Abstract:
A mattress for use in institutions, such as correctional facilities, detention centers, rehabilitation centers, hospitals and the like, includes a core formed of a transparent or translucent padding material and a transparent or translucent covering surrounding the core.

Description:
[0001]    This application claims priority to application Ser. No. 61/339,264 filed Mar. 2, 2010, and is a Continuation-in-Part of application Ser. No. 11/811,714 filed Jun. 12, 2007, which in turn claims priority from Provisional Patent Application Ser. No. 60/812,772 filed Jun. 12, 2006, the disclosures of which are fully incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to mattresses used in institutions, such as correctional facilities, detention centers, rehabilitation centers, hospitals and the like, and, more particularly, to mattresses that resist and detect tampering, tearing and alteration. 
         [0003]    Institutions, such as correctional facilities, jails, penitentiaries, detention centers, rehabilitation centers, hospitals and the like, house numerous people overnight. Accordingly, these institutions must provide bedding for each inmate, patient or guest. Such bedding typically includes a mattress supported on a metal frame and having a fabric covering sewn together at the seams. Unfortunately, some inmates, patients or guests of these institutions have a propensity to destroy or damage the mattress to which they are assigned by ripping and tearing the covering of the mattress. In addition, many inmates, patients or guests use their mattress to conceal contraband, such as drugs, weapons and the like, by tearing a small slit in the covering of the mattress and inserting the contraband inside the mattress. Such tears and slits may be taped, glued or otherwise closed making it difficult to see and detect the tear in the fabric covering of known mattresses. As a result, it may be a challenge for the institution&#39;s staff to detect the alteration of the mattress and find the contraband. 
         [0004]    Accordingly, benefits may be obtained from a mattress having an improved tear-resistant covering and a mechanism for detecting alterations, tears and/or contraband in the mattress. 
         [0005]    The present invention also relates to mattresses including vents which provide ventilation. Ventilation is beneficial to transfer heat or humidity, such as water vapor. Water vapor within a mattress may damage the structure of the mattress. Accordingly, benefits may be obtained from a mattress including a vent. 
         [0006]    Additionally, it would be advantageous to see into the mattress to see the contraband that is concealed, or to prevent the opportunity to conceal it. 
       SUMMARY 
       [0007]    The present invention provides mattresses for use in institutions, such as correctional facilities, detention centers, rehabilitation centers, hospitals and the like, where the mattress comprises a core formed of a padding material, the padding material being comprised of a transparent or translucent materiel; and a transparent or translucent covering surrounding said core. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein: 
           [0009]      FIG. 1  is a top view of a mattress according to one embodiment of the present invention wherein the covering of the mattress is partially cut away; 
           [0010]      FIG. 2  is a side view of the mattress of  FIG. 1 ; 
           [0011]      FIG. 3  is a sectional view of the mattress of  FIG. 1  taken along lines  3 - 3 ; 
           [0012]      FIG. 4A  is a sectional view of the mattress of  FIG. 2  taken along lines  4 - 4 ; 
           [0013]      FIG. 4B  is an enlarged view of the encircled region of the mattress of  FIG. 4A ; 
           [0014]      FIG. 5  is a perspective view of the mattress of  FIG. 1  wherein an alteration in the mattress has been detected; 
           [0015]      FIG. 6A  is a sectional view of a mattress according to another embodiment of the present invention; 
           [0016]      FIG. 6B  is an enlarged view of the encircled region of the mattress of  FIG. 6B ; 
           [0017]      FIG. 7  is a sectional view of a pillow according to one embodiment of the present invention; 
           [0018]      FIG. 8  is a perspective view of a mattress according to another embodiment of the present invention; 
           [0019]      FIG. 9  is an enlarged view of the encircled region of the mattress of  FIG. 8 ; 
           [0020]      FIG. 10  is a sectional view of the mattress of  FIG. 8  taken along lines  11 - 11 ; 
           [0021]      FIG. 11  is a perspective view of a mattress according to another embodiment of the present invention; 
           [0022]      FIG. 12  is an exploded view of a mattress according to another embodiment of the present invention; 
           [0023]      FIG. 13  is an enlarged view of the encircled region of the mattress of  FIG. 12 ; 
           [0024]      FIG. 14  is a perspective view of the mattress of  FIG. 12  wherein the cover has been folded; 
           [0025]      FIG. 15  is an enlarged view of the encircled region of the mattress of  FIG. 14 ; 
           [0026]      FIG. 16  is a perspective view of the mattress of  FIG. 14  wherein the flaps are adjacent to the rest of the cover; 
           [0027]      FIG. 17  is an enlarged view of the encircled region of the mattress of  FIG. 16 ; 
           [0028]      FIG. 18  is a perspective view of the mattress of  FIG. 16  wherein the cover is partially inverted; 
           [0029]      FIG. 19  is an enlarged view of the encircled region of the mattress of  FIG. 18 ; 
           [0030]      FIG. 20  is a perspective view of the mattress of  FIG. 18  wherein the cover has been inverted; 
           [0031]      FIG. 21  is a perspective view of the mattress of  FIG. 20  wherein a portion of the cover has been fastened to the rest of the cover; 
           [0032]      FIG. 22  is a perspective view of the mattress of  FIG. 18  wherein the core is configured to be inserted within the cover; 
           [0033]      FIG. 23  is a perspective view of the mattress of  FIG. 22  wherein the core is inserted within the cover; 
           [0034]      FIG. 24  is an enlarged view of the encircled region of the mattress of  FIG. 23 ; 
           [0035]      FIG. 25  is a top view of a mattress according to another embodiment of the present invention; and 
           [0036]      FIG. 26  is a view of the mattress of  FIG. 25  partially assembled. 
       
    
    
       [0037]    Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. Although the exemplification set out herein illustrates embodiments of the invention, in several forms, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed. 
       DETAILED DESCRIPTION 
       [0038]    The embodiments hereinafter disclosed are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following description. Rather the embodiments are chosen and described so that others skilled in the art may utilize its teachings. 
         [0039]    Referring first to  FIGS. 1-3  and  4 A- 4 B, mattress  10  in accordance with one embodiment of the present invention is illustrated. Mattress  10  generally includes core  12  and covering  14 , which surrounds core  12 . Core  12  is formed of any padding material suitable for use in mattresses. Such padding material may include, for example, various urethane foams, densified polyester batting, silicone foam, neoprene foam, cotton batting, or mixture thereof. The padding material may be formed using any means including, for example, vertical folding technology developed by, and the product of which is available from, Shinih Enterprise Co., Ltd (Taipei, TW). Mattress could also be made in accordance with our co-pending application Ser. No. 11/906,848 filed Oct. 4, 2007; the subject matter of which is incorporated herein be reference. 
         [0040]    Covering  14  includes inner surface  16 , which is disposed proximal to core  12 , and opposing outer surface  18 . Covering  14  is formed of a transparent or translucent, flexible fabric through which core  12  and inner surface  16  are visible. In addition, the fabric of covering  14  is of a strength and resiliency to resist tears under normal use. Such a fabric may include polyurethane, weldable vinyl, thermoplastic urethanes, or nylons with weldable backing. The fabric of covering  14  may further include rip-stop pattern  20  woven therein to further resist tears. Rip-stop pattern  20  is formed of string fibers, such as nylon, woven at regular intervals into the fabric of cover  14 . Rip-stop pattern  20  further resists tears and prevents the spread of small tears, thus making it difficult for a person to intentionally tear mattress  10 . Covering  14  may also be capable of filtering UV (ultraviolet) light (i.e. preventing UV light rays from passing through covering  14  and reaching inner surface  16  of covering  14  and/or core  12 ). Covering  14  is sealed about core  12  by sealing seams  22  together using any suitable means including, for example, heat sealing, thermal or sonic welding, adhesive bonding, and/or chemical bonding. 
         [0041]    Turning specifically to FIGS.  2  and  4 A- 4 B, mattress  10  also includes vents  24 , which provide ventilation through covering  14  between core  12  and the air outside of mattress  10 . Vents  24  include a plurality of vent holes  24   a  extending through covering  14  and microporous membrane  24   b  positioned over holes  24   a  and sealed to inner surface  16  of covering  14 . Vent holes  24   a  may be of any size sufficient to allow ventilation (i.e. the passage of air) between core  12  and the air outside mattress  10 . In some cases, it may be desirable to employ minimally sized vent holes  24   a . For example, in one embodiment vent holes  24   a  may be between 0.001 inches and 0.05 inches (0.0254 mm-1.27 mm) in diameter. However, this is only an exemplary embodiment and, as mentioned above, the size of vent holes  24   a  may vary. 
         [0042]    Vents  24  may be constructed by any suitable method. In one exemplary method, vents  24  are constructed by, first, forming holes  24   a  in covering  14  using any known method including, for example, stamping, drilling or stitching. In one particular embodiment, vent holes  24   a  are formed using a drill press having a plurality of drill bits or tips, which are spaced apart from one another but closely toleranced. The drill bits penetrate or puncture covering  14  to, thereby, form a pattern of closely spaced vent holes. The pattern of vent holes  24   a  may have any shape and form. Next, microporous membrane  24   b  is positioned over the pattern of vent holes  24   a  and may be sealed to covering  14  using any sealing technique including, for example, heat sealing, thermal or sonic welding, adhesive bonding, double-sided adhesive strips and/or chemical bonding. 
         [0043]    Referring now to  FIGS. 6A and 6B , vents  24  may alternatively be formed by, first, adhering double-sided adhesive strip  24   c  to inner surface  16  of covering  14 . Adhesive strip  24   c  may be any suitable type of double-sided adhesive strip including, for example, double-sided foam tape. Adhesive strip  24   c  includes opposing surfaces  24   d ,  24   e , each of which is coated with adhesive. Prior to use, each of adhesive surfaces  24   d ,  24   e  is covered with a piece of tape to cover and protect the adhesive until ready for use. To adhere adhesive strip  24   c  to inner surface  16  of covering  14 , the tape (not shown) is removed from surface  24   e  of strip  24   c  to expose the adhesive. Adhesive surface  24   e  is pressed against inner surface  16  of covering  14  to adhere strip  24   c  to inner surface  16 . Next, vent holes  24   a  are formed through both covering  14  and strip  24   c  using any method including, for example, stamping, drilling or stitching. Microporous membrane  24   b  is then adhered to surface  24   d  of adhesive strip  24   c , by removing the protective tape (not shown) to expose the adhesive surface  24   d  and pressing microporous membrane  24   b  against surface  24   d.    
         [0044]    Microporous membrane  24   b  may be an oliophobic and hydrophobic membrane that allows the passage of air flow in any direction, but prevents the passage of fluids, such as water, oil and bodily fluids, in a direction toward core  12 . Such a membrane may include Versipor available from Pall Specialty Materials of Port Washington, N.Y. Microporous membrane  24   b  may be sealed to outer surface  18  of covering  14  in addition to or in the alternative to inner surface  16 . 
         [0045]    It should be appreciated that the vents, given that they are provided in a high density pattern, could be provided in such a manner that they are configured as indicia. These indicia could be trademarks or logos or any other configuration. The material comprising the logos or other configuration could be formed from any material. 
         [0046]    Mattress  10  is also equipped with a mechanism for detecting when tears have been made in covering  14 . More particularly, in one embodiment, inner surface  16  is impregnated or coated with a color change composition. The color change composition provides inner surface  16  with an initial color. The initial color may be any color or may be clear. The color change composition is adapted to change the initial color to an activated color when covering  14  has been torn or penetrated. Activated color may be any color provided that the activated color is visibly and noticeably different from the initial color. Because covering  14  is transparent or translucent and inner surface  16  is visible through covering  14 , activated color is also visible through covering  14 . Color change composition may be any composition capable of changing colors when covering  14  is pierced, torn or penetrated. For instance, color change composition may be a photochromic dye, such as an aryl substituted heterocycle available from Color Change Corporation of Streamwood, Ill. 
         [0047]    In this case, the color change composition changes from the initial color to the activated color when exposed to UV light. Accordingly, because covering  14  filters UV light, inner surface  16  and the color change composition impregnated therein is shielded from UV light and remains the initial color. However, as shown in  FIG. 5 , when a tear  28  is made through covering  14 , UV light is permitted to pass through tear  28  thereby exposing the color change composition to the UV rays. As a result, the color change composition and inner surface  16  change to activated color  26  in the area of tear  28  thereby detecting the tear  28  and alteration in mattress  10 . The activated color  26  is visible through covering  14  so as to provide a visible alert of tear  28 . 
         [0048]    In practical use, mattress  10 , shown in  FIG. 5 , may be provided to inmates at a correctional facility, such as a prison, jail, juvenile detention center or other like facility. When an inmate attempts to hide contraband, such as knife  30 , in mattress  10 , the inmate attempts to cut or tear covering  14 . Rip-stop pattern  20  serves as a first line of defense by making it difficult for the inmate to successfully tear covering  14 . In the event the inmate is successful in creating tear  28  in covering  14  and inserting knife  30  into core  12  ( FIG. 1 ) of mattress  10 , the color change composition acts as a second line of defense by providing a visible alert of tear  28 . For instance, during a routine or for cause check or “shake-down” of the inmate&#39;s cell the correctional officers can strip mattress  10  of any sheets or blankets and expose mattress  10  to UV light. The UV light rays can now penetrate covering  14  through tear  28 . The UV light rays reach inner surface  16  and cause the color change composition to change from the initial color to activated color  26  in the region of tear  28 . The correctional officers can view activated color  26  through covering  14  and, thereby, identify the location of tear  28  and contraband  30 . 
         [0049]    In the embodiments described above, the color change composition is impregnated in or coated on inner surface  16  of covering  14 . However, it should be understood that core  12 , in addition or in the alternative to inner surface  16 , may be impregnated with the color change composition. In this case, core  12  would exhibit the activated color when the UV light rays penetrate the tear and reach core  12 . 
         [0050]    Although the embodiments described above use a photochromic dye as the color change composition, the present invention also contemplates using other suitable color changing dyes. For instance, hydrochromic or piezochromic dyes may be used to detect moisture or pressure changes within mattress  10 . Color change dyes may also be developed and used for detecting particular types of contraband. For instance, a color change composition adapted to change color upon contact with metal may also be used. 
         [0051]    In yet another embodiment, mattress  10  may also include an integrated pillow (not shown) protruding from core  12  and formed of padding material similar to that of core  12 . It may be desirable to form the integrated pillow of a padding material having a density lesser than that of the material of core  12  to provide a softer, more pliable pillow. The integrated pillow would be covered by covering  14 , and may include the mechanisms for resisting and detecting tears, as discussed above. In this embodiment, inmates and other users may be prevented from concealing contraband in their pillow because the pillow is integrated with the mattress and is provided with the same alteration detection mechanisms. 
         [0052]    It should also be understood that the concepts of the present invention are not limited in application to just mattresses. For instance, referring to  FIG. 7 , the concepts of the present invention may be adapted to form a pillow, such as pillow  110 . Pillow  110  generally includes core  112  and covering  114 , which surrounds core  112 . Core  112  is formed of padding material such as urethane foams, densified polyester batting, silicone foam, neoprene foam, cotton batting or mixture thereof. 
         [0053]    Covering  114  includes inner surface  116 , which is disposed proximal to core  112 , and opposing outer surface  118 . Similar to covering  14  of mattress  10  ( FIG. 1 ), covering  114  is formed of a transparent or translucent, flexible fabric through which core  112  and inner surface  116  are visible. In addition, the fabric of covering  114  is of a strength and resiliency to resist tears under normal use and may include a rip-stop pattern (not shown) woven therein to further resist tears. Covering  114  is sealed about core  112  by sealing seams  122  together using any suitable means including, for example, heat sealing, thermal or sonic welding, adhesive bonding, and/or chemical bonding. 
         [0054]    Pillow  110  may also include vents (not shown), which provide ventilation through covering  114  between core  112  and the air outside of pillow  110 . As described above with respect to mattress  10  ( FIG. 1 ), pillow  110  inner surface  116  and or core  112  may be impregnated or coated with a color change composition to provide an means for detecting alteration of pillow  110 . 
         [0055]    Finally, either of these items can be profiled for easy shipping, by compressing the items to deflate the foam, and then covering the vent with a covering tape. The tape holds the items in that compressed configuration, as the air can not refill the foam due to the lack of the suction through the vent. Removal of the tape causes the air to refill the foam and return the item to its inflated state. 
         [0056]    With reference now to  FIG. 8 , another embodiment of mattress is illustrated as  210 . Mattress  210  generally includes core  212  ( FIG. 10 ) and covering  214 , which surrounds core  212 , and vent  224 . Similar to previous embodiments, core  212  may be formed of any padding material suitable for use in mattress  210 . Such padding material may include, for example, various urethane foams, densified polyester batting, silicone foam, neoprene foam, cotton batting, or mixture thereof. Covering  214  includes inner surface  216  ( FIG. 10 ) and outer surface  218 . Inner surface  216  may include nylon; outer surface  218  may include polyurethane. 
         [0057]    As shown in  FIG. 9 , vent  224  includes at least one hole  226  through covering  214 , and a microporous membrane  228 . Vent  224  provides ventilation through covering  214 . Vent  224  may include a plurality of holes  226  extending through cover  214  and with microporous membrane  228  positioned over holes  226 . Microporous membrane  228  may be fastened to inner surface  216  ( FIG. 10 ) using any suitable means including, for example, heat sealing, thermal or sonic welding, adhesive bonding, and/or chemical bonding. Microporous membrane  228  may be comprised of any suitable filter as described herein, but in this embodiment, membrane  228  is from Pall Life Sciences, Part #E01008E. 
         [0058]    Overlay  230  may be fastened to covering  214  using any suitable means including, for example, heat sealing, thermal, RF or sonic welding, adhesive bonding, and/or chemical bonding. Overlay  230  may cover at least one hole  226 . While overlay  230  is not part of the vent  224 , it cosmetically covers the vent  224  and is breathable. Overlay  230  may be comprised of multiple possible materials, such as leather, cloths, or micro-suede, although micro-suede is preferred for its cosmetic look and feel, its workability and for its breathability. Overlay  230  can also be configured as an indicia. This indicia could be trademarks or logos or any other configuration. 
         [0059]    Referring now to  FIG. 10 , mattress  210  is shown including vent  224  in cross-section. Cover  214  is shown with inner surface  216  and outer surface  218 . Cover  214  may include a plurality of layers to include inner surface  216  and outer surface  218 . Inner surface  216  may include nylon; outer surface  218  may include polyurethane. Overlay  230  is shown adjacent to and covering vent holes  226 . Microporous filter  228  is shown adjacent to and covering vent holes  226 . 
         [0060]    Now referring to  FIG. 11 , vent  240  is shown. Vent  240  is substantially similar to vent  224  except for the following difference. As illustrated, filters  242  are circular or cylindrical in shape and are large enough to substantially cover vent holes  226 . Filters  242  attempt to minimize waste of filter material by substantially covering vent holes  226  without much excess. Filters  242  may be fastened to cover  214  in the same manner as filters  228  as previously disclosed. 
         [0061]    With the components as described, the assembly of the mattress will be described. Referring back to  FIG. 8 , cover  214  is sealed by sealing seams  222  together using any suitable means including, for example, heat sealing, sewing, thermal or sonic welding, adhesive bonding and/or chemical bonding. It should be noted that the additional fabric of cover  214  in relation to seam  222  may be located in the interior or exterior of mattress  210  or both. 
         [0062]    Referring now to  FIG. 12 , cover  214  is shown as a single sheet, prior to its formation. Inner surface  216  of covering  214  is shown. Outer surface  218  ( FIG. 18 ) is illustrated as on the bottom side of cover  214 . Vent  224  is illustrated as including at least one hole  226  extending through covering  214 . Microporous membrane  228  is illustrated as positioned adjacent to and covering vent holes  226  and is illustrated as sealed to inner surface  216  of covering  214 . Overlay  230  is also illustrated as positioned adjacent to and covering vent holes  226  and is also illustrated as sealed to outer surface  218  ( FIG. 18 ) of covering  214 . As shown in  FIG. 12 , lines  231  illustrate a potential folding arrangement. Folding arrangement will be described in greater detail below. Other folding arrangements are considered and described as alternative folding arrangements. 
         [0063]    Cover  214  defines slits  232  which aid in this folding arrangement. As there are alternative folding arrangements, there are also alternative slit arrangements to facilitate in alternative folding arrangements. Vent  224  is located within portion  234  of cover  214 . In one embodiment of a folding arrangement, portion  236  folds under portion  234  along arrow  238 . Now referring to  FIG. 13 , slits  232  are disclosed in greater detail. As illustrated, slits  232  define flaps  240 . 
         [0064]    As shown in  FIG. 14 , folded cover  214  is shown. Under this folding arrangement, inner surface  216  is shown exposed and outer surface  218  ( FIG. 18 ) is enclosed. The longitudinal sides of portions  234  and  236  are substantially adjacent in this folding arrangement. As illustrated, the longitudinal sides are seamed to the outside, creating seams  222 . In an alternative folding arrangement, longitudinal sides of portions  234  and  236  are seamed to the interior of cover  214 . 
         [0065]    Seams  222  may extend onto flaps  140 . As illustrated, portion  242  is not seamed. In an alternative folding arrangement, portion  242  of cover  214  may be partially vertical as illustrated in its folding pattern. As shown in  FIG. 15 , portion  242  may bulge or provide an opening  244  to the interior of cover  214 . In an alternative folding arrangement, flaps  240  may be placed within openings  244 . Referring back to  FIG. 14 , seam  222  extends along the length of the sides of portions  234  and  236 , including adjacent to portion  246 . 
         [0066]    Now referring to  FIG. 16 , flaps  240  are placed in close relationship to portion  242 . In an alternative folding arrangement, flaps  240  are sealed to portions of  242 . Referring now to  FIG. 17 , slits  232  ( FIG. 12 ) define edges  241  of flaps  240  to be placed adjacent to portion  242 . It is recognized that any suitable seaming slip pattern, any suitable folding arrangement, or seaming pattern is possible where appropriate. 
         [0067]    Now referring to  FIG. 18 , cover  214  may be turned inside out as illustrated by arrow  246 . Turning cover  214  inside out exposes outer surface  218  and overlay  230 . Turning cover  214  inside out also encloses outwardly directed seams  222  as best illustrated by  FIG. 19 . Turning cover  214  inside out also exposes inside seam  224 . Where the folding arrangement is such that flaps  240  were not seamed to portion  242 , portion  242  is shown in  FIG. 20  bulging away from the rest of cover  214 . Portion  242  may be seamed to the rest of cover  214  as shown in  FIG. 21 . 
         [0068]    Now referring to  FIG. 22 , core  212  is shown as configured to be inserted into the interior of cover  214  along arrow  248 . As previously mentioned, this is only one of several potential folding patterns. 
         [0069]    Referring now to  FIG. 23 , mattress  210  is shown including outwardly seamed edge  224  for one side. The other seamed portions are shown as inwardly seamed edges  222 , as best shown in  FIG. 24 . 
         [0070]    With respect now to  FIGS. 25 and 26 , another embodiment of the present mattress is shown. As shown in  FIG. 25 , mattress  310  is shown having an outer covering  314 . In this embodiment, covering  314  is also a transparent or translucent material similar to any of the materials discussed herein, and may or may not include a rip stop pattern  16  as also described about. In this embodiment, stuffing  312  is provided to fill cavity  320  of mattress cover  314 . In this embodiment, stuffing  312  is also transparent or translucent and could be comprised of foam, fiber, woven plastics, bubble wrap, gel beads, air pockets, densified fibers, and/or a combination of two or more of the above. As such, the entire mattress is transparent or translucent such that contraband (such as knife  30 ) can be seen directly through the mattress while the mattress is in a fully assembled condition. 
         [0071]    While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.