the mattress18. However, it is generally contemplated that the cord166may be any cord that may extend outward from the mattress18through the port164of the retention ridge152. By including the port164, the caregiver may easily access the cord166of the mattress18for patient care or hospital policy. Accordingly, the caregiver can adjust the hospital bed10while maintaining access to the cord166and minimizing shifting of the mattress18relative to the sleep deck12. It is generally contemplated that the mattress retention assembly22may include any combination of the retention features described herein, as well as any other mattress retention assembly options as known in the art.

Referring now toFIGS.7A and7B, the outer mattress shell20includes the interior surface50and the exterior surface52. The exterior surface52generally defines a patient support portion180and a sleep deck portion182. The mattress retention assembly22(FIGS.1A-6B) described above may be coupled to or disposed on the sleep deck portion182in any one of the configurations described above. It is generally contemplated that the interior surface50of the outer mattress shell20may be a non-coated fabric while the exterior surface52of the outer mattress shell20is a coated fabric such as, for example, a polyurethane-based fabric. The use of coated fabric on the exterior surface52allows the caregiver to easily sterilize the mattress18between users. Additionally, the outer mattress shell20may include a fold188that may be constructed from excess portions of the outer mattress shell20. The fold188covers the access points of the outer mattress shell20through which the caregiver can access the mattress18disposed within the outer mattress shell20. By way of example, not limitation, the access points may be the location at which the patient support portion180is coupled to the sleep deck portion182of the outer mattress shell20.

The fold188allows a caregiver to maintain cleanliness standards between users by directing user-fluids and other liquids past portions of the outer mattress shell20configured to provide the caregiver access to the mattress18. In one aspect of the present disclosure, the outer mattress shell20and the fold188may be sealed with a weld190, which couples a bonding strip192to a first section194and/or a second section196of the interior surface50of the outer mattress shell20. Further, the weld190can couple a fastening strip198to the exterior surface52of the outer mattress shell20and the fold188. A stitch200can further couple the fastening strip198to the outer mattress shell20and the fold188, wherein the stitch200(FIG.7B) may be any securing member known in the art. Additionally, the weld190may maintain the fold188of the outer mattress shell20in its folded state.

It is generally contemplated that the weld190may be a radiofrequency weld. The radiofrequency weld allows for a more secure and sterile seal between the patient support portion180and the sleep deck portion182of the outer mattress shell20, such that liquids may be prevented from penetrating the outer mattress shell20. As such, the use of the radiofrequency weld may allow a caregiver to readily clean the outer mattress shell20between users with minimal risk of residual contamination possibly entering the mattress18through the weld190. The radiofrequency weld is incorporated by applying electromagnetic energy and pressure to the outer mattress shell20and the bonding strip192to form the weld190. The weld190can be formed, for example, in a shear configuration202(FIG.7A). The formatting of the weld190in the shear configuration202further allows the weld190to generally withstand more force during use, for example, a pulling force by the caregiver during cleaning, as it is generally perpendicular relative to the outer mattress shell20. Consequently, the weld190will be stronger if the shear configuration202were to be used.

In addition, the bonding strip192can be used to strengthen the weld190as the bonding strip192is configured to stabilize the fold188under strong pulling forces that may occur during use. Further, the use of more than one bonding strip192results in a stronger weld hold. When the multiple bonding strips192are used, the multiple bonding strips192may at least partially overlap, such that the bonding strips192are at least partially coupled together, as illustrated and discussed below with reference toFIGS.9A and9B. Alternatively, the multiple bonding strips192may entirely overlap such that the bonding strips192are entirely coupled together (FIGS.9A and9B). As illustrated inFIG.7B, the multiple bonding strips192are coupled to the first section194and the second section196of the interior surface50proximate the fold188of the outer mattress shell20. Alternatively, the bonding strip192can be positioned in a central position204within the fold188of the outer mattress shell20. Due to the increased bonding strength, the caregiver may more rigorously clean the outer mattress shell20where the bonding strips192are used to strengthen the weld190.

Additionally in one of the depicted aspects, the fastening strip198couples a clasp locker206(commonly referred to as a zipper) to the exterior surface52of the outer mattress shell20. The clasp locker206can be coupled directly to the outer mattress shell20and the fold188such that the mattress18does not include the fastening strip198, as depicted inFIGS.7A and7B. In such disclosures, the clasp locker206may be a weldable zipper and coupled to the exterior surface52of the outer mattress shell20using a radiofrequency weld. When the clasp locker206couples directly to the exterior surface52of the outer mattress shell20, the caregiver may again be more rigorous in cleaning and removing the outer mattress shell20due to the strength of the coupling. It will be understood by one having ordinary skill in the art that a variety of different clasp lockers206may be available for direct coupling to the outer mattress shell20and the fold188. In either depiction, the clasp locker206allows the caregiver to remove the outer mattress shell20to thoroughly sterilize the outer mattress shell20between users.

With reference now toFIGS.8A and8B, the mattress18can further include a flap208coupled to the outer mattress shell20via the weld190. The addition of the flap208may provide similar advantages to those of the fold188, such as allowing a caregiver to maintain cleanliness between users of the hospital bed10while covering potential access points to the mattress18within the outer mattress shell20. It is generally contemplated that the flap208may be of a length longer than that of the fold188providing greater distance for liquids to travel away from the patient support portion180of the outer mattress shell20. When the weld190is applied in the shear configuration202, described above, the flap208may be coupled directly to the exterior surface52of the outer mattress shell20without the use of the bonding strip192. However, it is also contemplated that the bonding strip192may be used when using the weld190in shear configuration202to strengthen the bond when the flap208is coupled to the exterior surface52of the outer mattress shell20. The bonding strip192may be disposed between the flap208and the exterior surface52of the outer mattress shell20. The use of the shear configuration202may allow a caregiver to clean the outer mattress shell20with a minimized risk of the weld190pulling apart due to the strength of the shear configuration202. As previously noted, when the weld190is in the shear configuration202it may withstand more force than the weld190in a peel configuration209.

As shown inFIG.8B, in an alternate depiction, the weld190may be in a peel configuration209having a generally horizontal overlap of the flap208and a vertical weld210. The peel configuration209may include the vertical weld210to couple the bonding strip192and the flap208to the sleep deck portion182of the outer mattress shell20. In this alternate depiction, it is generally contemplated that multiple bonding strips192may be coupled to the sleep deck portion182of the outer mattress shell20and the flap208. The addition of multiple bonding strips192strengthens the bond of the flap208with the outer mattress shell20in the peel configuration209. In addition, it is generally contemplated that when using the flap208, the fastening strip198may be coupled to the sleep deck portion182of the outer mattress shell20by the stitch200. The flap208may be additionally coupled to the outer mattress shell20by a fastening member212, which provides additional strength to the flap208such that the caregiver may apply more force while adjusting or repositioning the flap208during cleaning.

With reference now toFIGS.9A and9B, the corner portions60and the outer mattress shell20may be sealed using the bonding strip192and a corner weld220. In the depicted description, multiple bonding strips192are used to self-couple the interior surface50of the outer mattress shell20. In order to achieve the depicted description, an incision is made at each of the corner portions60of the outer mattress shell20, and a corner edge is removed at the incision points from each corner portion60of the outer mattress shell20to define a first side224and a second side226of each corner portion60. In this instance, a first bonding strip228may be disposed on the first side224and a second bonding strip230may be disposed on the second side226. It is generally contemplated that the first and the second bonding strips228,230are coupled together using the corner weld220, such that the first and second bonding strips228,230at least partially overlap. It is further contemplated that the corner portions60can then be sealed with a secondary weld232. The corner weld220and the secondary weld232may be radiofrequency welds. The corner weld220reduces the likelihood that contaminants may penetrate the outer mattress shell20into the mattress18. As described above, the radiofrequency weld can be used for both the corner weld220and the secondary weld232so the outer mattress shell20has a strong seal allowing liquids to pass over the corner weld220and the secondary weld232without penetrating the outer mattress shell20. Accordingly, with the corner weld220and secondary weld232, the caregiver may thoroughly sterilize the outer mattress shell20while ensuring the internal padding of the mattress18remains undisturbed from outside contaminants to maintain cleanliness standards.

Referring now toFIG.10, and with further reference toFIGS.1A-9B, a method300for manufacturing the mattress18begins with a step302of forming the mattress18with the outer mattress shell20, which includes the patient support portion180and the sleep deck portion182. The outer mattress shell20defines the interior surface50and the exterior surface52. The method300also includes a next step304of applying at least one bonding strip192to adjacent sections306of the interior surface50of the outer mattress shell20. Further, a step307includes positioning a first bonding strip228and a second bonding strip230on the outer mattress shell20, with the first bonding strip228and the second bonding strip230being separated by an adjoining section of the outer mattress shell20.

Next, a step308includes coupling the clasp locker206to detachably couple the patient support portion180to the sleep deck portion182proximate the bonding strip192. A next step310includes applying electromagnetic energy to the outer mattress shell20and the at least one bonding strip192at an attachment site312(FIGS.7A-8B) to operably couple the outer mattress shell20with the at least one bonding strip192. The method300may also include a step314of applying pressure to the outer mattress shell20and the at least one bonding strip192at the attachment site312. A further step316includes folding the outer mattress shell20around the at least one bonding strip192to define a fold188of the outer mattress shell20, positioning a fastening strip198proximate to the fold188, and welding with radiofrequency the fold188, the at least one bonding strip192, and the fastening strip198. Next, a step318includes removing a portion of the outer mattress shell20to define a corner portion60. The first bonding strip228and the second bonding strip230are positioned proximate the corner portion60of the outer mattress shell20(step320), and the corner portion60is folded proximate to the first and second bonding strips228,230, such that the first and second bonding strips228,230at least partially overlap (step322). The corner portion60including the first bonding strip228and the second bonding strip230, may then be welded using radiofrequency (step324).

According to one aspect of the present disclosure, a hospital bed includes a sleep deck that has an upper portion, a middle portion, and a lower portion that each define a support surface and an underbody that defines a notch. An opening is defined by and extends through the upper portion. A space is defined between at least the upper portion and the middle portion. A mattress is disposed on the support surface of the sleep deck. An outer mattress shell encases the mattress. The outer mattress shell includes a fold that is defined by a weld extending through the outer mattress shell. A mattress retention assembly is operably coupled to the outer mattress shell. The mattress retention assembly includes a first magnet and a second magnet that selectively couples the mattress and the outer mattress shell to the sleep deck.

According to another aspect of the present disclosure, a hospital bed includes a sleep deck that has an upper portion, a middle portion, and a lower portion that each define a support surface and an underbody that defines a notch. An opening is defined by and extends through the upper portion. A space is defined between at least the upper portion and the middle portion. A mattress is disposed on the support surface of the sleep deck. An outer mattress shell encases the mattress. The outer mattress shell includes a fold that is defined by a weld extending through the outer mattress shell. A mattress retention assembly is operably coupled to the outer mattress shell. The mattress retention assembly includes a portion of the mattress retention assembly extends between the outer mattress shell and the sleep deck.

According to yet another aspect of the present disclosure, a hospital bed includes a sleep deck that has an upper portion, a middle portion, and a lower portion that each define a support surface and an underbody that defines a notch. An opening is defined by and extends through the upper portion. A space is defined between at least the upper portion and the middle portion. A mattress is disposed on the support surface of the sleep deck. An outer mattress shell encases the mattress. The outer mattress shell includes a fold that is defined by a weld extending through the outer mattress shell. A mattress retention assembly is operably coupled to the outer mattress shell. The mattress retention assembly includes an affixing member is disposed on the outer mattress shell.

According to still another aspect of the present disclosure, a hospital bed includes a sleep deck that has an upper portion, a middle portion, and a lower portion that each define a support surface and an underbody that defines a notch. An opening is defined by and extends through the upper portion. A space is defined between at least the upper portion and the middle portion. A mattress is disposed on the support surface of the sleep deck. An outer mattress shell encases the mattress. The outer mattress shell includes a fold that is defined by a weld extending through the outer mattress shell. A mattress retention assembly is operably coupled to the outer mattress shell. The mattress retention assembly includes a retention ridge extends through the space that is defined by the sleep deck.

According to another aspect, a mattress retention assembly further includes a first strap operably coupled with a first magnet and a second strap operably coupled with a second magnet. The second magnet of the second strap is selectively coupled with the first magnet of the first strap.

According to another aspect of the present disclosure, a first magnet and a second magnet of a mattress retention assembly are coupled to a strap. The strap extends through an opening defined by an upper portion of a sleep deck.

According to another aspect of the present disclosure, an outer mattress shell includes a handle that is coupled to a strap of a mattress retention assembly. The handle and the strap are coupled to a mattress and the outer mattress shell to a sleep deck.

According to another aspect of the present disclosure, a first magnet of a mattress retention assembly is disposed on a head portion of a outer mattress shell and a second magnet of the mattress retention assembly is disposed on a foot portion of the outer mattress shell. The first magnet and the second magnet each include a material having a coefficient of friction exceeding 0.3μ.

According to another aspect of the present disclosure, a material is disposed on an upper magnetic portion and a lower magnetic portion of a sleep deck.

According to another aspect of the present disclosure, an upper magnetic portion of a sleep deck is coupled to a first magnet and a lower magnetic portion of the sleep deck is coupled to a second magnet.

According to another aspect of the present disclosure, an affixing member of a mattress retention has a coefficient of friction exceeding 0.3μ.

According to another aspect of the present disclosure, a mattress retention assembly includes a hook that has a planar portion and a clasping portion. The planar portion is coupled to an outer mattress shell. The clasping portion is coupled to a sleep deck.

According to another aspect of the present disclosure, a mattress retention assembly includes a retention feature having a planar portion that extends between an outer mattress shell and a sleep deck. The retention feature also has a clasping portion frictionally engaged with a notch defined in an underbody of the sleep deck.

According to another aspect of the present disclosure, a retention ridge includes a port that is configured to receive at least one of a power cord and a data cord from a mattress.

According to still another aspect, a mattress retention assembly includes a locking flap having a flat portion that extends between an outer mattress shell and a sleep deck. The locking flap also includes securing members that are configured to couple a mattress to the sleep deck.

According to another aspect, a footboard includes posts that are operably coupled to securing members of a locking flap and coupled to a lower portion of a sleep deck.

According to another aspect of the present disclosure, a mattress assembly includes a mattress and an outer mattress shell that is covering the mattress and has a patient support portion and a sleep deck portion. The outer mattress shell defines an interior surface and an exterior surface. A bonding strip is coupled to the interior surface of the outer mattress shell. A fastening strip is coupled to the exterior surface of the outer mattress shell. A weld extends through the exterior surface and through the interior surface of the outer mattress shell. A clasp locker is operably coupled to the fastening strip and detachably couples the patient support portion to the sleep deck portion of the outer mattress shell.

According to another aspect, a flap may be coupled to an outer mattress shell via a weld. A bonding strip is disposed between the flap and an exterior surface of the outer mattress shell.

According to yet another aspect, an outer mattress shell includes a fold. A bonding strip is positioned within the fold. The bonding strip and the fold are coupled to an outer mattress shell via a weld.

According to another aspect, a bonding strip includes a first bonding strip and a second bonding strip. The first bonding strip is disposed on a first side of a corner portion of an outer mattress shell and the second bonding strip is disposed on a second side of the corner portion of the outer mattress shell.

According to yet another aspect of the present disclosure, a method for manufacturing a mattress includes forming the mattress that has an outer mattress shell that includes a patient support portion and a sleep deck portion. The outer mattress shell defines an interior surface and an exterior surface. The method further includes applying at least one bonding strip to the interior surface of the outer mattress shell. The method further includes coupling a clasp locker to detachably couple the patient support portion of the outer mattress shell to the sleep deck portion that is proximate the at least one bonding strip. The method further includes applying electromagnetic energy to the outer mattress shell and the at least one bonding strip at an attachment site to operably couple the outer mattress shell with the at least one bonding strip. The method further includes applying pressure to the outer mattress shell and the at least one bonding strip at the attachment site.

According to another aspect, the method applies at least one bonding strip and further comprises the steps of positioning a first bonding strip and a second bonding strip on an outer mattress shell. The first bonding strip and the second bonding strip are separated by an adjoining section of the outer mattress shell.

According to still another aspect, the method further includes removing a portion of an outer mattress shell to define a corner portion. The method further includes positioning a first bonding strip and a second bonding strip proximate the corner portion of an outer mattress shell. The method further including folding the corner portion of an outer mattress shell proximate the first bonding strip and the second bonding strip such that the first bonding strip and the second bonding strip at least partially overlap. A radiofrequency is welded to the corner portion, the first bonding strip, and the second bonding strip.

According to yet another aspect, a method further includes folding an outer mattress shell around the at least one bonding strip to define a fold of an outer mattress shell. The method further includes positioning a fastening strip proximate the fold. The method further includes welding with radiofrequency the fold, the at least one bonding strip, and the fastening strip.