U.S. patent application number 10/094828 was filed with the patent office on 2002-09-12 for mattress structure.
Invention is credited to Dalton, Roger D., Luff, Larry E., Marasligiller, Ares, Reeder, Ryan A., Stolpmann, James R., Washburn, Robyn P., Weigold, Steven E., Westerfeld, Steven R..
Application Number | 20020124320 10/094828 |
Document ID | / |
Family ID | 24258474 |
Filed Date | 2002-09-12 |
United States Patent
Application |
20020124320 |
Kind Code |
A1 |
Washburn, Robyn P. ; et
al. |
September 12, 2002 |
Mattress structure
Abstract
A bed and mattress structure includes an articulating frame
having longitudinally spaced head, seat, thigh, and foot sections.
The head, thigh and foot sections are movable relative to each
other and relative to the seat section. A deck on the frame
supports a user. A mattress is interposed between the deck and the
user. The mattress includes a plurality of longitudinally spaced
apart, transversely extending air bladders corresponding
respectively to the frame sections. A power driver tilts the frame
sections to desired tilted positions. An air supply fills each
bladder to desired air pressures to support the user. A drive
controller controls the power drive for tilting the frame sections
to various desired positions. An air supply controller controls the
air supply for filling the air bladders to desired air pressures. A
hand held controller includes a key pad cooperating with a
programmable device to provide signals through a cord in response
to inputs from the user. The key pad includes memory set buttons
providing the signals when the buttons are activated by the user.
The controller controls the power drive and the air supply in
response to the signals. The memory set buttons are arranged in
order of the frequency of use. A display is mounted on the
substrate and selectively indicates the positions of the sections
of the articulating frame and the pressures of the air
bladders.
Inventors: |
Washburn, Robyn P.;
(Batesville, IN) ; Reeder, Ryan A.; (Brookville,
IN) ; Luff, Larry E.; (Batesville, IN) ;
Marasligiller, Ares; (Villa Hills, KY) ; Stolpmann,
James R.; (Charleston, SC) ; Dalton, Roger D.;
(Monks Corper, SC) ; Westerfeld, Steven R.;
(Batesville, IN) ; Weigold, Steven E.; (Hamilton,
OH) |
Correspondence
Address: |
Barnes & Thornburg
11 S. Meridian Street
Indianapolis
IN
46204
US
|
Family ID: |
24258474 |
Appl. No.: |
10/094828 |
Filed: |
March 11, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10094828 |
Mar 11, 2002 |
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09033116 |
Mar 2, 1998 |
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6378152 |
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09033116 |
Mar 2, 1998 |
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08565409 |
Nov 30, 1995 |
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5815865 |
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Current U.S.
Class: |
5/713 ;
5/710 |
Current CPC
Class: |
A61G 7/05776 20130101;
A61G 2203/12 20130101; Y10S 5/926 20130101; Y10S 5/935
20130101 |
Class at
Publication: |
5/713 ;
5/710 |
International
Class: |
A47C 027/10 |
Claims
1. A control system for a bed and a mattress structure comprising a
frame and a mattress comprising a plurality of longitudinally
spaced apart, transversely extending air bladders and an air supply
for filling each bladder to desired air pressures to support the
user, the control system comprising: an air controller cooperating
with the air supply for filling the air bladders to desired air
pressures; a hand-held controller in communication with the air
controller, the hand-held controller being configured for receiving
air memory set inputs from the user permitting the user to
establish at least one preferred air-firmness setting in the air
bladders and receiving at least one air memory input from the user
recalling the preferred air-firmness settings; and the air
controller filling the air bladders to the at least one preferred
air-firmness setting in response to the air memory input.
2. The control system of claim 1, wherein the air controller
includes microprocessor and software in communication with the
hand-held controller for storing at least one air memory set input
received from the hand-held controller and controlling the air
supply controller to establish desired bladder pressures in
response to receiving the at least one memory input from the
hand-held controller.
3. The control system of claim 1, in which the hand-held controller
includes a key pad having a first end and a second end, the first
end being positioned generally above the second end when held by
the user, the key pad including buttons arranged having the most
frequently selected buttons positioned near the first end, the
least frequently selected buttons positioned near the second end,
and the remaining buttons positioned therebetween in the order of
frequency of use with the most frequently used buttons positioned
nearest the first end.
4. The control system of claim 1, in which the hand-held controller
includes a key pad having a first end and a second end, the first
end being positioned generally above the second end when held by
the user, the key pad including buttons arranged in the order that
the user generally will use the buttons in a typical operation
sequence, the first buttons generally used in the typical operation
sequence being positioned nearest the first end and the last
buttons generally used in the typical operation sequence being
positioned nearest the second end.
5. The control system of claim 1, wherein the frame includes
longitudinally spaced head, seat, thigh, and foot sections, the
head, thigh, and foot sections being movable relative to each other
and relative to the seat section and further comprising a drive
controller for tilting the frame sections to various desired
positions.
6. The control system of claim 5, wherein the hand-held controller
is further configured for receiving drive memory set inputs from
the user permitting the user to establish preferred positions of
the frame sections and for receiving at least one drive memory
input from the user recalling the preferred position settings, the
drive controller tilting the frame sections to the preferred
position setting in response to the drive memory input.
7. The control system of claim 6, wherein the drive controller
includes microprocessor and software in communication with the
hand-held controller for storing at least one drive memory set
input received from the hand-held controller and controlling the
drive controller to establish desired frame section positions in
response to receiving the at least one drive memory input from the
hand-held controller.
8. A control system for a bed and a mattress structure comprising a
frame and a mattress comprising a plurality of longitudinally
spaced apart, transversely extending air bladders and an air supply
for filling each bladder to desired air pressures to support the
user, the control system comprising: an air controller cooperating
with the air supply for filling the air bladders to desired air
pressures; a hand-held controller in communication with the air
controller, the hand-held controller including a key pad having a
first end and a second end, the first end being positioned
generally above the second end when held by the user, the key pad
including air adjustment buttons, a memory set button to establish
at least one preferred air-firmness setting in the air bladders,
and at least one memory button to recall the preferred air-firmness
setting; and the air controller filling the air bladders to the at
least one preferred air-firmness setting in response to the user
activating the memory button.
9. The control system of claim 8, wherein the at least one memory
set button is positioned to lie adjacent the first end of the key
pad.
10. The control system of claim 9, wherein the at least one memory
button is positioned to lie adjacent the memory set button.
11. The control system of claim 9, wherein the air adjustment
buttons are positioned to lie between the at least one memory
button and the second end of the key pad.
12. The control system of claim 8, wherein the air controller
includes microprocessor and software in communication with the
hand-held controller for storing at least one memory set input
received from the hand-held controller upon activation of the at
least one memory set button and controlling the air supply
controller to establish desired bladder pressures in response
activation of at least one memory button.
13. The control system of claim 8, wherein the frame includes
longitudinally spaced head, seat, thigh, and foot sections, the
head, thigh, and foot sections being movable relative to each other
and relative to the seat section and further comprising a drive
controller for tilting the frame sections to various desired
positions.
14. The control system of claim 13, wherein the drive controller
includes microprocessor and software in communication with the
hand-held controller for storing at least one memory set input
received from the hand-held controller upon activation of the at
least one memory set key and controlling the drive controller to
establish desired frame section positions in response to activation
of the at least one memory key.
15. The control system of claim 14, wherein the air controller
includes microprocessor and software in communication with the
hand-held controller for storing at least one memory set input
received from the hand-held controller upon activation of the at
least one memory set button and controlling the air supply
controller to establish desired bladder pressures in response
activation of at least one memory button.
16. A hand held controller operable by a user for a bed and
mattress structure comprising an articulating frame including
longitudinally spaced head, seat, thigh, and foot sections, the
head, thigh, and foot sections being movable relative to each other
and relative to the seat section, the deck supporting the head and
shoulder, seat, thigh, and feet of a user, a mattress interposed
between the deck and the user, the mattress comprising a plurality
of longitudinally spaced apart, transversely extending air bladders
corresponding respectively to the frame sections, power driver for
tilting the frame sections to desired tilted positions, an air
supply for filling each bladder to desired air pressures to support
the user, and a drive controller for controlling the power drive
for tilting the frame sections to various desired positions and an
air supply controller for controlling the air supply for filling
the air bladders to desired air pressures, the hand held controller
comprising a substrate having a generally upper first end, a
generally lower second end, and a surface therebetween generally
facing the user when the user operates the hand held controller, a
cord extending from the second end of the substrate for carrying
signals to the controller, a programmable device carried by the
substrate for storing and retrieving inputs from the user, and a
key pad carried by the top surface of the substrate, the key pad
cooperating with the programmable device to provide signals to the
controller through the cord in response to inputs from the user,
the key pad including memory set buttons providing the signals to
the cord when the buttons are activated by the user, the controller
manipulating the power drive and the air supply in response to the
signals, the buttons being arranged so that buttons are ordered
from the first end to the second end in order of the frequency of
use of the buttons so that the most frequently used buttons are
positioned to lie nearest the first end and the least frequently
used buttons are nearest the second end of key pad, and a display
mounted on the substrate and selectively indicating the relative
position of the sections of the articulating frame and the relative
pressure of the air bladders.
17. The controller of claim 16, in which the display is positioned
adjacent to the first end of the substrate.
18. The controller of claim 16, in which the substrate includes
spaced-apart longitudinal first and second sides connecting the
first and second ends and the display includes a plurality of
spaced-apart light emitting diodes extending transversely between
the first and second sides.
19. The controller of claim 18, in which the plurality of light
emitting diodes cooperate to indicate the relative positions of the
sections of the articulating frames and the relative pressures of
the air bladders by energizing individual light emitting diodes
which cooperate to form a pattern of energized light emitting
diodes indicating the extent of the selected parameter.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of copending application
Ser. No. 08/565,409 filed Nov. 30, 1995
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to bed and mattress structures
and particularly to mattress structures which may be customized for
individual users at the point of sale. The mattress of the present
invention may be delivered to the user in a variety of forms
assembled from kits provided at the point of sale to accommodate
the musculoskeletal condition of the user. The mattress may also be
customized at the factory or at some assembly location other than
the point of sale based on a customer's reaction to a test mattress
used at the point of sale, the test mattress comprising a plurality
of air bladders arranged under the user with a system for recording
air pressures producing the desired support and firmness for the
user. These bladder air pressures may be converted at the factory
to equivalent foam core structures having the desired support and
firmness characteristics.
[0003] It is well known to provide foam support pads or mattresses
for supporting a user reclining on the pad. For example, U.S. Pat.
Nos. 4,879,776; 5,038,433; 5,077,849; 5,111,542; and 5,172,439, all
to Farley, disclose mattress overlays and pads for supporting a
user. In addition, U.S. Pat. Nos. 4,449,261 to Magnusson and
4,991,244 to Walker disclose mattress borders for receiving core
mattresses, and U.S. Pat. No. 5,105,488 to Hutchinson et al.; U.S.
Pat. No. 4,803,744 to Peck et al.; and U.S. Pat. Nos. 4,424,600 and
4,435,864 to Callaway, disclose supporting surfaces having
selectively adjustable firmness.
[0004] What is needed is a mattress that can be prepared using a
mattress kit for customizing the mattress either at the point of
sale or at a factory using data generated at the point of sale to
provide a user with a mattress having reduced interface pressure
while providing the user with his or her individually desired
support and firmness characteristics. The improved mattress should
be capable of side-by-side customization when the mattress is sized
for use on queen-sized beds and king-sized beds so that two
sleeping partners are each provided with their individually desired
support and firmness characteristics on the same bed. The improved
mattress should also be compatible with an articulating bed so that
the mattress can be moved to a variety of positions selected by the
user.
[0005] In addition, the improved mattress should be provided with
features such as a "warm air release" to warm the extremities of
the user, multiple longitudinal zones that can be controlled to
vary the support and firmness characteristics perceived by the
user, and it should be provided with a hand held controller having
a key pad including a display that is easy to read to determine the
status of various features of the bed, buttons that are located for
convenient manipulation for adjusting various aspects of the bed
and mattress structure, and memory setting capability for matching
a desired bed deck position with desired firmness and support
characteristics so that by simply pressing one button the bed
automatically moves to the user-selected position and the mattress
automatically assumes the user-selected firmness and support
characteristics selected for each zone of the mattress.
[0006] According to the present invention, a plurality of mattress
structure components is provided. The components are arranged for
selective assembly of the components to provide a customized
mattress structure at the point of sale to accommodate the
musculoskeletal condition and interface pressure preference of the
user. The mattress structure components include a perimetral frame
having a head end foam section, a foot end foam section, and
longitudinally extending side foam sections joining the head and
foot foam sections to provide a longitudinally extending foam
frame. The foam frame has a central opening above which the user
will rest and the frame sections have upper surfaces lying
generally in the same common plane.
[0007] The mattress structure components additionally include a
plurality of cores for filling the central opening. The cores are
provided in a variety of firmness and support characteristics such
that various combinations of firmness and support can be provided.
A plurality of toppers cover the frame and the central opening and
the selected cores therein. The plurality of toppers include
toppers having various firmness and support characteristics and can
be made from foam rubber and can include air bladders, water
bladders, or bladders for containing other fluids.
[0008] In preferred embodiments, the mattress is supported by an
articulating deck having longitudinally spaced head, seat, thigh,
and foot sections. The head, thigh, and foot sections of the
illustrative articulating deck are movable relative to each other.
The head, thigh, and foot sections are infinitely adjustable
between a generally planar sleeping position and reclining
positions to allow the bed to attain any desired position within
the range of movement of the head, thigh, and foot sections, thus
accommodating changes of position of the user on the bed.
Preferably, the range of movement of the foot section is limited to
positions generally parallel to the seat section and the downward
range of movement of the thigh section is limited to the sleeping
position so that the feet of the user remain elevated above the
torso of the user.
[0009] The mattress is suitable for use with such an articulating
deck. The mattress includes a head portion for supporting the
scapula and the lumbar of the user, a seat portion for supporting
the user's sacrum, a thigh portion for supporting the thighs of the
user, and a foot portion. Each named mattress portion is associated
respectively with the head, seat, thighs, and feet of the person
resting on the sleeping surface of the bed as well as with the
underlying head, seat, thigh, and foot sections of the deck.
[0010] The mattress includes a mattress cover having a top mattress
cover and a bottom mattress cover attached to the top mattress
cover by a perimetral zipper. The top and bottom mattress covers
define a mattress interior receiving a plurality of mattress
structure components. The zipper is positioned so that the bottom
cover can be placed on a surface and used as a template for
building the mattress with a "bottom up" assembly technique placing
the components on the bottom of the mattress on top of the bottom
cover and building the other components thereon. The zipper is also
positioned to facilitate a "top down" assembly by starting with the
top cover and first adding the components on the top of the
mattress to the top cover and building the other components
thereon.
[0011] The mattress structure components include a frame preferably
made from a relatively firm foam rubber such as a high resiliency,
high density urethane foam. The frame is positioned generally along
the perimeter of the mattress. Use of a relatively firm foam
provides support characteristics that aid users as they ingress and
egress to and from an upwardly-facing sleeping surface of the
mattress and that prevent the user from rolling off of the sleeping
surface. The frame is formed to include a central opening beneath
the sleeping surface and above which the user will rest.
[0012] A plurality of cores including air bladders, "zone foam"
elements, "sculptured foam" shaped from foam blocks, and
combinations thereof are provided for filling the central opening.
The cores are selected to customize the firmness, support, and
interface pressure characteristics to meet the individual desires
of each user. To customize the mattress in such a fashion requires
considering the combination of each individual's height, weight,
body type, weight distribution, health conditions, and
preferences.
[0013] The preferred method for customizing the mattress is
initiated when a potential user completes a questionnaire to aid in
the analysis of that user's "sleep profile." The sleep profile
assesses such factors as the user's general health and sleep
habits. A firmness recommendation is computed either in terms of a
pressure for various zones of a "test mattress" containing an air
bladder or in terms of a foam type and density for each zone. In
addition, a surface recommendation is established based on the
user's responses to a surface recommendation questionnaire.
[0014] Once the surface and hardness recommendations are
established, the user lies on a test sleeping surface containing an
air bladder that is pressurized to match the firmness
recommendation. Zones of the air bladder are then adjusted to match
the preferences of the user and the resulting preferred firmness
readings are recorded. An algorithm has been developed that
translates the preferred firmness readings into a customized bed
configuration. For example, the preferred firmness readings can be
translated to establish the foam density that, if incorporated into
a mattress will provide the firmness and support characteristics
similar to those provided by the test sleeping surface having the
preferred firmness readings.
[0015] Once the customized bed configuration is established, a
mattress can be assembled from a kit at the point of sale
containing the plurality of cores for the user to test and verify
that the mattress meets his or her preferences. If the mattress is
not satisfactory, it can be adjusted at the point of sale. Once the
user is satisfied, he or she can immediately take delivery of the
completed customized mattress if desired. In the alternative, once
the customized bed configuration is established, the data
describing this configuration can be transmitted to a factory at
which the mattress is assembled for delivery to the user.
[0016] In preferred embodiments, the mattress in accordance with
the present invention can be sized for a twin bed, a double bed, a
queen-sized bed, or a king-sized bed. When the mattress is sized
for queen- and king-sized beds, both sides of the mattress can be
individually customized if desired to provide the firmness and
support characteristics desired by individual sleep partners by
customizing the core and customizing the topper to provide the
desired firmness and support for each side of the bed. In such a
"side-by-side" customization, the core and toppers supporting each
user on separate halves of the mattress are distinct and separate.
Having distinct and separate cores and toppers facilitates this
customization while also serving to minimize the transmission of
motion from one half of the mattress to the other when one of the
sleeping partners moves.
[0017] As mentioned above, the mattress can be provided with an air
bladder having independent zones that are selectively adjustable by
the user to provide varied firmness and support characteristics. If
the same mattress is used on a bed having an articulating deck, the
mattress can be provided with a hand held controller for use by the
user that controls the adjustment of both the position of the deck
and the support characteristics of each bladder zone. In addition,
the hand held controller can include a "memory set" feature which
allows the user to establish preferred deck and mattress
combination settings.
[0018] For example, the user may desire a first set of support
characteristics at each zone of the mattress when the deck is in a
generally planar sleeping position. The user could establish this
set of characteristics as the first memory setting. The user may
also desire a different set of support characteristics at each zone
of the mattress when the deck is positioned in a reclining position
away from the generally planar sleeping position. If the user
establishes this second set of characteristics as the second memory
setting, the user can automatically move the bed and mattress
structure to either of the first or second set of characteristics
by simply pressing a button. Of course, even with these memory
settings established, the user can move the bed and mattress to
other positions as desired.
[0019] In addition, the mattress can be provided with combinations
of air bladders, zone foam elements, and sculptured foam to produce
a "combination mattress." For example, the mattress can be provided
having an air bladder supporting the scapula, foam supporting the
lumbar, an air bladder in the seat portion supporting the sacrum,
and foam supporting the thighs and legs. If desired, the air
bladders can be in fluid communication so that they inflate and
deflate at the same times and to the same pressures or the air
bladders can be independent of one another and independently
controlled by the user so that they user can establish different
characteristics of support and firmness for each of the scapula and
the sacrum.
[0020] It is therefore an object of the present invention is to
provide a unique mattress structure which may be customized for
individual use to provide the optimum health and comfort
characteristics for the user and also to provide, for use with such
a mattress, an articulating frame. In some embodiments of the
present invention, the mattress comprises air cores or air bladders
arranged in longitudinally spaced zones and a control system for
controlling the firmness of the zones of the mattress with respect
to various positions of the articulating frame so that the user can
customize the mattress for his or her preferred firmness and
support characteristics at any angular position of the deck. In
other embodiments, the mattress comprises a sculptured foam core or
a plurality of longitudinally spaced foam zone cores or blocks
selected to match the musculoskeletal condition of the user.
[0021] The mattress of the present invention may be assembled at
the point of sale to comprise a foam perimetral frame defining a
longitudinally extending central opening above which the user will
rest and into which various core structures from a supply of
different core structures may be selectively placed. For example,
the central space may be filled with an air bladder core, the
pressure of which may be controlled and such air cores may have one
zone throughout the length of the space or a plurality of
longitudinally spaced air zones or air bladders throughout the
length of the space, for example, one zone for the head and
shoulder portion supporting the scapula and the lumbar, one zone
for the seat portion supporting the sacrum, one zone for the thigh
portion, and one zone for the foot portion. In other cases, the
central space may be filled with a sculptured foam core or a
plurality of foam zone cores or blocks which are selected from a
variety of zone foam blocks having various characteristics of
support and firmness. The frame with the filled core opening may be
covered with one or more toppers, each of which may be selectively
picked from a stock of toppers to give the user a desired
comfort.
[0022] It is another object of the present invention, therefore, to
provide, at the point of sale where the user will be available, a
modular kit for constructing a mattress which has the firmness and
body support characteristics best suited for the user. The present
invention contemplates that a plurality of cores of various
characteristics will be stocked along with the foam frames and
plurality of toppers. Each mattress may be customized by selecting
components from the stock of parts at the point of sale. For ease
of transportation, the selected assembly may be given to the user
at the point of sale in knocked-down-assembly or KDA form for
transportation home and reassembly.
[0023] It is another object of the present invention to provide, in
combination with such a mattress, an articulating frame of the type
typically referred to as a hospital bed frame. Such articulating
frames have a movable head and shoulder section which includes the
lumbar section, a fixed seat section, a movable thigh section and a
movable foot section. It is well known that the head and shoulder
section tilts upwardly from the horizontal position to an upper
position and selected points therebetween. The seat section is
typically fixed to stay horizontal. The thigh section typically
tilts upwardly from the seat section and the foot section typically
remains generally parallel to the seat section. These head and
shoulder, seat, thigh and foot sections are longitudinally spaced
on an articulating frame. It is also well known that these
articulating frame sections may be selectively moved by all sorts
of drive means including elective motor driven systems, hydraulic
systems or pneumatic systems. It will be appreciated that, in
accordance with the present invention, various mechanical and
electromechanical actuators and drivers may be used to raise and
lower the intermediate frame on the base frame as well as to raise
and lower individual deck sections relative to the intermediate
frame.
[0024] It is well known in the hospital bed art that electric drive
motors with various types of transmission elements including lead
screw drives and various types of mechanical linkages may be used
to cause relative movement of portions of hospital beds. It is also
well known to use pneumatic actuators to actuate and/or move
individual portions of hospital beds. As a result, the terms "means
for raising and lowering" in the specification and in the claims,
therefore, are intended to cover all types of mechanical,
electromechanical, hydraulic and pneumatic mechanisms, including
manual cranking mechanisms of all types, for raising and lowering
portions of the hospital bed of the present invention. It is
another object of the present invention to provide a control system
for an articulating frame with the control system comprising a
computer and software designed to preselect air bladder firmness to
accommodate various articulated positions of the frame
sections.
[0025] Still another object of the present invention is to provide
a method for selecting mattress structure components to provide a
customized foam mattress structure to accommodate the
musculoskeletal condition of the user comprising the steps of
providing a plurality of mattress structure components arranged for
selective assembly of the components, the components comprising a
plurality of foam cores for filling a longitudinally extending
central opening in a mattress, the foam cores having a variety of
shapes and support and firmness characteristics from which to
select a desired assembly. A test mattress is also provided having
a similar longitudinally extending central opening filled with a
plurality of longitudinally spaced apart air bladders extending
transversely across the central opening and an air supply for
selectively filling each air bladder to various pressures. A user
is placed above the central opening supported on the plurality of
air bladders. The air pressure in each bladder is adjusted to a
selected pressure to provide the support and firmness desired by
the user. Then, using the air pressure established for each
bladder, an equivalent foam core is selected to have the desired
support and firmness characteristics corresponding to the air
pressure readings. The selected equivalent foam core is placed in
the central opening to provide the customized mattress. The
selected equivalent foam core may comprise a plurality of
transversely extending zone foam blocks to occupy the positions,
respectively, of the air bladders in the test mattress with each
zone foam block having firmness and support characteristics
corresponding to the selectively determined air pressure of its
associated air bladder. Further, the selected equivalent foam core
may comprise a sculptured foam core having a width and a length
conformingly to fit into the central opening with transversely
extending, longitudinally spaced sections of the sculptured core
being shaped and formed to provide firmness and support
characteristics corresponding to the selectively determined air
pressures of their respective associated air bladders in the test
mattress. It will be appreciated that software having appropriate
algorithms may be used for making the selection of foam cores to
match the selected air pressure.
[0026] Another object of the present invention is to provide a
control system for such a bed and mattress structure with the bed
having such an articulating deck with movable sections. The control
system comprises means for controlling the drive means for tilting
the deck sections to various desired positions, means for
controlling the air supply for filling the air bladders to desired
air pressures, and a microprocessor and software for controlling
the drive control means and the air supply control means to
establish the desired frame positions and corresponding bladder
pressures. The software of the present invention may be programmed
to permit the user to preselect desired air pressures in the
bladders to correspond to various positions of the deck sections.
The software may also be programmed to permit the user to preselect
and store in the control system various desired frame section
positions and corresponding pressures. The control system of the
present invention may include a receiving control unit mounted on
the bed structure and a portable, hand-held remote transmitting
control unit for actuation by the user.
[0027] Another object of the present invention is to provide a
mattress structure comprising an elongated sculptured foam mattress
core having a head end, foot end, longitudinally extending sides, a
bottom surface and an upper surface above which the user rests.
This sculptured core has longitudinally spaced apart, transversely
extending sections to be under, respectively, the head and
shoulder, seat, thigh and feet of the user. At least some of the
core sections are sculptured by removal of foam by transversely
extending cuts from the upper surface of the core to provide
sections having desired firmness and support characteristics. These
transversely extending cuts may illustratively extend between the
sides of the core to provide transversely extending grooves having
selected depths and longitudinal spacing therebetween to provide
upwardly and transversely extending ridges for supporting the user,
each of the ridges having support and firmness characteristics
determined by the firmness of the foam and the longitudinal and
depth dimensions of the grooves. Such a core may also be provided
with longitudinally spaced, transversely and upwardly extending
cuts in the lower surface to accommodate the tilting movement of
the mattress by the bed frame upon which the mattress is placed,
the lower surface cuts being longitudinally spaced to accommodate
tilting movement of the head and shoulder, seat, thigh and feet
section of the core. A foam frame may be placed about such a
sculptured core in accordance with the present invention. At least
one foam topper may be placed above the frame and core upper
surface with the toppers selected to have desired support and
firmness characteristics. In addition, a foam and fiber pillow top
(foam covered with a fiber fabric) also selected to have desired
support and firmness characteristics may be placed on top of the
topper.
[0028] Another object of the present invention is to provide a
mattress structure comprising a bottom layer of material providing
an upwardly facing rectangular platform upon which the mattress
rests and defining the ends and sides of the mattress, a perimetral
rectangular frame comprising foam side and end sections to provide
a longitudinally extending central opening above which the user
will rest, a core structure for filling the central opening, at
least one foam topper covering the frame and the core structure,
and a mattress cover enclosing the bottom layer of material, frame,
core structure and topper. In accordance with the present
invention, the mattress cover is provided with an opening adjacent
the bottom of the mattress and through which the mattress is
designed for either bottom-up or top-down assembly through the
mattress cover opening. Top-down assembly includes, for example,
sequentially placing the topper, frame, core structure and bottom
layer of material to build the mattress structure, while bottom-up
assembly includes sequentially placing the bottom cover, frame,
core structure, and topper to build up the mattress structure. The
mattress cover opening may be defined by a perimetral zipper
closure along the perimeter of the bottom of the mattress.
[0029] Another object is to provide such a mattress with a double
wide frame providing first and second longitudinally extending
openings above which separate users will rest. A first core
structure is provided for filling the first opening and a second
core structure is provided for filling the second opening. The
first and second core structures have firmness and support
characteristics separately customized for their separate users in
accordance with this invention.
[0030] Still another object of the present invention is to provide
such a mattress structure comprising an air heater arrangement
disposed in the mattress to provide a "warm air release,"
preferably to warm the extremities of the user. The top cover of
the mattress can be formed to include an enclosed channel receiving
air from a source of compressed air. The enclosed channel is
preferably made from a light weight and air impermeable material so
that air is directed along the length of the channel. The material
is formed to include small openings that direct a small volume of
air from the channel across the surface of the mattress. This "cool
air release" can improve the comfort of the user.
[0031] In addition, an air heater is interposed between the source
of compressed air and the channel so that heated air can be
supplied to the channel. The air heater can be selectively operated
so that when the air heater is operating, the released air is warm,
the "warm air release" warming the user. Preferably, the warm air
is directed to warm the extremities of the user. In preferred
embodiments, a valve is positioned between the source of compressed
air and the channel so that the channel can be operated or not
operated at the discretion of the user.
[0032] Additional objects, features, and advantages of the
invention will become apparent to those skilled in the art upon
consideration of the following detailed description of the
preferred embodiments exemplifying the best mode of carrying out
the invention as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The detailed description particularly refers to the
accompanying figures in which:
[0034] FIG. 1(a) is an exploded perspective view of a mattress in
accordance with the present invention showing a bottom cover
positioned beneath a foam bottom and a frame, a plurality of cores
receivable above the foam bottom in a central opening formed in the
frame, the plurality of cores including either a sculptured foam
core, transversely extending zone foam blocks, an air bladder, or a
combination thereof, the mattress also including a foam topper
positioned to lie above the frame and the core, a top cover
surrounding the topper, the frame, and the foam bottom, the top
cover including a zipper half engaging a zipper half on the bottom
cover to attach the top cover thereto, and a pillow top attached to
the top of the top cover;
[0035] FIG. 1(b) is a view similar to FIG. 1(a) showing a mattress
including a core having a combination of zone foam blocks and air
bladders with zone foam blocks positioned to support the lumbar
region of the back of the user and the thighs and legs of the user
and air bladders positioned to support other portions of the
user;
[0036] FIG. 1(c) is a view similar to FIG. 1(b) showing a mattress
including a core having a combination of zone foam blocks and air
bladders with air bladders positioned to support the lumbar region
of the back of the user and the thighs of the user and zone foam
blocks positioned to support other portions of the user;
[0037] FIG. 2 is an exploded perspective view of a king-sized
mattress similar to the mattress of FIG. 1(a) showing the bottom
cover, the foam bottom, the frame, a foam divider received in the
central opening of the frame to divide the central opening into two
equally-sized side openings, the plurality of cores being
alternatively receivable in the two side openings, the king-sized
bed also including the topper, the top cover, and the pillow
top;
[0038] FIG. 3 is an exploded perspective view of a mattress and bed
stricture in accordance with the present invention including a
foundation and the mattress and showing the mattress positioned to
lie above the foundation and a pillow top positioned to lie above
the mattress, the mattress being attached to the foundation by a
pair of elongated hook and loop type fasteners attached to the
foundation and to the mattress at a foot end of the mattress to
allow relative longitudinal motion at a head end of the mattress
and foundation during articulation of the mattress and foundation,
the pillow top being connected to the top cover of the mattress by
a pair of elongated hook and loop type fasteners attached to a top
cover of the mattress and attached to the pillow top, the pillow
top also being coupled to the mattress by a pair of elongated
straps fixed to the head end of the top cover of the mattress to
form longitudinal loops and short straps which feed through the
loops and are attached to the pillow top so that the head end of
the pillow top can slide longitudinally relative to the top cover
of the mattress while remaining generally fixed in the transverse
direction relative to the pillow top;
[0039] FIG. 4 is a diagrammatic view of an articulating deck for
carrying the mattress in accordance with the present invention
showing the deck moved to a position other than a generally planar
sleeping position;
[0040] FIG. 5 is a diagrammatic sectional view taken along line 5-5
of FIG. 1(a) showing a sculptured foam core resting on an
articulating deck of a bed, the deck being in a generally planar
sleeping position;
[0041] FIG. 6 is a view similar to FIG. 5 showing the deck in a
position having the head section lifted to an upward raised
position, the thigh section lifted slightly to an upward raised
position, and the foot section elevated above and generally
parallel to the seat section, cuts formed in the sculptured foam
core on the surface opposite the folds allowing the sculptured foam
core to generally conform to the shape of the deck;
[0042] FIG. 7 is a perspective view of the frame and the foam
divider of FIG. 2 showing the frame and the foam divider rail moved
by an articulating deck (not shown) to a position other than the
generally planar sleeping position, cuts formed in side foam
sections of the frame on the surface opposite the bends and cuts
formed in the foam divider rail on the surface opposite the bends
allowing the frame and foam divider rail to generally conform to
the shape of the deck;
[0043] FIG. 8(a) is a diagrammatic bottom view of a "four-zone" air
bladder and pressurized air supply with portions broken away
showing the pockets formed in the air bladder by I-beams (not
shown) attached to the interior of the air bladder, and showing
each I-beam having first and second transverse ends, the first and
second ends of a first set of I-beams being spaced-apart from the
edge of the air bladder to form openings allowing fluid
communication between pockets, and a diagrammatic manifold of the
pressurized air supply;
[0044] FIG. 8(b) is a view similar to FIG. 8(a) of a four-zone air
bladder in which zones of the air bladder which are not adjacent to
one another are in fluid communication showing an upper back zone
in fluid communication with a seat zone through a first tube
positioned outside of an internal region of the air bladder and a
lower back zone in fluid communication with a foot zone through a
second tube positioned outside of an internal region of the air
bladder;
[0045] FIG. 9 is a diagrammatic illustration of a sectional view
taken along line 9-9 of FIG. 8(a) showing the four-zone air bladder
having pockets separated by I-beams with the selected I-beams
defining the zones of the air bladder, the ends of a second set of
I-beams sealingly engaging the edge of the air bladder to separate
pockets adjacent to the I-beams to form separate and independently
inflatable and deflatable zones of the air bladder;
[0046] FIG. 10 is a schematic view of a valve manifold for a
one-zone air bladder showing a compressed air line, an exhaust
line, an air line in fluid communication with the interior region
of the air bladder, and a transducer for transducing a pressure
measurement to an electronic output signal;
[0047] FIG. 11 is a diagrammatic sectional view of the bladder of
FIG. 8(a) showing an interior region of the partially inflated air
bladder including I-beams of generally uniform height with one
I-beam being significantly taller than the remaining I-beams;
[0048] FIG. 12 is a view similar to FIG. 11 showing the air bladder
fully inflated so that the air bladder adjacent to the pockets
defined by the significantly taller I-beam project above the air
bladder adjacent to the other pockets so that the mattress adjacent
to the projecting pockets provides a user with additional support
and firmness;
[0049] FIG. 13 is a sectional view taken along line 13-13 of FIG.
8(a) showing an interior region of the partially inflated air
bladder including I-beams of generally uniform height with two
I-beams being significantly taller than the remaining I-beams;
[0050] FIG. 14 is a view similar to FIG. 13 showing the air bladder
fully inflated so that the air bladder adjacent to the pockets
defined by the significantly taller I-bemas project above the air
bladder adjacent to the other pockets so that the mattress adjacent
to the projecting pockets provides a user with additional support
and firmness;
[0051] FIG. 15 is a view similar to FIG. 9 showing the air bladder
having a plurality of significantly taller I-beams so that the air
bladder adjacent to pockets adjacent to the lumbar region of the
user, pockets adjacent to the thigh of the user, and pockets
adjacent to the heel of the user project above the air bladder
adjacent to the other pockets to provide a user with additional
support and firmness near portions of the mattress adjacent to the
projecting pockets and to provide additional pressure relief to the
heels of the user;
[0052] FIG. 16 is a view of the mattress of FIGS. 1(a) and 2
showing an air supply providing pressurized air to an air bladder
inside of the mattress and to an enclosed channel formed along the
perimeter of the upwardly-facing sleeping surface of the mattress
and an air heater interposed between the air supply and the channel
to heat the air received by the channel, the material enclosing the
channel being formed to include small openings that direct a small
volume of air from the channel across the sleeping surface to warm
or cool the user;
[0053] FIG. 17 is a perspective view of an arm rest in accordance
with the present invention showing the foam interior of the arm
rest;
[0054] FIG. 18 is a sectional view of taken along line 18-18 of
FIG. 17 showing a cover surrounding the arm rest and showing a cup
(in phantom) received in a cup holder formed in the arm rest;
[0055] FIG. 19 is a view similar to FIG. 18 showing a bed having an
articulated deck moved to a position away from the generally planar
sleeping position, a mattress received on the deck, and the arm
rest in a first orientation;
[0056] FIG. 20 is a view similar to FIG. 19 showing the deck moved
to a different position away from the generally planar sleeping
position, the mattress on the deck, and the arm rest in a second
orientation;
[0057] FIG. 21 is a perspective view of the hand held controller of
FIG. 16 for controlling the positions of the articulating portions
of the articulating deck of the bed, controlling the pressure of
air in the four zones of the bladder, and for pre-setting in memory
air pressures selected by the user corresponding to deck positions
selected by the user so that by pressing a single button the deck
will adjust to the preselected position and the bladder will adjust
pressures in the four zones to the preselected pressures; and
[0058] FIG. 22 is a plan view of a portion of the hand held
controller of FIG. 21 showing the indicia on the hand held
controller and showing "bed position buttons" on a first end, the
buttons being arranged in a "use-frequency arrangement" having the
most frequently used buttons positioned to lie adjacent to the
first end, the least frequently used buttons positioned to lie
adjacent to the second end which is opposite the first end, and the
remaining buttons positioned to lie therebetween arranged in order
of the frequency of use with the more frequently used buttons being
positioned closer to the first end than the less frequently used
buttons;
[0059] FIG. 23 is a schematic block diagram illustrating the
electrical components of a control system for controlling features
of the bed and mattress structure in accordance with the present
invention; and
[0060] FIGS. 24A-24L are flow charts illustrating steps performed
by the control system for manipulating the bed and mattress
structure in response to inputs made by the user by way of the hand
held controller.
DETAILED DESCRIPTION OF THE DRAWINGS
[0061] A bed and mattress structure 50 includes a mattress 52 in
accordance with the present invention as illustratively shown in
FIGS. 1(a) and 2. As used in this description, the phrase "head end
46" will be used to denote the end of any referred-to object that
is positioned to lie nearest head end 46 of bed and mattress
structure 50. Likewise, the phrase "foot end 48" will be used to
denote the end of any referred-to object that is positioned to lie
nearest foot end 48 of bed and mattress structure 50.
[0062] Mattress 52 includes a bottom cover 54 having a perimeter
edge 56 and a first zipper half 58 attached to perimeter edge 56 as
shown in FIGS. 1(a) and 2. Mattress 52 also includes a top cover 60
which cooperates with bottom cover 54 to define a mattress interior
72.
[0063] Top cover 60 includes an upwardly-facing top portion 62 and
a downwardly-extending side portion 66 as shown in FIGS. 1(a) and
2. Side portion 66 includes a bottom edge 68 and a second zipper
half 64 attached to bottom edge 68, second zipper half 64 attaching
to first zipper half 58 to form zipper 70 which connects top cover
60 and bottom cover 54.
[0064] Although zipper 70 is positioned to lie adjacent to bottom
edge 68, a bottom cover could be provided having an
upwardly-extending side portion 67 as shown in FIGS. 1(b) and 1(c)
defining a mattress side and the second zipper half could be
attached to side portion 67 of the bottom cover so that zipper 70
could be positioned along the mattress side or the upper perimetral
edge of mattress 52. Zipper 70 can therefore be positioned to lie
adjacent to bottom edge 68 or at any position along the mattress
side, which in preferred mattress 52 includes side portion 66,
without exceeding the scope of the invention as presently
perceived. However, positioning zipper 70 adjacent bottom edge 68
provides certain assembly related advantages described below while
also improving the appearance of mattress 52 by allowing zipper 70
to be easily hidden.
[0065] A frame 74 having a head end foam section 76, a foot end
foam section 78, and longitudinally extending side foam sections 80
joining the head end and foot end foam sections 76, 78 is received
in mattress interior 72 as shown in FIGS. 1(a) and 2. In preferred
embodiments, frame 74 is formed with rounded corners to enhance the
appearance of mattress 52. In addition, joints 83 connect head end
foam section 76 to side foam sections 80 and foot end foam section
78 to side foam sections 80. Joints 83 are preferably lap joints
having portions of head end and foot end foam sections 76, 78
overlapping and fastened to respective portions of side foam
sections 80. Forming joints 83 in this manner results in additional
support provided to head end foam section 76 when mattress 52
slides past head end 46 of foundation 120 during articulation of
deck 138.
[0066] Head end, foot end, and side foam sections 76, 78, 80 of
frame 74 cooperate to define a central opening 82 as shown best in
FIGS. 1(a) and 2 above which a user (not shown) will rest. A foam
bottom 84 is received in central opening 82 and foam bottom 84 and
frame 74 lay against bottom cover 54. A topper 86 rests against the
top of frame 74 and above central opening 82 to engage top portion
62 of top cover 60. A core or core structure 88 is received in
central opening 82 and is positioned to lie between foam bottom 84
and topper 86. Having topper 86 sized to cover both frame 74 and
core 88 minimizes the ability of the user to perceive the interface
between frame 74 and core 88.
[0067] In preferred embodiments, a pillow top 90 is attached to the
top of top portion 62 of top cover 60 and is positioned to lie
outside of mattress interior 72 as shown in FIGS. 1(a) and 2 to
define a sleeping surface 122 on which a user will rest. Top cover
60 is preferably made from a material having a low coefficient of
friction such as a polypropylene anti-shear material to allow for
the sliding movement of pillow top 90 relative to top cover 60 near
head end 46 of mattress 52. In addition, top cover 60 should be
somewhat elastic so that the user can "sink into" mattress 52
allowing mattress 52 to conform to the user's shape, thereby
relieving interface pressure.
[0068] Pillow top 90 typically includes a foam pad (not shown)
covered by fabric and adorned, for example, by buttons 124,
ornamental stitching, or the like to enhance the appearance of
pillow top 90. Pillow top 90 can be attached to top cover 60 using
any suitable method such as by a zipper (not shown), adhesive (not
shown), straps (not shown), or even sewing pillow top 90 to top
cover 60. However, as described below with reference to FIG. 3,
pillow top 90 is preferably attached to top cover 60 using hook and
loop type fasteners so that pillow top 90 is easily removable and
replaceable. Mattress 52 can alternatively be provided without
pillow top 90, in which case the upwardly-facing surface of top
portion 62 of top cover 60 serves as sleeping surface 122.
[0069] Core 88 can alternatively include either a set of zone foam
blocks 92, a sculptured foam core 94, an air bladder 96, or a
combination thereof as shown in FIGS. 1(a)-(c) and 2. In preferred
embodiments, frame 74, foam bottom 84, topper 86, zone foam blocks
92, sculptured foam core 94, and an interior portion (not shown) of
pillow top 90 may be made from a foam rubber such as urethane foam.
The firmness and support characteristics of the foam rubber can be
varied in accordance with the desires of the user of mattress 52.
The firmness and support characteristics of the foam rubber is
varied by varying either the density of the foam or the shape of
the outer surfaces of the foam.
[0070] Although urethane foam is the preferred material for these
components, any material providing support and firmness
characteristics similar to those provided by foam rubber can be
used without exceeding the scope of the invention as presently
perceived. For example, topper 86 can be made from latex foam or
urethane foam, or in the alternative it can include an air bladder,
a water bladder, or a bladder for other fluids without exceeding
the scope of the invention as presently perceived.
[0071] Mattress 52 typically rests on a foundation 120, as shown in
FIG. 3, such as box springs, a stationary deck of a bed, an
articulating deck of a bed, or the like. Mattress can also rest on
a floor or any other generally planar, upwardly facing surface
without exceeding the scope of the invention as presently
perceived.
[0072] In preferred embodiments, foundation 120 and the underside
of bottom cover 54 are provided with elongated mating portions of
hook and loop type fasteners 164 so that mattress 52 is removably
attached to foundation 120 as shown in FIG. 3. Fasteners 164
prevent lateral movement of mattress 52 relative to foundation 120.
However, fasteners 164 are preferably spaced apart from head end 46
of bed and mattress structure 50 so that head end 46 of mattress 52
can slide longitudinally relative to head end 46 of foundation 120
as described below.
[0073] In addition, the underside of pillow top 90 and the upper
side of top portion 62 of top cover 60 of mattress 52 are both
provided with elongated mating portions of hook and loop type
fasteners 168 as shown in FIG. 3 so that pillow top 90 is removably
attached to mattress 52. Mattress 52 is also provided with a pair
of longitudinally extending long loops 170 and pillow top 90 is
provided with a pair of transversely extending short loops 172.
Each short loop 172 includes a first end 174 that is fixed to
pillow top 90 and a second end 176 that is attached to pillow top
90 using hook and loop type fasteners 178. Second end 176 of each
short loop 172 is received by one of long loops 170 respectively so
that short loops 172 cooperate with long loops 170 to prevent
transverse movement of pillow top 90 relative to mattress 52 while
allowing the longitudinal sliding of pillow top 90 relative to
mattress 52 during articulation of deck 138.
[0074] As described above, mattress 52 is configured for use on
both stationary, generally planar, and upwardly facing surfaces on
which mattress 52 rests during use by a user, as well as on a bed,
table, or other device (not shown) having an articulating deck 138
as shown diagrammatically in FIG. 4. Illustrative articulating deck
138 includes a head section 144, a seat section 146, a thigh
section 148, and a foot section 150. A light (not shown) or other
illuminating device can be provided having an arm (not shown) or
extending bracket attached to head section 144 so that the light
extends to a position illuminating mattress 52. By attaching the
arm to head section, the relative position of user's head and the
light will remain generally fixed.
[0075] Typically, seat section 146 of deck 138 is fixed relative to
the bed having a generally horizontal upwardly-facing surface
carrying mattress 52 and head, thigh, and foot sections 144, 148,
150 are movable with respect to the bed (not shown) and with
respect to each other to move mattress 52 so that the position of
mattress 52 and the position of the user on top of mattress 52
changes. Drivers for moving head, thigh, and foot sections 144,
148, 150 are diagrammatically indicated by arrows 152 in FIG. 4. In
the preferred articulating deck 138, foot section 150 is movable
only to positions in which foot section 150 is generally parallel
to seat section 146. In addition, the movement of preferred thigh
section 148 is limited to positions between the generally
horizontal sleeping position and positions upwardly from the
sleeping position so that the feet of the user (not shown) remain
generally vertically even with or elevated above the torso of the
user.
[0076] It will be appreciated that various mechanical and
electromechanical actuators and drivers may be used to raise and
lower individual deck sections 144, 146, 148, 150 relative to the
bed as shown in FIGS. 4-5. It is well known in the hospital bed art
that electric drive motors with various types of transmission
elements including lead screw drives and various types of
mechanical linkages may be used to cause relative movement of
portions of hospital beds. It is also well known to use pneumatic
actuators including various types of air bladders powered by
pressurized air to actuate and/or move individual portions of
hospital beds. The terms "means for raising or lowering" in the
specification and in the claims, therefore, are intended to cover
all types of mechanical, electromechanical, hydraulic, and
pneumatic mechanisms, including manual cranking mechanisms of all
types, for raising and lowering portions of chair bed 50 of the
present invention.
[0077] As indicated above, mattress 52 is attached to foundation
120 and pillow top 90 is attached to mattress 52 to allow sliding
movement of head end 46 of mattress 52 relative to foundation 120
and of pillow top 90 relative to mattress 52. It will be apparent
to those skilled in the art, that fixing one end of mattress 52 and
pillow top 90 and then moving articulating deck 138 will cause
shear forces between mattress 52 and foundation 120 and between
pillow top 90 and mattress 52. Connecting mattress 52 to foundation
120 and pillow top 90 to mattress 52 as described above with
respect to FIG. 3 will alleviate the shear forces by allowing head
end 46 of mattress 52 and pillow top 90 to slide longitudinally
relative to foundation 120 and relative to each other.
[0078] As described above, core 88 can include zone foam blocks 92.
A typical set of zone foam blocks 92 found in mattress 52 includes
a plurality of transversely extending zone foam blocks 92 that
longitudinally abut one another. If mattress 52 is for use in a
single bed as shown in FIG. 1(a) so that central opening 82 is a
first width 110, each block 92 typically extends the full width 110
of central opening 82 to engage opposing side foam sections 80.
Typically the plurality of zone foam blocks 92 fills the entire
central opening 82 so that a first of blocks 92 engages head end
foam section 76, a last of zone foam blocks 92 engages foot end
foam section 78, and zone foam blocks 92 therebetween engage one
another.
[0079] If the mattress is for use in a queen-sized bed (not shown),
central opening 82 is a second width and each block 92 typically
extends only one-half of the second width. In such instance, core
88 can alternatively include side-by-side combinations including a
set of zone foam blocks 92, sculptured foam core 94, and air
bladder 96. For example, sculptured foam core 94 can be received in
opening 82 engaging one of side foam sections 80 and zone foam
blocks 92 can be received in opening 82 engaging sculptured foam
core 94 on one side and the other of side foam sections 80.
[0080] For another example, central opening 82 can receive
side-by-side left and right sets of zone foam blocks 92. A first of
the zone foam blocks 92 of the left set of zone foam blocks 92
engages head end foam section 76, a last of the zone foam blocks 92
of the left set of zone foam blocks engages foot end foam section
78, and each zone foam block 92 of the left set of zone foam blocks
92 engages one of side foam sections 80. A first of the zone foam
blocks 92 of the right set of zone foam blocks 92 also engages head
end foam section 76, a last of the zone foam blocks 92 of the right
set of zone foam blocks engages foot end foam section 78, and each
zone foam block 92 of the right set of zone foam blocks 92 engages
the other of side foam sections 80. In addition, zone foam blocks
92 of the left set of zone foam blocks engage zone foam blocks 92
of the right set of zone foam blocks 92. Thus, in a queen-sized bed
zone foam blocks 92 abut one another longitudinally and
side-by-side.
[0081] If mattress 52 is for use in a king-sized bed as shown in
FIG. 2, central opening 82 is a third width 112 and each block 92
typically extends less than one-half of the full width 112 of
central opening 82. In such an instance, core 88 can additionally
include a foam divider rail 114. Foam divider rail 114 divides
central opening 82 into a first side opening 116 and a second side
opening 118.
[0082] Preferably, first and second side openings 116, 118 have
equal widths, and preferably foam divider rail 114 is sized so that
the widths of first and second side openings 116, 118 are the same
as first width 110 as shown in FIG. 2. Thus, blocks 92, sculptured
foam core 94, and air bladder 96 can interchangeably fit in each of
opening 82 of a single or twin bed as shown in FIG. 1(a) and first
and second side openings 116, 118 and engage one of side rails 80
and foam divider rail 114 as shown in FIG. 2.
[0083] First opening 116 can receive any of zone foam blocks 92,
sculptured foam core 94, and air bladder 96 and second opening 118
can receive any of the zone foam blocks 92, sculptured foam core
94, and air bladder 96 as shown in FIG. 2. The selection of pieces
of core 88 received by first opening 116 is independent of the
selection of pieces of core 88 of second opening 118, so that core
88 for a mattress for use with a king-sized bed can include foam
divider rail 114, zone foam blocks 92, sculptured foam core 94, air
bladder 96, or a combination thereof.
[0084] For example, if core 88 includes two sets of zone foam
blocks 92 as described above for a queen-sized mattress, each block
92 will extend the full width of the respective first or second
opening 116, 118 to engage foam divider rail 114 and opposing side
foam section 80. Typically each set of zone foam blocks 92 fills
the entire first or second opening 116, 118 so that a first of
blocks 92 engages head end foam section 76, foam divider rail 114,
and one of the side foam sections 80, a last of zone foam blocks 92
engages foot end foam section 78, foam divider rail 114, and the
same of the side foam sections 80, and blocks 92 therebetween
engage one another, foam divider rail 114, and the same of the side
foam sections 80.
[0085] Each zone foam block is preferably provided with an
anti-shear coating so that each zone foam block 92 can move in a
vertical direction independently of adjacent zone foam blocks 92
and independently of frame 74. The anti-shear coating can be a
coating formed on or applied to zone foam blocks 92 as well as a
sleeve 98 having an interior 100 receiving zone foam block 92 as
shown in FIGS. 1(a) and 2. Sleeve 98 is preferably made from a
material having a low coefficient of friction such as "parachute
material" or nylon.
[0086] The firmness of zone foam blocks 92 can vary from zone foam
block 92 to zone foam block 92. Preferably, the firmness ranges
approximately between an average indention load deflection (ILD) of
15 to 98. Preferred zone foam blocks 92 are provided with ribbed
upper and lower surfaces as shown in FIGS. 1(a)-(c) and 2. Ribs on
the surfaces result in less force being required to compress zone
foam blocks 92 than would be required without the ribs. This means
that even when little weight is applied to zone foam blocks 92,
blocks 92 will compress and contour to user's shape, thereby
reducing interface pressures, and essentially reducing the ILD so
that the ILD can be "fine-tuned" by the addition of ribs.
[0087] As described above, core 88 can also include sculptured foam
core 94 as shown in FIGS. 1(a), and 2-4. Sculptured foam core 94 is
typically a unitary piece of foam of uniform firmness that has been
sculptured to a desired shape. However, sculptured foam core 94 can
be formed from a piece of foam having firmness that varies along
its length or across its width without exceeding the scope of the
invention as presently perceived.
[0088] Sculptured foam core 94 is formed to include transversely
extending troughs 130 along a top surface 132 of sculptured foam
core 94 as well as transversely extending cuts 134 extending
inwardly from both top surface 132 and a bottom surface 136 of
sculptured foam core 94, as shown best is FIGS. 5 and 6 which show
sculptured foam core 94 resting on a diagrammatic articulating deck
138 of a bed (not shown). Each cut 134 includes a
transversely-extending slit 140 extending inwardly from the
respective surface 132, 136 and terminating in a
transversely-extending cylindrical opening 142.
[0089] As described above, each of the head, thigh, and foot
sections 144, 148, 150 of articulating deck 138 typically move
relative to seat section 146, relative to one another, and relative
to the bed as shown in FIGS. 5 and 6. Portions of sculptured foam
core 94 adjacent to each of sections 144, 146, 148, 150 are
configured to move with each respective section 144, 146, 148, 150.
Slits 140 allow for folding movement of sculptured foam core 94 in
a direction inwardly away from slits 140 as shown, for example, in
FIG. 6, and openings 142 prevent the inadvertent tearing of
sculptured foam core 94 when sculptured foam core 94 is folded.
[0090] Cuts 134 are positioned so that at least one of cuts 134
lies generally between the head and seat sections 144, 146, at
least one of cuts 134 lies generally between the seat and thigh
sections 146, 148, and at least one of cuts 134 lies generally
between the thigh and foot sections 148, 150 as shown in FIGS. 5
and 6. In preferred embodiments, sculptured foam core 94 is
provided with a plurality of cuts 134 at each position as shown
best in FIGS. 5 and 6 so that the above holds true when sculptured
foam core 94 is used with a variety of beds having articulating
decks, the longitudinal lengths of the head, seat, thigh, and foot
sections 144, 146, 148, 150 of which may vary from bed to bed.
[0091] As mentioned above, sculptured foam core 94 is also provided
with transversely extending troughs 130 formed on top surface 132
shown best in FIGS. 5 and 6. Troughs 130 can be positioned to
facilitate the folding of sculptured foam core 94 as shown in FIG.
6 by providing additional space for the surface 132, 136 opposite
cuts 134 to compress upon itself. However, troughs 130 are not
necessary for the portions of sculptured foam core 94 to move with
the head, seat, thigh, and foot sections 144, 146, 148, 150 or
articulating deck 138.
[0092] Each trough 130 is formed to include a depth 160 and a width
162 as shown best in FIGS. 5 and 6, and both of depth 160 and width
162 can be varied to vary the characteristics of support and
firmness exhibited by sculptured foam core 94 adjacent to troughs
130. For example, by increasing depth 160 of troughs 130,
sculptured foam core 94 adjacent to troughs 130 provides the user
(not shown) with support and firmness characteristics that would be
expected from a non-sculptured foam mattress having foam that is
less firm than the foam comprising sculptured foam core 94.
Likewise, by increasing width 162 of troughs 130, sculptured foam
core 94 adjacent to troughs 130 provides the user (not shown) with
support and firmness characteristics that would be expected from a
non-sculptured foam mattress having foam that is less firm than the
foam comprising sculptured foam core 94. Thus, by varying depth 160
and width 162 of troughs 130, the support and firmness
characteristics of portions of sculptured foam core 94 can be
varied.
[0093] In preferred embodiments, troughs 130 are formed in top
surface 132 of sculptured foam core 94. It has been found, however,
that by sculpturing troughs 130 onto the surface of sculptured foam
core 94 engaging the bed so that sculptured foam core 94 presents a
generally planar top surface 132 provides for decreases of the
firmness and support characteristics of mattress 52 carrying
sculptured foam core 94, these decreases being less than the
decreases experienced when the sculptured surface faces upwardly.
Thus, by sculpturing sculptured foam core 94 on the downward
surface engaging the bed, the firmness and support characteristics
of mattress 52 can be further adjusted. It is within the scope of
the invention as presently perceived to sculpt the sculptured foam
core to include troughs 130 only on top surface 132, only on the
downwardly-facing surface of sculptured foam core 94 engaging the
bed, and on both above-mentioned surfaces.
[0094] Side foam sections 80 of frame 74 and foam divider rail 114
can also be sculptured to allow for each of these members 80, 114
to move as shown in FIG. 7 along with head, seat, thigh, and foot
sections 144, 146, 148, 150 of articulating deck 138. Foam divider
rail 114 is typically sculptured to have the same pattern of
troughs 130 and cuts 134 as described above with respect to
sculptured foam core 94.
[0095] In preferred embodiments, frame 74 is formed from foam
having a significantly greater firmness than core 88 so that frame
74 provides additional support along the sides and ends of mattress
52. Such additional support is particularly useful when a user
enters and exits the bed. However, use of such additionally firm
side foam sections 80 requires that side foam sections 80 are
sculptured to ensure that side foam sections 80 move with the head,
seat, thigh, and foot sections 144, 146, 148, 150 of deck 138.
[0096] As with sculptured foam core 94, side foam sections 80 of
frame 74 are provided with transverse cuts 134 having slits 140 and
cylindrical openings 142 as shown in FIG. 7. Side foam sections 80
can also be provided with troughs 130 to vary the firmness and
support characteristics of side foam sections 80 as described above
with respect to sculptured foam core 94.
[0097] Core 88 can also include air bladder 96 as shown in FIGS.
1(a), 2, and 8(a)-15. Air bladder 96 is preferably inflated and
deflated using air, however any acceptable fluid such as other
gasses or liquids such as water and water having additives to
adjust the viscosity of the resultant liquid can be used to inflate
air bladder 96 without exceeding the scope of the invention as
presently perceived. Thus, throughout the specification and claims
such fluid will be referred to as air, although it is understood
that other fluids may be used.
[0098] Air bladder 96 can be a "one-zone" air bladder (not shown)
having one continuous air pocket extending through the air bladder
so that the entire air bladder is uniformly inflated and deflated
each time air is added to or removed from the air bladder. In
preferred embodiments, however, air bladder 96 is a multiple-zoned
air bladder having independently inflatable zones. Preferred and
illustrative air bladder 96 is a "four-zone" air bladder 96 as
shown in FIGS. 8(a) and 9 having independently inflatable zones
including an upper back zone 192 supporting the scapula, a lower
back zone 194 supporting the lumbar region, a seat zone 196
supporting the sacrum, and a foot zone 198 supporting the thighs,
legs, and feet of the user.
[0099] Air bladder 96 is constructed from an upper sheet 210 of an
air impermeable material that is adhesively connected to a lower
sheet 212 of an air impermeable material by a perimetral bead 214
of adhesive applied therebetween as shown in FIGS. 8(a), 8(b), and
9 to form an air-tight perimetral seal. Upper and lower sheets 210,
212 cooperate with bead 214 to define an internal region 216 of air
bladder 96 that is air impermeable. Bead 214 is slightly spaced
apart from outer edges of upper and lower sheets 210, 212 forming a
two-layered perimetral flange 217.
[0100] Transversely extending I-beams 218, 219 are received inside
of internal region 216 as shown in FIGS. 9 and 11-15. Each I-beam
218, 219 includes a top lip 220 sewn and adhesively attached to
upper sheet 210 and a lower lip 222 sewn and adhesively attached to
lower sheet 212 as shown best in FIGS. 11 and 14. The adhesive
forms an air impermeable seal between top lip 220 and upper sheet
210 and between lower lip 222 and lower sheet 212. Each I-beam 218,
219 cooperates with upper sheet 210, lower sheet 212, and each
adjacent I-beam 218, 219 to define a pocket 224 so that when air
bladder 96 is inflated it defines a longitudinally extending series
of transverse pockets 224 as shown best in FIGS. 8(a), 8(b), 9, and
11-15. Each pocket 224 is a predetermined size when pocket 224 is
inflated to its full capacity.
[0101] Each I-beam 218, 219 has a transverse first end 226 and a
transverse second end 228 as shown in FIG. 8(a). First and second
ends 226, 228 of I-beams 218 are spaced apart from bead 214 to
define openings 230 in fluid communication with adjacent pockets
224 defined by I-beams 218, thereby allowing the passage of air
therebetween. However, first and second ends 226, 228 of I-beams
219 are adhesively attached to bead 214 to form air impermeable
seals between adjacent pockets 224 defined by I-beams 219. Thus,
adjacent pockets 224 defined by I-beams 219 are not in fluid
communication through I-beams 219. I-beams 219 are placed to define
each of the separate and distinct upper back, lower back, seat, and
foot zones 192, 194, 196, 198 of air bladder 96 as shown in FIGS.
8(a), 8(b), and 9.
[0102] Each zone 192, 194, 196, 198 is provided with a tube 232 in
fluid communication with pockets 224 of each respective zone 192,
194, 196, 198, and tubes 232 are each in fluid communication with a
pressurized air supply 234 as shown diagrammatically in FIG. 8(a).
Preferred pressurized air supply 234 includes a source of
compressed air 236 such as an air compressor, a pressurized air
tank, or the like, a manifold 238 connecting each tube 232 to
source of compressed air 236, and valves 240 individually
controlling the flow of compressed air to and from each tube 232 as
shown in FIGS. 1(a), 2, and 8(a). In preferred embodiments,
manifold 238 is positioned to lie in an opening 243 formed in foot
end foam section 78 of frame 74 as shown in FIGS. 1(a) and 2.
[0103] Valves 240 include a three-way normally open source/exhaust
valve 260 connecting manifold 238 to source of compressed air 236
when source/exhaust valve 260 is open and connecting manifold 238
to an exhaust line 258 when source/exhaust valve 260 is energized
as shown in FIGS. 8(a) and 8(b). An upper back valve 262 is a
normally closed valve that connects upper back zone 192 to manifold
238 when upper back valve 262 is energized. A lower back valve 264
is a normally closed valve that connects lower back zone 194 to
manifold 238 when lower back valve 264 is energized. A seat valve
266 is a normally closed valve that connects seat zone 196 to
manifold 238 when seat valve 266 is energized. A foot valve 268 is
a normally closed valve that connects foot zone 198 to manifold 238
when foot valve 268 is energized.
[0104] To increase the support and firmness characteristics of
mattress 52 having four-zone air bladder 96 adjacent to upper back
zone 192, the user energizes upper back valve 262 to bring upper
back zone 192 into fluid communication with manifold 238 as shown
in FIG. 8(a). Source/exhaust valve 260 is normally open so that
when upper back zone 192 is in fluid communication with manifold
238, upper back zone 192 is also in fluid communication with source
of compressed air 236 so that upper back zone 192 inflates.
Likewise, to increase the firmness and support characteristics of
matters 52 adjacent to lower back, seta, or foot zones 194, 196,
198, the user simply energizes lower back valve, seat valve, or
foot valve 264, 266, 268 respectively to bring the respective zone
194, 196, 198 of air bladder 96 into fluid communication with
source of compressed air 236. To increase the firmness and support
characteristics of the entire mattress 52 simultaneously, the user
simply energizes all four of the upper back, lower back, seat, and
foot valves 262, 264, 266, 268 simultaneously to bring all four
zones 192, 194, 196, 198 into fluid communication with source of
compressed air 236 at the same time.
[0105] To decrease the support and firmness characteristics of
mattress 52 having four-zone air bladder 96 adjacent to upper back
zone 192 to provide the user with a more plush feel, the user
energizes source/exhaust valve 260 to bring manifold 238 into fluid
communication with exhaust line 258 as shown in FIGS. 8(a) and
8(b), and then energizes upper back valve 262 to bring upper back
zone 192 into fluid communication with manifold 238. Typically,
exhaust line 258 vents directly to the atmosphere, so that
energizing both source/exhaust valve 260 and upper back valve 262
brings upper back zone 192 into fluid communication with the
atmosphere, causing upper back zone 192 to deflate and providing
mattress 52 with a more plush feel for the user.
[0106] Likewise, to decrease the firmness and support
characteristics of mattress 52 adjacent to lower back, seat, or
foot zones 194, 196, 198, the user simply energizes lower back
valve, seat valve, or foot valve 264, 266, 268 respectively to
bring the respective zone 194, 196, 198 of air bladder 96 into
fluid communication with manifold 238, and thus the respective zone
194, 196, 198, and at the same time energizes source/exhaust valve
258 to bring manifold 238, and thus the respective zone 194, 196,
198, into fluid communication with exhaust line 258 as shown in
FIGS. 8(a) and 8(b). To decrease the firmness and support
characteristics of the entire mattress 52 simultaneously, the user
simply energizes all five of the upper back, lower back, seat,
foot, and source/exhaust valves 262, 264, 266, 268, 260
simultaneously to bring all four zones 192, 194, 196, 198 into
fluid communication with exhaust line 258 at the same time so that
all four zones 192, 194, 196, 198 simultaneously vent to the
atmosphere.
[0107] If desired, manifold 238 and valves 240 can be rearranged to
"link" the performance of separate zones of four zone air bladder
96 as shown in FIG. 8(b). For example, tube 232 communicating with
upper back zone 192 can also be brought into fluid communication
with tube 232 communicating with seat zone 196 by connector tube
263 communicating with both upper back zone 192 and seat zone 196.
Connector tube 263 can be brought into fluid communication with
source of compressed air 236 through an upper back and seat valve
267 and manifold 238 so that both upper back and seat zones 192,
196 are inflated generally simultaneously and to the same extent to
increase the firmness and support characteristics of these zones
192, 196 of mattress 52. Connector tube 263 can also be brought
into fluid communication with exhaust line 258 to simultaneously
and to the same extent deflate both upper back and seat zones 192,
196, and decrease the firmness and support characteristics of
mattress 52 accordingly.
[0108] As can be seen, any two or more of zones 192, 194, 196, 198
can be linked by a connector tube to cause separate portions of
mattress 52 to provide similar firmness and support
characteristics. Likewise, a second connector tube 265 can be
formed to bring tubes 232 not connected to the first common line
into fluid communication. For example, if upper back and seat zones
192, 196 are in fluid communication through connector tube 263,
tube 232 communicating with lower back zone 194 can be brought into
fluid communication with tube 232 communicating with foot zone 198
by second connector tube 265 so that lower back zone 194 is in
fluid communication with foot zone 198. By bringing second
connector tube 265 into fluid communication with source of
compressed air 236, both lower back and foot zones 194, 198 will
simultaneously inflate, increasing the firmness and support
characteristics of mattress 52 adjacent to lower back and foot
zones 194, 198 at the same time and to the same extent. Likewise,
by bringing the second connector tube 265 into fluid communication
with exhaust line 258, the firmness and support characteristics of
mattress 52 adjacent to lower back and foot zones 194, 198 will
decrease generally simultaneously and generally to the same extent.
Thus, independent zones of air bladder 96 can be linked so that the
support and firmness characteristics of mattress 52 adjacent to the
linked zones change at the same time to the same extent when
adjusted by the user.
[0109] In preferred embodiments of mattress 52 having four-zone or
one-zone air bladder 96, the pressure of each zone 192, 194, 196,
198 can be automatically controlled by placing air bladder 96 into
"computer" mode. Once a user establishes a desired pressure for
each zone 192, 194, 196, 198 that results in the desired firmness
and support characteristics, the pressure in one or more of the
zones 192, 194, 196, 198 can change. For example, if the user moves
so that a heavier or lighter portion of the user's body is
supported by the affected zone, the pressure in the affected zone
will change, changing the firmness and support characteristics of
the affected zone.
[0110] Each zone 192, 194, 196, 198 of air bladder 96 is provided
with a transducer 296 for providing an output signal in response to
the pressure of each respective zone 192, 194, 196, 198 so that the
pressure in each zone 192, 194, 196, 198 can be monitored, and bed
and mattress structure 50 can be configured to compensate for these
changes in pressure. For example, if the pressure in upper back
zone 192 decreases from a set point established by the user, upper
back valve 262 can be automatically energized to bring upper back
zone 192 into fluid communication with source of compressed air 236
until the pressure in upper back zone 192 increases back to the set
point, thus increasing the firmness and support characteristics of
mattress 52 to the selected level. Likewise, if the pressure in
seat zone 196 increases above the set point established by the
user, seat valve 266 and source/exhaust valve 260 can be
automatically energized to bring seta zone 196 into fluid
communication with exhaust line 258, deflating seta zone 196 until
the pressure is reduced back to the set point, thus returning the
support and firmness characteristics of mattress 52 adjacent to
seat zone 196 to the selected level. By monitoring and adjusting
the pressure in each zone 192, 194, 196, 198 of air bladder 96, the
user's selected support and firmness characteristics can be
maintained.
[0111] When mattress 52 is sized for a king- or queen-sized bed as
shown in FIG. 2 and core 88 includes two side-by-side air bladders
96, one source of compressed air 236 can be used to inflate and
deflate both air bladders 96. Typically, each air bladder 96 is
provided with manifold 238 and valves 240, with each source/exhaust
valve 260 being in fluid communication with a "T-connector" (not
shown) bringing each source/exhaust valve 260 into fluid
communication with source of compressed air 236.
[0112] As described above, both air bladders 96 can operate in a
"computer" mode wherein the pressure of each respective zone 192,
194, 196, 198 is maintained by automatically inflating and
deflating each zone to compensate for movement of the user that
changes the load carried by each respective zone. The
above-described valve configuration in accordance with the present
invention prevents a "continuous run" condition. A continuous run
condition is present in side-by-side air bladders 96, both of which
are on computer mode, when one air bladder 96 is exhausting so that
one manifold 238 is in fluid communication with exhaust line 258 at
the same time the other air bladder 96 is inflating so that the
other manifold 238 is in fluid communication with source of
compressed air 236. Since both manifolds 238 are connected by the
T-connector, the possibility exists that compressed air source 236
might be in fluid communication with exhaust line 258 so that
neither air bladder 96 reaches the desired state, causing the
system to run continuously as it attempts to inflate and deflate
each air bladder.
[0113] However, each source/exhaust valve 260 is a three-way valve
that positively blocks the flow between exhaust line 258 and
manifold 238 when source/exhaust valve 260 is open to bring
manifold 238 into fluid communication with source of compressed air
236. In addition, source/exhaust valve 260 blocks the flow from
source of compressed air 236 when source/exhaust valve 260 is
energized to bring manifold 238 into fluid communication with
exhaust line 258. Thus, use of a three-way valve for source/exhaust
valve 260 eliminate the possibility of inadvertently achieving a
continuous run condition when operating two side-by-side air
bladders.
[0114] The operation of a one-zone air bladder 96 as shown in FIG.
10 is simpler than the operation of four-zone air bladder 96. An
inlet valve 292 is normally open to block the fluid communication
between source of compressed air 236 and manifold 238. Likewise, an
exhaust valve 294 is normally closed to block the fluid
communication between exhaust line 258 and manifold 238. Manifold
238 is in fluid communication with air bladder 96 and a transducer
296 for converting a measured pressure to an output signal for use
by a controller 370 is in fluid communication with air bladder 96
through manifold 238. To increase the firmness and support
characteristics of mattress 52 having one-zone bladder 96, user
simply energizes inlet valve 292 to restore fluid communication
between source of compressed air 236 and air bladder 96 through
manifold 238 to inflate air bladder 96. To decrease the firmness
and support characteristics of mattress 52, user energizes exhaust
valve 294 to restore fluid communication between exhaust line 258
and air bladder 96 through manifold 238 to deflate air bladder
96.
[0115] I-beams 218, 219 are generally of similar height so that
pockets 224 are generally uniform in size and shape as shown in
FIG. 9. The height of I-beams 218, 219 can be varied as shown in
FIGS. 11-14 for I-beams 218' which are taller than I-beams 218, 219
to produce pockets 224' defined by I-beam 218' that inflate to a
size larger than pockets 224 that are not adjacent to I-beam 218'.
Pockets 224' produce a portion on mattress 52 adjacent to pockets
224' at which the user perceives additional support and firmness.
By placing I-beam 218' as shown in FIGS. 11-15, air bladder 96 will
provide additional support and firmness for the lumbar portion of
the user's adjacent to the lower back zone 194.
[0116] Typically, I-beams 218, 219 are generally the same height so
that pockets 224 are generally uniform in size and shape as shown
in FIG. 9. Air bladder 96 can be made, however, having selected
I-beams 218' which are taller than I-beams 218, 219 as shown in
FIGS. 11-15 to produce pockets 224' defined by taller I-beams 218'
that inflate to a size larger than pockets 224 defined only by
I-beams 218, 219 so that upper and lower sheets 210, 212 adjacent
to pockets 224' project beyond upper and lower sheets 210, 212
adjacent to pockets 224 defined only by I-beams 218, 219 when
pockets 224, 224' are fully inflated, as shown best in FIG. 15. By
including isolated pockets 224' that project past the other
surfaces of air bladder 96, mattress 52 provides additional
firmness and support characteristics at longitudinal zones adjacent
to projecting pockets 224'.
[0117] For example, a single I-beam 218' can be positioned to lie
between two I-beams 218, 219 as shown diagrammatically in FIGS. 11
and 12 for air bladder 96 resting on a generally planar surface.
When air bladder 96 is fully inflated, upper sheet 210 adjacent to
two adjacent pockets 224, which are both defined in part by I-beam
218', projects above upper sheet 210 adjacent to pockets 224 as
shown in FIG. 11. Likewise, two adjacent I-beams 218' can be
positioned to lie between I-bemas 218, 219 as shown
diagrammatically in FIGS. 13 and 14 for air bladder 96 resting on a
generally planar surface. When air bladder 96 is fully inflated,
upper sheet 210 adjacent to three adjacent pockets 224', each of
which are defined at least in part by I-bemas 218', projects above
upper sheet 210 adjacent to pockets 224 as shown in FIG. 14.
Although only one and two adjacent I-beams 218' that are taller
than I-beams 218, 219 are shown in FIGS. 11-15, the height of any
number of adjacent I-beams 218' may be varied to cause a desired
portion of upper and lower sheets 210, 212 of air bladder 96 to
project beyond the remaining portions of upper and lower sheets
210, 212.
[0118] Taller I-beams 218' can be used to provide firmness and
support characteristics that vary longitudinally along mattress 52
including air bladder 96 as shown in FIG. 15, even if air bladder
96 is a one-zone air bladder. In addition, use of taller I-beams
218' can cause each zone of a multiple zone air bladder 96 to
provide mattress 52 with multiple firmness and support
characteristics adjacent to the zone.
[0119] For example, I-beams 218' can be used to form pockets 224'
in foot zone 198 adjacent to seat zone 196 as shown in FIG. 15.
Mattress 52 including air bladder 96 with such pockets 224' will
provide the user with additional firmness and support adjacent to
his or her thighs. Thus foot zone 198, which includes pockets 224,
224' that are all in fluid communication so that the air pressure
in each pocket 224, 224' of foot zone 198 is generally equivalent,
will simultaneously provide the portion of mattress 52 adjacent to
foot zone 198 with multiple firmness and support
characteristics.
[0120] For another example, I-beams 218' can be used to form
pockets 224' in foot zone 198 adjacent to the ankles of the user as
shown in FIG. 15. Mattress 52 including air bladder 96 with such
pockets 224' will provide the user with additional firmness and
support adjacent to his or her ankles. In addition, by providing
this additional support adjacent to the ankles of the user,
mattress 52 will operate to relieve interface pressure against the
heels of the user to help alleviate pressure ulcers that can
develop on the heels of the user. Air bladder 96 can thus be used
to adjust the support and firmness characteristics of mattress 52
both by having adjustable air pressure in one or multiple
longitudinal zones, for example zones 192, 194, 196, 198, and by
suing I-beams 218' that are taller than other I-bemas 218, 219 so
that portions of upper and lower sheets 210, 212 of air bladder 96
project beyond portions of upper and lower sheets 210, 212 adjacent
only to I-beams 218, 219.
[0121] Flange 217 of air bladder 96, which is positioned to lie
outside of perimetral bead 214 as shown in FIGS. 8(a), 8(b), and 9,
is formed from outer portions of both the upper and lower sheets
210, 212. Flange 217 is formed to include a plurality of
spaced-apart openings 244 that extend therethrough. Openings 244
are used during the manufacturing process to stabilize air bladder
96 as manufacturing operations are performed thereon.
[0122] Openings 244 can also be used, however, to stabilize air
bladder 96 in mattress 52. For example, when mattress 52 is
provided for a queen-sized bed (not shown) so that core 88 includes
elements in side-by-side abutting engagement, if core 88 includes
side-by-side air bladders 96, then openings 244 of the first air
bladder 96 can be tied to openings 244 of the second air bladder 96
to prevent relative transverse movement of the first air bladder 96
relative to the second air bladder 96. Even if core 88 includes
side-by-side elements only one of which is an air bladder 96,
openings 244 can still be used to stabilize air bladder 96 if
desired.
[0123] In preferred embodiments of bed and mattress structure 50,
top cover 60 of mattress 52 can be formed to include an enclosed
"warm air release" channel 250 receiving air from source of
compressed air 236 as shown in FIG. 16. Enclosed channel 250 is
preferably made from a light weight and air impermeable material so
that air is directed along the length of channel 250. The material
is formed to include small openings (not shown) that allow a small
amount of air to escape from channel 250. The openings direct the
air across the surface of mattress 52 as shown by arrows 252 in
FIG. 12.
[0124] An air heater 254 is interposed between source of compressed
air 236 and channel 250 as shown in FIG. 16 so that heated air can
be provided to channel 250. Air heater 254 can be selectively
operated so that when air heater 254 is operating, air 252 is the
warm air release warming the user and particularly warming the
extremities of the user. When air heater 254 is not operating, air
252 is a room temperature air release cooling the user during
operation of channel 250. Of course, in preferred embodiments, a
valve is positioned between source of compressed air 236 and
channel 250 so that channel 250 can be operated or not operated at
the discretion of the user.
[0125] Channel 250 can be positioned about the perimeter of top
cover 60 as shown in FIG. 16. As mentioned above, the preferred
material of construction of much of mattress 52 is foam rubber
which is a thermal insulator. As such, it is important that channel
250 be as close as possible to sleeping surface 122 and the user.
As a result, if mattress 52 includes pillow top 90, then channel
250 can be formed around an outer edge of pillow top 90 rather than
top cover 60 so that channel 250 is adjacent to sleeping surface
122.
[0126] Also in preferred embodiments, a hand held controller 256 is
provided for use by the user as shown in FIG. 16 for controlling
the operation of bed and mattress structure 50. Hand held
controller 256 can operate both source of compressed air 236 and
air heater 254 as well as other mattress functions as described in
detail below with reference to FIGS. 21 and 22.
[0127] Bed and mattress structure 50 can additionally be provided
with arm rests 270 as shown in FIGS. 17-20. Arm rest 270 includes a
curved top surface 272, a curved bottom surface 274, and generally
planar sides 276. Top and bottom surfaces 272, 274 can each be
formed to include openings 278 sized to receive drinking glasses,
drinking cups, beverage cans, or the like (shown in phantom in FIG.
18). The preferred arm rest 270 includes a foam rubber pad 280 and
a fabric covering 282 conformingly shaped to fit around pad 280 as
shown best in FIG. 18. Top and bottom surfaces 272, 274 are spaced
apart by a first distance 284 near a first end 286 of arm rest 270
and taper together so that top and bottom surfaces 272, 274 are
spaced apart by a second distance 288 near a second end 290 of arm
rest 270.
[0128] Arm rest 270 is positioned between the elbow of the user
(not shown) and sleeping surface 122. The distance between the
elbow and sleeping surface 122 varies somewhat between users
resting on sleeping surface 122. By moving arm rest 270
longitudinally relative to the elbow of the user, most users will
find a position on arm rest 270 having a distance between top and
bottom surfaces 272, 274 at which the user can comfortably rest his
or her elbow. If the user finds that it is most comfortable to rest
his or her elbow nearer to first end 286 than to second end 290,
the user will most likely prefer to use arm rest 270 with top side
272 facing upwardly as shown in FIG. 19 so that upwardly-facing
opening 278 is on the portion of arm rest 270 extending
longitudinally away from seat section 146. Conversely, if the user
finds that it is most comfortable to rest his or her elbow nearer
to second end 290 than to first end 286, the user will most likely
prefer to use arm rest 270 with bottom side 274 facing upwardly as
shown in FIG. 20 so that once again upwardly-facing opening 278 is
on the portion of arm rest 270 extending longitudinally away from
seat section 146. It can be seen in each instance that the shapes
of top and bottom surfaces 272, 274 generally conform to the shape
of sleeping surface 122 of mattress 52 when deck 138 is articulated
away from the generally planar sleeping position.
[0129] As mentioned above, hand held controller 256 is provided as
shown in FIGS. 16, 21, and 22 for controlling the operation of bed
and mattress stricture 50. Hand held controller 256 includes a
first end 310, a second end 312, a power and communication cord 314
extending away from second end 312 and toward bed and mattress
stricture 50, an upper face 316, and a key pad 318 carried on upper
face 316 for receiving inputs from the user, bed and mattress
structure 50 adjusting its various features in response to the
inputs from keypad 318 as described below. When the user is holding
hand held controller 256 to operate bed and mattress structure 50,
hand held controller 256 will typically be held in a generally
upright orientation as shown in FIG. 21 having first end 310
positioned to lie generally above second end 312.
[0130] Illustrative key pad 318 includes a light emitting diode
(LED) primary display 320, memory buttons 322, bed position buttons
324, mattress control buttons 326, massage control buttons 328, and
a bed select button 330 as shown in FIG. 22. In addition, key pad
318 includes an LED computer on/off display 332, an LED zone
display 334, and an LED bed select display 336. As described below,
illustrative key pad 318 is configured for use with a king- or
queen-sized bed having an articulating deck 138 and having at least
one four-zone air bladder 96. Other beds having other features
would include hand held controller 256 having a key pad 318
including at least some of these buttons.
[0131] Key pad 318 is arranged so that primary display 320 is
positioned adjacent to first end 310 of key pad 318 as shown in
FIG. 22. The remaining buttons and displays are positioned to lie
in longitudinally spaced-apart relation between primary display 320
and second end 312. Memory buttons 322 are positioned adjacent to
primary display 320, bed position buttons 324 are positioned
adjacent memory buttons 322, mattress control buttons 326 are
positioned adjacent bed position buttons 324, massage control
buttons 328 are positioned adjacent mattress control buttons 326,
and bed select button 330 is positioned adjacent massage control
buttons 328 and adjacent second end 312 of key pad 318.
[0132] Memory buttons 322 provide the user with the ability to
establish one or more preferred "memory positions" of articulating
deck 138. In addition, the memory positions include a corresponding
air pressure in zones 192, 194, 196, 198 of air bladder 96 selected
by the user to provide selected firmness and support
characteristics to correspond to each preferred position of
articulating deck 138, as shown in FIG. 22 in which illustrative
key pad 318 allows the user to establish two memory positions. Once
the user establishes the memory positions, the user simply presses
the memory button corresponding to the desired position and
articulating deck 138 will automatically move to its prescribed
position while each zone 192, 194, 196, 198 of air bladder 96 is
automatically inflated or deflated to its prescribed pressure so
that mattress 52 provides the preselected firmness and support
characteristics selected by the user to correspond to the selected
position of articulating deck 138.
[0133] Bed position buttons 324 allow the user to manipulate the
articulating sections of articulating deck 138. In addition,
certain of the individual LEDs of primary display 320 will be
energized to indicate the relative position of articulating deck
138. In addition, primary display 320 indicates the relative air
pressure in zones 192, 194, 196, 198 of air bladder 96. Primary
display 320 will provide an indication for the last button pressed.
If more than one function is running one time or if memory buttons
322 are pressed, primary display 320 will indicate the relative
position of head section 144 of deck 138. Also, bed position
buttons 324 include a preset "lounge" button 338 and a preset "bed
flat" button 340 which are additional memory keys that are set
during assembly of mattress 52 in accordance with inputs from the
customer profile sheet.
[0134] Mattress control buttons 326 shown in FIG. 22 include a
"zones" button 342 for selecting a zone 192, 194, 196, 198 of air
bladder 96 in response to user pressing zones button 342, zone
display 334 including LED indicators, one of which will be
energized to indicate the selected zone 192, 194, 196, 198, a
"firm" button 344 for increasing the air pressure in the selected
zone in response to user pressing firm button 344 to increase the
firmness of mattress 52 adjacent to the selected zone, and a "soft"
button 346 for decreasing the air pressure in the selected zone in
response to user pressing soft button 346 to decrease the firmness
of mattress 52 adjacent to the selected zone. As described above,
when the user presses zones button 342 to select a selected zone,
primary display 320 will indicate the relative air pressure in the
selected zone.
[0135] In addition, mattress control buttons 326 include a mattress
computer on/off button 348. Once a user has selected a desired air
pressure for each zone 192, 194, 196, 198, the user may move
relative to air bladder 96. As the user moves, heavier or lighter
body parts of the user may be supported by each respective zone
192, 194, 196, 198 than were support by the zone when the desired
air pressure was originally selected. If the amount of air in zones
192, 194, 196, 198 were fixed, this movement of user could change
the forces exerted on each zone 192, 194, 196, 198, thus changing
the air pressure in each zone and the support and firmness
characteristics of mattress 52 adjacent to each zone 192, 194, 196,
198.
[0136] Mattress 52 preferably includes transducers 296, described
above with reference to FIGS. 8(a), 8(b), and 10, for measuring the
air pressure in each zone 192, 194, 196, 198. If, after selecting
the desired firmness and support characteristics for each zone 192,
194, 196, 198 the user presses computer on/off button 348 to turn
on the "computer mode," an internal computer will monitor output
signals provided from each transducer 296 in response to the air
pressure in each zone 192, 194, 196, 198 and will automatically
operate valves 240 when necessary and in the manner described above
with reference to FIGS. 8(a) and 8(b) to maintain the pressure in
each respective zone 192, 194, 196, 198 at a set point that
corresponds to the firmness and support characteristics chosen by
the user. If computer mode is turned on, the LED of computer on/off
display 332 will be energized to indicate such status.
[0137] Mattress 52 can also be provided with a massage feature. The
presently preferred massage feature is provided by first and second
motors (not shown), the first motor being attached to articulating
deck 138 adjacent to head section 144 and the second motor being
attached to articulating deck 138 adjacent to foot section 150.
Each motor rotates a generally horizontally extending shaft. An
off-center weight is fixed to each shaft so that as each shaft
rotates, each shaft, each motor, and deck 138 adjacent to each
motor vibrates. To increase the level of vibration felt by the
user, the rotation speed of the shafts is increased and to decrease
the level of vibration felt by the user, the rotation speed of the
shaft is decreased.
[0138] As mentioned above, mattress control buttons 326 include
massage control buttons 328, including head end massage increase
button 350, head end massage decrease button 352, foot end massage
increase button 354, foot end massage decrease button 356, and wave
buttons 358. When the user presses head end massage increase button
350, the motor attached to articulating deck 138 adjacent to head
section 144 increases the rotational speed of its shaft until a
maximum rotational speed is reached at which point the rotational
speed of the shaft cannot be further increased.
[0139] When the user presses head end massage decrease button 352,
the motor attached to articulating deck 138 adjacent to head
section 144 decreases the rotational speed of its shaft until a
minimum rotational speed is reached. The motor will halt the
rotation of the shaft if head end massage decrease button 352 is
pressed when the shaft is rotating at the minimum rotational speed.
Likewise, pressing foot end massage increase button 354 and foot
end massage decrease button 356 causes the motor attached to
articulating deck 138 adjacent to foot section 150 to increase and
decrease the rotational speed of its shaft. Pressing wave buttons
358 causes the motors to operate together to provide a coordinate
massage effect.
[0140] Finally, if mattress 52 is for a queen- or king-sized bed
having side-by-side air bladders 96, hand held controller 256 will
control both halves of bed and mattress structure 50. Pressing bed
select button 330, shown in FIG. 22, will toggle between the two
halves of the bed and mattress structure 50 so that when the "left"
LED of bed select display 336 is energized control inputs from the
user to key pad 318 will operate to manipulate the left side of bed
and mattress structure 50, and when the "right" LED of bed select
display 336 is energized, control inputs from the user to key pad
318 will operate to manipulate the right side of bed and mattress
structure 50.
[0141] Typically when the user operates bed and mattress structure
50 including articulating deck 138 and four-zone air bladder 96
using illustrative key pad 318 shown in FIG. 22, the user will
press one of memory buttons 322. However, on occasion, the user may
choose to adjust the position of articulating deck 138 using bed
position buttons 324 and may probably less frequently, wish to
adjust the support and firmness characteristics of mattress 52 by
pressing mattress control buttons 326. Occasionally, the typical
user will utilize the massage feature by pressing massage control
buttons 328.
[0142] Thus, illustrative key pad 318 is arranged so that buttons
are ordered from first end 310 to second end 312, or from top to
bottom, in order of the frequency of use of the buttons so that the
most frequently used buttons are positioned to lie nearest the top
or first end 310 of key pad 318 and the least frequently used
buttons are nearest the bottom or second end 312 of key pad 318. In
addition, it can also be seen that illustrative key pad 318 is
arranged so that buttons are ordered from first end 310 to second
end 312, or from top to bottom of key pad 318, generally in the
order that the user will use the buttons so that the first buttons
generally used in a typical operation sequence are nearest the top
of key pad 318 and the last buttons used in a typical operation
sequence are nearest the bottom of key pad 318.
[0143] Hand held controller 256 provides the man-machine interface
for the user. By depressing buttons 322, 324, 326, 328, 330
(graphically displayed) the user can select various operations.
These operations are bed position, mattress computer, memory,
massage, mattress zones, and firm or soft controls. These commands
are sent by way of an RS232 wire connection 372 to the compressor
board 374 as shown in FIG. 23. The compressor board 374 acts as an
interconnection interface to the mattress control board 376,
massage and bed position motors 378. Signals generated at hand held
controller 256 pass through compressor board 374 to mattress
control board 376. Mattress controller operates valves 240 to
control the flow of compressed air or exhaust from zone to zone.
Mattress controller also receives signals from transducers 296 that
monitor the air pressure at each zone and provides signals back to
hand held controller 256 for display.
[0144] Hand held controller 256 is a microprocessor based control
system capable of remotely controlling up to eight bladders or
individual air zones of air bladders 96 via a serial link with
pressure control system. The system will also receive and display
relative pressure information by way of the serial link. The link
itself is to be either a wire or a wireless link.
[0145] The system is based on a Microchip 16 C series surface mount
one time programmable device. There are two microcontrollers used.
One located in hand held controller 256 and the other is in
mattress control board. They communicate VIA an RS232 serial
link.
[0146] The primary benefit of the Microchip device is the
implementation of control algorithms due to the controller's
reduced instruction set. Additional benefits include:
[0147] Simplified memory requirement predictions, and timing
calculations due to the single line, predominantly single cycle
instructions.
[0148] Low Cost.
[0149] No additional program memory required.
[0150] Software is directly portable to other devices in the large
family allowing for easier upgrades.
[0151] Specialized sleep capability, and external interrupts allow
a power consumption savings.
[0152] Built in, independent watch dog timer prevents system crash
due to an unresponsive controller.
[0153] Separate program and data memory prevents unintentional
program corruption due to accidental program memory access.
[0154] A salient feature for this system is the implementation of a
direct feed back display on key pad 318 at the man-machine
interface. Primary display 320 presents the user with direct real
time feed back of control operations. Mattress control board 376
receives signals from transducers 296 in response to the air
pressure in each zone and uses that information to display pressure
setting and the controlled zones of air bladder 96 on primary
display 320 of hand held controller 256.
[0155] Mattress 52 is ideally suited for providing a user with
sleeping surface 122 that is customized to provide firmness and
support characteristics established by and for the user. As
described above, mattress 52 can include air bladder 96 having
either one zone or multiple zones, and within each zone air bladder
96 can be provided with I-beams of varying height to provide
multiple firmness and support characteristics within each zone.
Mattress 52 can also include sculptured foam core 94 or zone foam
blocks 92 as described above. In addition, however, mattress 52 may
be provided with combinations of the above as shown in FIGS. 1(b)
and 1(c).
[0156] Mattress 52 can be provided with a combination of zone foam
blocks 92 and air bladders 96 as shown in FIG. 1(b) which
illustratively shows air bladders 96 for supporting the scapula and
sacrum of the user and zone foam blocks 92 for supporting the
lumbar region and the thighs and legs of the user. Air bladders 96
can operate individually and separately, or air bladders 96 can be
brought into fluid communication with one another in a manner
similar to that described above with respect to FIG. 8(b) so that
they inflate and deflate generally at the same time and to
generally the same extent.
[0157] Likewise, mattress 52 can illustratively include zone foam
blocks 92 positioned to support the upper back, the seat, and the
lower legs of the user and air bladders 96 to support the lumbar
region and thighs of the user as shown in FIG. 1(c). As mentioned
above, air bladders 96 can operate individually and separately, or
air bladders 96 can be brought into fluid communication with one
another in a manner similar to that described above with respect to
FIG. 8(b) so that they inflate and deflate generally at the same
time and to generally the same extent. As can be seen, any
combination or positioning of zone foam blocks 92 and air bladders
96 can be provided in mattress 52 to meet the desired firmness and
support characteristics of the user. Although preferred sculptured
foam core 94 generally extends the full length of central opening
82, shorter sculptured foam cores (not shown) can be provided for
use in combination with air bladders 96 and zone foam blocks 92 if
desired to provide the user with his or her preferred firmness and
support characteristics without exceeding the scope of the
invention as presently perceived.
[0158] Mattress 52 along with a "test mattress" (not shown)
containing a multiple zone air bladder 96 can be used to determine
the firmness, support, and interface pressure preferences of the
user and to use the same to customize mattress 52 for each user.
The preferred method for customizing mattress 52 is initiated when
a potential user completes a questionnaire to aid in the analysis
of that user's "sleep profile." The sleep profile assesses such
factors as the user's general health and sleep habits. A firmness
recommendation is computed either in terms of a pressure for
various zones of the test mattress or in terms of a foam type and
density for each zone. In addition, a surface recommendation is
established based on the user's responses to a surface
recommendation questionnaire.
[0159] Once the surface and hardness recommendations are
established, the user lies on the test mattress and air bladder 96
is pressurized to match the firmness recommendation. Zones of air
bladder 96 are then adjusted to match the preferences of the user
and the resulting preferred firmness readings are recorded.
[0160] An algorithm has been developed that correlates the air
bladder pressure readings once the preferred firmness and support
characteristics have been established by the user into a customized
bed configuration. For example, the preferred firmness readings can
be translated to establish the foam density that, if incorporated
into a mattress will provide the firmness and support
characteristics similar to those provided by the test sleeping
surface having the preferred firmness readings.
[0161] This correlation can be developed by comparing the
deformation of air bladder 96 having a selected air pressure when a
known force is applied thereto by a probe of a known size, and then
determining a foam ILD that provides the same deflection when the
same force is applied to the foam by the same probe. A pressure
deformation response curve can be developed that shows the foam ILD
that provides generally the same deflection as air bladder 96 for
various air pressures within bladder 96.
[0162] Once the air pressure readings have been found that provide
the user with his or her preferred firmness, support, and interface
pressure characteristics, mattress 52 can be prepared using the
pressure deformation response curve so that mattress 52 has
mattress structure components or cores 88 including sculptured foam
core 94, zone foam blocks 92, air bladder 96, or a combination
thereof that provide the user with the preferred characteristics.
In addition, if desired, a computer can be used to map the pressure
readings of the test mattress after finding the user's preferred
firmness and support characteristics and a program can utilize the
pressure map and the pressure deformation response curve to
determine the arrangement of mattress structure components that
will provide mattress 52 that meets the user's preferences.
[0163] Once the customized bed configuration is established,
mattress 52 can be assembled from a kit at the point of sale
containing the plurality of cores 88 for the user to test and
verify that assembled mattress 52 meets his or her preferences. If
mattress 52 is not satisfactory, cores 88 can be replaced at the
point of sale. Once the user is satisfied with the arrangement of
cores 88, he or she can immediately take delivery of the completed
customized mattress if desired. In the alternative, once the
customized bed configuration is established, the data describing
this configuration can be transmitted to a factory at which the
mattress 52 can be assembled for delivery to the user.
[0164] In addition, if the user determines after assembly and
delivery that the user prefers alternate firmness or support
characteristics, cores 88 can again be readjusted or upgraded until
the mattress 52 provides the desired firmness and support
characteristics. If desired, a kit of cores 88 can be provided to
the user so that the user can adjust the firmness and support
characteristics.
[0165] The method for selecting mattress structure components or
cores 88 to provide a customized foam mattress 52 to accommodate
the musculoskeletal condition of the user includes providing a
plurality of mattress structure components arranged for selective
assembly of the components. The components comprise a plurality of
foam cores 88 for filling longitudinally extending central opening
82 in mattress 52 above which the user rests. Foam cores 88 should
have a variety of shapes and support and firmness characteristics
from which to select a desired assembly.
[0166] The method also includes providing a test mattress having a
similar longitudinally extending central opening filled with a
plurality of longitudinally spaced apart air bladders extending
transversely across the central opening and an air supply for
selectively filling each air bladder to various pressures. A user
is placed above the central opening of the test mattress and
supported on the plurality of air bladders. The air pressure in
each bladder is adjusted to a selected pressure to provide the
support and firmness desired by the user. An equivalent foam core
having the desired support and firmness characteristics
corresponding to the selected air pressures is then selected and
placed in the central opening to provide the customized
mattress.
[0167] In preferred embodiments, the mattress 52 in accordance with
the present invention can be sized for a twin bed or a double bed
as shown in FIGS. 1(a)-1(c), or a queen-sized or a king-sized bed
as shown in FIG. 2. When mattress 52 is sized for the queen and
king-sized beds, both sides of mattress 52 can be individually
customized if desired to provide the firmness and support
characteristics desired by individual sleep partners. Both cores 88
and toppers 86 can be selected for each side of mattress 52 to
provide the desired firmness and support for each side of the bed.
This flexibility results from the separate cores 88 that are
provided for each side of mattress 52.
[0168] In addition to this flexibility, use of distinct cores 88
for each half of mattress 52 operates to reduce the transmission of
movement from one side of mattress 52 to the other. Thus, when one
sleeping partners moves, the amount of movement experienced by the
other sleeping partner as a result is minimized.
[0169] As mentioned above, mattress 52 can be provided with an air
bladder having independent zones that are selectively adjustable by
the user to provide varied firmness and support characteristics. If
the same mattress 52 is used on a bed having articulating deck 138,
mattress 52 can be provided with hand held controller 256 for use
by the user to control the adjustment of both the position of deck
138 and the support characteristics of each zone of air bladder 96.
In addition, hand held controller 256 can include a "memory set"
feature which allows the user to establish preferred combination
settings for deck 138 and mattress 52.
[0170] In addition, the mattress can be provided with combinations
of air bladders 96, zone foam elements 92, and sculptured foam core
94 to produce a "combination mattress." Illustratively, mattress 52
can be provided having air bladder 96 supporting the scapula of the
user, zone foam blocks 92 supporting the lumbar of the user, air
bladder 96 in the seat portion supporting the sacrum of the user,
and zone foam blocks 92 supporting the thighs and legs. If desired,
air bladders 96 can be in fluid communication so that they inflate
and deflate at the same times and to the same pressures or air
bladders 96 can be independent of one another and independently
controlled by the user so that the user can establish different
characteristics of support and firmness for each of the scapula and
the sacrum.
[0171] Although the invention has been described in detail with
reference to preferred embodiments, additional variations and
modifications exist within the scope and spirit of the invention as
described and defined in the following claims.
* * * * *