U.S. patent application number 10/603070 was filed with the patent office on 2004-04-22 for memory foam mattress system.
Invention is credited to Lonstein, Jeff, Martens, Wendell, Roizen, Wendy.
Application Number | 20040074008 10/603070 |
Document ID | / |
Family ID | 30773513 |
Filed Date | 2004-04-22 |
United States Patent
Application |
20040074008 |
Kind Code |
A1 |
Martens, Wendell ; et
al. |
April 22, 2004 |
Memory foam mattress system
Abstract
A memory foam mattress system includes a viscoelastic mattress,
a slat-type mattress support, and a viscoelastic pillow. The
mattress includes a viscoelastic top layer atop a denser foam core
layer, surrounded by a removable cover. The viscoelastic foam
material is configured to provide a substantially uniform
viscoelastic response over a room temperature range of from about
55.degree. F. to about 85.degree. F. The mattress support includes
a perimeter frame with a plurality of transverse slats spanning the
frame, including seven adjustable pairs of slats, with a support
slat under each adjustable pair. A moveable adjustment clip
attaches each support slat to a corresponding adjustable pair, to
allow adjustment of the stiffness of the adjustable pair. The
pillow has a body of viscoelastic foam with a contoured top and a
flat bottom, surrounded by a cover. The contoured top has two
support ridges, a larger one for side sleeping, and a smaller one
for back sleeping. Foam inserts of varying densities are disposable
in insert pockets in each ridge to adjust the firmness of the
ridges.
Inventors: |
Martens, Wendell;
(Clarkston, MI) ; Lonstein, Jeff; (Westborough,
MA) ; Roizen, Wendy; (Swamp Scott, MA) |
Correspondence
Address: |
THORPE NORTH & WESTERN, LLP.
8180 SOUTH 700 EAST, SUITE 200
P.O. BOX 1219
SANDY
UT
84070
US
|
Family ID: |
30773513 |
Appl. No.: |
10/603070 |
Filed: |
June 23, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60390982 |
Jun 22, 2002 |
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60390984 |
Jun 22, 2002 |
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60390985 |
Jun 24, 2002 |
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Current U.S.
Class: |
5/740 ; 5/636;
5/727; 5/728 |
Current CPC
Class: |
A47G 2009/1018 20130101;
A47C 23/068 20130101; A47G 9/109 20130101 |
Class at
Publication: |
005/740 ;
005/636; 005/727; 005/728 |
International
Class: |
A47C 027/15; A47G
009/00 |
Claims
What is claimed is:
1. A mattress system, comprising: A) a mattress, including (i) a
core layer providing a base support; and (ii) a top layer of
viscoelastic foam, disposed atop the core layer, having a density
of from about 3.0 to about 4.5 lb/ft.sup.3.
2. A mattress system in accordance with claim 1, wherein the core
layer comprises foam material having a density of from about 2.0 to
about 2.7 lb/ft.sup.3.
3. A mattress system in accordance with claim 2, wherein the core
layer has a thickness of from about 3" to about 7".
4. A mattress system in accordance with claim 2, wherein the core
layer of foam material is selected from the group consisting of
polyurethane foam, latex foam and a combination of polyurethane
foam and latex foam.
5. A mattress system in accordance with claim 1, wherein the top
layer has a thickness of from about 2" to about 4".
6. A mattress system in accordance with claim 1, wherein the top
layer is attached to the core layer with a chemical adhesive.
7. A mattress system in accordance with claim 1, further comprising
a removable cover surrounding the core layer and the top layer.
8. A mattress system in accordance with claim 1, wherein the
viscoelastic foam layer is configured to provide a substantially
uniform response over a room temperature range of from about
55.degree. F. to about 85.degree. F.
9. A mattress system in accordance with claim 1, further
comprising: B) a mattress support, configured to support the
mattress, including: (i) a perimeter frame; (ii) a plurality of
slats, spanning transversely across the perimeter frame and
positioned to directly contact a bottom surface of the mattress,
including at least seven pairs of adjustable slats, each pair being
positioned to support a specific area of a body disposed atop the
mattress; (iii) a plurality of stiffener slats, spanning
transversely across the perimeter frame, each stiffener slat being
disposed beneath a corresponding pair of adjustable slats; and (iv)
at least one moveable adjuster clip, interconnected between each
stiffener slat and the corresponding pair of adjustable slats,
configured to be selectively moveable across the span of the slats,
so as to adjust a relative flexural stiffness of the corresponding
pair of adjustable slats.
10. A mattress system in accordance with claim 9, further
comprising: (a) a center support, longitudinally bisecting the
perimeter frame; and wherein (b) the plurality of slats comprises
first and second pluralities of slats transversely spanning between
a side of the perimeter frame and the center support, each
plurality of slats including seven pairs of adjustable slats
positioned to support a specific area of a body disposed atop the
mattress, seven stiffener slats disposed beneath a corresponding
pair of adjustable slats, and at least one moveable adjuster clip,
interconnected between each stiffener slat and the corresponding
pair of adjustable slats, configured to be selectively moveable
across the span of the slats, so as to adjust the relative flexural
stiffness of the corresponding pair of adjustable slats; so as to
allow independent stiffness adjustment of the support system on
each side of the center support.
11. A mattress system in accordance with claim 9, wherein, at least
one of the pairs of adjustable slats is positioned to support a
shoulder region of the body disposed atop the mattress.
12. A mattress system in accordance with claim 1, further
comprising: C) a pillow, including (i) a body of viscoelastic foam,
having a contoured top side including a ridge, and a bottom side
with an insert pocket; and (ii) a foam insert, configured to be
inserted into the insert pocket so as to increase the stiffness of
the pillow below the ridge.
13. A mattress system in accordance with claim 12, wherein the
insert pocket comprises a first insert pocket and a second insert
pocket, and the foam insert comprises two foam inserts.
14. A mattress system in accordance with claim 13, wherein the
contoured top side further comprises: (a) a back support ridge,
parallel to and above the first insert pocket, to support a user's
head and neck when the user is lying on the user's back; and (b) a
side support ridge, parallel to and above the second insert pocket,
to support the user's head and neck when the user is lying on the
user's side, whereby the foam is prevented from collapsing, so that
the user's neck will be better supported.
15. A mattress system in accordance with claim 13, wherein the foam
inserts comprise elongate pieces of polyurethane, having a
semicylindrical cross-section.
16. A mattress system in accordance with claim 12, wherein the
viscoelastic foam material of the body is configured to provide a
substantially uniform response over a room temperature range of
from about 55.degree. F. to about 85.degree. F.
17. A mattress, comprising: a) a core layer of foam material,
having a core density primarily configured to support a human body;
b) a top layer of viscoelastic foam, disposed atop the core layer,
having a composition that maintains substantially uniform
viscoelastic response over a room temperature range of from about
55.degree. F. to about 85.degree. F.
18. A mattress in accordance with claim 17, wherein the core layer
has a density of from about 2.4 to 2.7 lb/ft.sup.3, and the top
layer of viscoelastic foam has a density of from about 3.0 to about
4 lb/ft.sup.3.
19. A mattress in accordance with claim 17, wherein the
viscoelastic response of the top layer varies by less than about
15% within a range from about 30.degree. F. to about 100.degree.
F.
20. A pillow, comprising: a) a body of viscoelastic foam, having a
contoured top side including a ridge, and a bottom side with at
least one insert pocket, the viscoelastic material being configured
to provide a substantially uniform viscoelastic response over a
room temperature range of from about 55.degree. F. to about
85.degree. F.; b) a cover, surrounding the body, having an opening
configured to allow access to the at least one insert pocket; and
c) at least one foam insert, configured to be inserted into the at
least one insert pocket below the ridge, and thereby increase the
stiffness of the pillow below the ridge.
Description
[0001] The present application claims priority from the following
U.S. provisional patent applications: Ser. No. 06/390,982; Ser. No.
60/390,984; and Ser. No. 60/390,985, all filed on Jun. 22,
2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to mattresses. More
particularly, the present invention relates to a mattress system
including a viscoelastic foam mattress, an adjustable slat-type
mattress support system, and an adjustable density viscoelastic
foam pillow.
[0004] 2. Related Art
[0005] It is estimated that over 100 million Americans are
sleep-deprived. New research shows that sleep is the third
essential component, combined with good diet and regular exercise,
for a long and healthy life. Recent clinical sleep studies and
research findings indicate disturbing dangers for people who
short-change their daily sleep needs even a little. Sleep debt
could be a factor in the national epidemics of obesity and
diabetes. The lack of sleep reduces growth hormone secretion, which
controls the body's proportions of fat and muscle, accelerating
fatty weight gains. In a 1999 University of Chicago sleep study,
healthy young men with no other risk factors developed to a
pre-diabetic state after getting four hours of sleep per night for
just one week.
[0006] Inadequate sleep can also weaken immune systems. Human
studies show that inadequate sleep changes white blood cell counts
and immune response modifiers--biological evidence that the body is
having trouble fighting infection. Recent sleep deprivation studies
have found that people with less sleep scored lower on tests of
judgment, response time, attention, and had more mistakes than
those who slept 8 hours. About half of the sleep-deprived subjects
were having uncontrolled sleep attacks, in which they could not
stay awake. The National Sleep Foundation attributes about 100,000
highway crashes a year to sleep deprivation. This results in an
enormous loss of productivity at work as individuals struggle to
remain awake. In their personal lives, lack of adequate sleep also
causes increased irritability, which can place a significant strain
on interpersonal relationships, especially marital and family
relationships, as well as between friends, acquaintances, and
coworkers.
[0007] The most often-reported cause of sleep deprivation is an
uncomfortable mattress. Traditional bedding systems incorporate a
mattress consisting of an outer layer of fabric and foam padding,
surrounding a series of spring coils. The fabric is stretched
tightly across the foam to hold it in place, which in most cases
creates a surface that is too hard. The mattress is usually
supported by a flexible box spring to allow the mattress to
compress where needed. However, the stiffness of the box springs
causes it to push back against the mattress in the areas of
greatest compression, usually the regions of the shoulders and
hips. When the shoulders and hips do not sink into the mattress
sufficiently, there is inadequate support for the spine, causing it
to bend downward towards the mattress.
[0008] It is becoming increasingly clear that conventional mattress
and box spring systems are not healthy. A standard flat mattress
puts higher pressure on shoulders, hips, and thighs, which
constricts the veins and disrupts cell function. Heart rate
increases, the heart pumps harder to keep blood flowing, causing
blood pressure to climb, thereby stressing the body. Major studies
show that pressure becomes unhealthy at levels over 40 mmHg
(millimeters of mercury). Standard U.S. major branded mattresses
put an average of 56 mmHg on weight bearing surfaces of the body.
Side sleeping can place 61 mmHg pressure on the hip alone. This
will cause a person to toss and turn up to 200 times a night as
opposed to 20 to 40 times. The more restless a body is, the less
rest it will get.
[0009] Studies also show that traditional mattresses and box
springs can twist the spine by resisting the weight of the
shoulders and hips, resulting in two negative consequences. First,
poor support contorts the back and body, resulting in bone and
muscle stress, increasing discomfort, and interrupting sleep
patterns. Second, this creates pressure points that impair
circulation, which increase heart rate and blood pressure. These
changes combined with the discomfort from the pressure points
results in poor sleep.
[0010] The human spine at rest has a different shape depending on
the orientation from which it is viewed. Viewed from the back, the
spine should appear essentially straight. Viewed from the side, the
spine has an S-curved shape. When the spine is bent out of its
natural orientation for long periods of time, the result is back
pain and discomfort. Most people sleep on conventional mattresses
that have a tendency to do just that--contorting their spines out
of the comfortable range every night, producing symptoms ranging
from mild discomfort to severe back pain. For an individual lying
on their side, this causes the spine to bend laterally out of the
preferred orientation, thus curving the normally straight spine as
seen from the back. For an individual lying on their back, this
causes the spine to sag downwards out of the preferred orientation,
thus straightening the normally curved spine, particularly toward
the small of the back, as seen from the side.
[0011] Changing the stiffness and the number of spring coils in the
mattress can alleviate this problem to some degree. However, the
optimal stiffness of the coils should be different depending on
body type and weight. Traditionally, U.S. bedding manufacturers
tend to ignore body types and weight, and market sleep systems
constructed under the inaccurate assumption that 95% of the
population has the same body type.
[0012] One attempt to provide a mattress that can contour itself to
the shape of the body in such a way as to keep the spine in a more
neutral alignment uses a mattress consisting of a soft core layer
of polyurethane foam, topped with a layer of viscoelastic foam. An
example of this type of construction is the Tempur-Pedic.RTM.
mattress. Viscoelastic foam is an open-celled material that is
temperature and weight sensitive, becoming more soft and pliable
with increases in temperature. Viscoelastic foam conforms to the
body shape due to a combination of weight distribution and the
increase in temperature associated with body contact. As the
position of the body changes, the viscoelastic foam adjusts to the
resulting shape. It is thought that because the viscoelastic
material compresses to a greater extent in areas around the
shoulders and hips where body temperature and weight are the
highest, the spine will be supported, thus decreasing back pain. In
reality, a large number of these mattresses are routinely returned
to their sellers because they actually cause increased discomfort
and back pain, suggesting that they do not support the spine in the
optimal position when a user is lying on their side or back.
[0013] Another possible approach to providing better sleep support
is to modify the box spring. One such approach is to use a
slat-type mattress support instead of a box spring. This type of
mattress support utilizes a system of transverse wooden slats
attached across a perimeter frame, upon which the mattress sits.
Some of these slat-type systems include multiple pairs of slats
attached to the frame, with some of the pairs being adjustable. The
adjustable pairs of slats correspond to various regions of the body
from the knees to the middle of the back. One problem with prior
slat systems pertains to individuals with unusual body proportions,
such as a person with very large shoulders or a person with a very
small waist and wide hips. There is generally not enough
flexibility or adjustability in the slats of prior systems to
accommodate these people. Similarly, existing slat systems
generally do not provide adjustability for the shoulders, a region
of the body that is important in maintaining proper spinal
alignment.
[0014] The range of motion of the neck also makes it very
susceptible to harm, including harm from an improper sleeping
position. Slouching without proper support can triple the weight
load on the neck, often causing soreness, stiffness, and eventually
pain throughout the night. Soreness, stiffness and pain are body
signals that harm is being done to the upper spine. This hinders
sleep patterns, resulting in morning fatigue, headaches, and
stiffness of the neck and shoulders, and eventually possible spinal
disc damage.
[0015] Traditional rectangular pillows, consisting of an outer
layer of fabric or plastic surrounding a soft core of feathers,
soft foam pieces, or other similar material, tend to lose their
ability to support the head and neck soon after a body lies on
them. To compensate, sleepers frequently place their arm under
their pillow or head while sleeping to make up for lost support.
Sleeping in this position "shrugs" the shoulders up. To compensate,
the sleeper, is forced to round their back, stressing the back and
neck, making pain in the morning more likely.
[0016] Depending on the core material, these pillows can have a
wide range of compressible and elastic properties. Pillows made
from feathers or down are softer and compress more easily, thus
providing little or no support to the cervical curve, a property
that worsens over time with use. Pillows with foam chips are very
elastic, but do not compress as readily. When lying on one's back,
the head will tend to be rotated too far forward, relative to the
spine, with a foam core pillow, and too far back with a feather
pillow. When lying on one's side, the head will tend to be rotated
toward the bed with a soft feather core pillow, and away from the
bed with a foam core pillow. The result of both of these situations
is that the head is rotated out of its optimal cervical alignment
with the spine, thus placing strain on the neck, creating an
uncomfortable sleep environment and eventually damaging the
cervical curve of the neck.
[0017] Another important issue related to head and neck support
concerns the asymmetries associated with lying in the different
positions. Because of the shape and orientation of the head
relative to the shoulders, the area required for optimal support
while lying on the side is different from what is required when
lying on the back. In other words, the curvature and space under
the back of the head and neck when lying on one's back are small
compared to the corresponding distance from the end of the shoulder
to the underside of the head and neck when lying on one's side.
[0018] One attempt to solve this problem provides a pillow with a
contoured top. Such pillows have asymmetrical, semicylindrical
ridges in a contoured top, a large one for lying on the side, and a
smaller one for lying on the back. Some pillows of this type are
made from viscoelastic or "memory" foam, surrounded by a cover
material. The viscoelastic foam conforms to the head and neck shape
due to a combination of weight distribution and the increase in
temperature associated with body contact. As the position of the
head and neck changes, the viscoelastic foam adjusts to the
resulting shape. It is thought that the combined effects of the
contoured ridges and the shape-conforming properties of the
viscoelastic foam would provide good support for the head and neck,
thus maintaining neck-spine alignment. It is hoped that this would
decrease neck discomfort and allow a more comfortable and restful
sleep.
[0019] In reality these pillows do not adequately support the head
and neck for different body shapes, such as broader shoulders,
resulting in increased neck discomfort for different body shapes.
Also, as the viscoelastic foam conforms to the head and neck, it
begins to trap body heat. This makes the foam more pliable, causing
the head and neck to continue to sink into the pillow, ultimately
reducing support for the cervical curve, similar to a feather core
pillow. In addition, most viscoelastic foam contour pillows in the
market are affected by room temperature, which can adversely affect
the hardness of the pillow, particularly as temperature decreases.
This can create pressure points that can result in contortion of
the neck and additional neck pain.
OBJECTS AND SUMMARY OF THE INVENTION
[0020] It is therefore an object of the present invention to
provide a mattress system that keeps the spine properly supported
regardless of the body shape or weight of the user.
[0021] Another object of the invention is to provide a mattress
system that allows the spine to remain in a more neutral position
for both side and back sleepers.
[0022] Another object of the invention is to provide a mattress
system that is adjustable for individual body shapes, reduces blood
circulation restriction, minimizes the telegraphing of motion, and
reduces pressure points on the shoulders and hips.
[0023] Another object of the present invention is to provide a
mattress and/or pillow that is not significantly affected by the
surrounding room temperature.
[0024] An object of the present invention is to provide a pillow
that adequately supports the head and neck when lying on the back
or the side.
[0025] Another object of the present invention is to provide a
pillow with adjustable firmness for different body shapes.
[0026] In accordance with one aspect thereof, the invention
provides a mattress system, comprising a mattress, including a core
layer providing a base support, and a top layer of viscoelastic
foam, disposed atop the core layer, having a density of from about
3.0 to about 4.5 lb/ft.sup.3.
[0027] In accordance with a more detailed embodiment thereof, the
core layer may comprise foam material having a density of from
about 2.5 to about 2.7 lb/ft.sup.3.
[0028] In accordance with another aspect thereof, the invention
provides a mattress, comprising a core layer of foam material,
having a core density primarily configured to support a human body,
and a top layer of viscoelastic foam, disposed atop the core layer.
The top layer has a composition that maintains substantially
uniform viscoelastic response over a room temperature range of from
about 55.degree. F. to about 85.degree. F.
[0029] In another embodiment, the invention provides a mattress
support system, comprising a perimeter frame, with a plurality of
pairs of slats spanning the width of the frame and attached to the
frame by suspension clips. The plurality of pairs of slats include
nonadjustable pairs and adjustable pairs. A support slat is
disposed beneath each pair of adjustable slats. A total of 7 pairs
of adjustable slats span the regions from the shoulder to the knees
of an individual lying on a mattress atop the mattress support.
Each stiffener slat is connected to a corresponding adjustable pair
of slats by an adjustment clip, such that sliding the adjustment
clip along the length of the adjustable pair of slats changes the
stiffness of the adjustable pair of slats, thereby adjusting the
stiffness of the mattress support in each of seven regions between
the shoulders and hips.
[0030] In accordance with another aspect thereof, the invention
provides a pillow, comprising a viscoelastic foam body with a
contoured top and a flat bottom. Advantageously, the viscoelastic
foam material is configured to provide a substantially uniform
viscoelastic response over a room temperature range of from about
55.degree. F. to about 85.degree. F. The contoured top has two
support ridges, a large one for supporting the head and neck when
lying on one's side, and a small one for supporting the head and
small of the neck when lying on one's back. Within the support
ridges are two insert pockets. Foam inserts are disposed in the
insert pockets, so as to support the viscoelastic foam in the
support ridges. Different density foam inserts can be disposed into
the insert pockets to adjust the firmness. The viscoelastic foam
and the inserts are surrounded by a cover with an opening to access
the inserts.
[0031] Additional features and advantages of the invention will be
apparent from the detailed description which follows, taken in
conjunction with the accompanying drawings, which together
illustrate, by way of example, features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a cross-sectional view of a memory foam mattress
in accordance with an embodiment of the present invention.
[0033] FIG. 2 is a perspective view of a mattress support system in
accordance with an embodiment of the present invention.
[0034] FIG. 3 is a cross-sectional view of the mattress support
system with a viscoelastic mattress in accordance with an
embodiment of the present invention.
[0035] FIG. 4 is a cross-sectional view of a pair of adjustable
slats, a stiffener slat and an adjustment clip.
[0036] FIG. 5 is a side view of an individual lying on a
viscoelastic mattress and mattress support.
[0037] FIG. 6 is a perspective view of a pillow in accordance with
an embodiment of the present invention;
[0038] FIG. 7 is a cross-sectional view of the pillow of FIG.
1;
[0039] FIG. 8 shows a perspective view of the spine curvature for a
person lying on their back; and
[0040] FIG. 9 shows a perspective view of the spine for a person
lying on their side.
DETAILED DESCRIPTION
[0041] Reference will now be made to the exemplary embodiments
illustrated in the drawings, and specific language will be used
herein to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended. Alterations and further modifications of the inventive
features illustrated herein, and additional applications of the
principles of the inventions as illustrated herein, which would
occur to one skilled in the relevant art and having possession of
this disclosure, are to be considered within the scope of the
invention.
[0042] One of the major problems in the prior art concerns the
tendency for a viscoelastic mattress to allow the spine to sag
downward. Viscoelastic foam mattresses typically use a soft
polyurethane core layer having a density of about 1.8 lb/ft.sup.3,
to support a 5 lb/ft.sup.3 viscoelastic layer, It is thought that
this combination of materials can adequately support the spine,
create comfortable sleeping conditions, and decrease the occurrence
of mattress-related back pain. In reality, the inventors believe
that the combination of a relatively soft core layer with a
relatively dense viscoelastic layer actually causes increased
discomfort and back pain, because it does not adequately support
the spine. The lack of support causes the spine to straighten (as
seen from the side) from its naturally curved shape when an
individual lies on their back, or to curve (as seen from the back)
from its naturally straight shape when the individual lies on their
side.
[0043] This problem is compounded by the temperature sensitivity of
the top layer of viscoelastic material. As the shoulders and hips
press down they trap heat in the layer. This increase in
temperature causes the material to become softer, thus causing even
greater compression. In addition to compounding the crooked spine
problem, the increased heat can become uncomfortable and interrupt
sleep.
[0044] To address these problems, most makers of viscoelastic foam
mattresses have gone to a denser viscoelastic foam top with a
softer polyurethane core. The inventors believe this approach is
the opposite of what is needed. To address some of the failings of
prior mattresses, the inventors have invented a mattress comprising
a core layer with a greater density than the prior art, combined
with a viscoelastic top layer with a lower density than the prior
art.
[0045] As shown in FIG. 1, the present invention provides a
mattress 10 comprising a top layer of viscoelastic foam 12, and a
core layer 14. The preferred viscoelastic foam layer ranges in
density from about 3 to about 4.5 lb/ft.sup.3 and can be from about
2 to about 4 inches thick. In one embodiment of the invention, the
viscoelastic foam layer is about 4 lb/ft.sup.3 in density and is
about 3" thick. A suitable material having these properties is the
3510 viscoelastic foam available from Domfoam International, Inc.
of Quebec, Canada. This material has a density that typically
ranges from about 3.5 to 4.0 lb/ft.sup.3. The core layer is
preferably polyurethane foam, about 3 to 7 inches thick, with a
density of about 2.5.+-.5% lb/ft.sup.3 (2.3 to 2.7 lb/ft.sup.3), or
any other material or material combination with similar compression
properties. For example, the core layer can be polyurethane foam,
latex foam, or a combination of polyurethane and latex foams.
Additionally, spring coils, a honeycomb spring structure, or any
other material providing similar support characteristics could be
used for the core layer. In one embodiment, the core layer consists
of about a 5" layer of high resilient polyurethane foam with a
density of about 2.5 lbs/ft.sup.3. The viscoelastic layer 12 and
the core layer 14 are attached together with a chemical adhesive,
such as a clean hot melt glue, and surrounded by a cover 16 to
protect the mattress. Other adhesives could also be used, such as
water based glues, latex bases glues, and ethylene chloride based
glues. The cover is removable, and includes a zipper 18 for
allowing removal from the mattress, such as to facilitate washing,
etc. In one embodiment, the cover is quilted terry cloth made of a
cotton/polyester blend. Alternatively, the cover could be made of
cotton stretch fabric. It will be apparent that quilting is
optional. Moreover, the cover could be permanently attached to the
mattress, such as by sewing or with an adhesive, rather than being
removable. The cover can also include such additions as an
anti-microbial treatment and a breathable liquid barrier inner
lining.
[0046] The lower density viscoelastic layer compresses to a greater
extent than the higher density viscoelastic foam of the prior art.
This effect, coupled with the reduced compressibility of the denser
polyurethane core layer, provides greater spine support as the
shoulders and hips sink into the combination of materials. This
results in the spine being supported more closely to its optimally
curved orientation when lying on the back, and its optimally
laterally straight orientation when lying on the side. In addition,
the lower density viscoelastic foam is not as affected by
temperatures in the range of the body.
[0047] One common problem of viscoelastic mattresses is the
sensitivity of the mattress to the surrounding ambient temperature.
With other viscoelastic materials, the mattress is more sensitive
to temperature changes. The colder the room temperature, the harder
the mattress becomes. For example, other viscoelastic mattresses
become quite hard and unpliable at temperatures at or below about
65.degree. F. Indeed, at temperatures below about 50.degree. F. the
denser viscoelastic foam of the Tempur-Pedic.RTM. mattress can
actually break if one attempts to bend it. As another example,
Serta produces a mattress with a viscoelastic foam having a density
of about 2.5 lb/ft.sup.3 that becomes noticeably hard at
temperatures below 65.degree. F. Consequently, some producers of
these mattresses insist that the user must maintain a specific room
temperature (e.g. 71.degree. F.) for the mattress to function
properly.
[0048] Advantageously, the firmness and consistency of the mattress
of the present invention is more consistent over a wider variety of
temperatures, providing a more consistent level of support and
comfort, regardless of room temperature. Specifically, the
inventors have found that the 3510 viscoelastic foam mentioned
above remains substantially moldable and pliable at temperatures as
low as 30.degree. F., and starts to become noticeably former at
temperatures close to 0.degree. F. and below. More particularly,
this foam material has a density that is preferably in the range of
from about 3.5 to about 3.8 lb/ft.sup.3 (though the density can
vary up to about 4 lb/ft.sup.3), and exhibits an indentation
deflection force (IDF) of 10.+-.3 (i.e. an IDF range of 7-13).
Indentation deflection force is a standard measure used in the foam
industry to measure the strength of foam materials. The IDF
measures the pressure (e.g. in psi) required to depress and hold a
flat metal plate of a standard size (e.g. 12" square) a certain
distance (e.g. 1/2") into the surface of a foam material. The
inventors have found that for the 3510 viscoealstic foam the
variation in IDF over a temperature range of from about 30.degree.
F. to 100.degree. F. is less than about 15%. Within the range of
typical room temperatures (e.g. from about 60.degree. F. to about
85.degree. F.) the variation is much less. Thus, within the range
of likely room temperatures, the moldability and viscoelastic
response of the present mattress is substantially constant, and any
variation over this temperature range is substantially unnoticeable
to an ordinary user.
[0049] The temperature insensitivity of this viscoelastic material
was an unexpected result. Specifically, this viscoelastic material
was apparently not developed with the intent of reducing
temperature sensitivity. The producers of the material did not
recognize this property, and did not recognize its suitability to
bedding applications. However, after selecting this material for
use in the invention, the inventors discovered this property and
recognized its advantages.
[0050] People with back trouble fall along a continuum from mild
discomfort to severe back pain. Those individuals that have severe
back problems have a very difficult time finding a comfortable
mattress. With the mattress of the present invention, the inventors
have found that most individuals with severe back problems that
tried the mattress experienced improved sleeping. What was
surprising, however, was that this mattress also helped others to
sleep better, not just those with back problems.
[0051] There are a variety of different types of mattress support
systems, including platform systems, box springs, electric
adjustable frames, and slat-type supports. Conventional mattresses
are not equally compatible with each of these types of systems, and
present various drawbacks when used with each of them, such as
producing pressure points and contorting the spine. Advantageously,
the viscoelastic mattress disclosed above is compatible with all of
these types of systems by reducing pressure points and giving
greater support for the spine. For greater support and
adjustability, the present invention advantageously provides an
improved adjustable slat-type mattress support system. Traditional
slat support systems generally do not provide a region of
adjustability to differentially support the shoulders.
Additionally, individuals with extreme body proportions may derive
little benefit from conventional slat systems because the range of
adjustability of the slats may not encompass a range including
their body type. Advantageously, the inventors have developed a
bedding system that provides adequate adjustability to support the
shoulders, and an increased range of flexibility to allow adequate
alignment of the spine for those individuals with extreme body
proportions.
[0052] Typical adjustable slat support systems incorporate up to 6
pairs of adjustable slats, corresponding to regions of the body
from the thighs to the upper region of the back. A stiffener slat
is disposed beneath each of the adjustable pairs and attached by a
pair of adjustor clips. The adjustor clips can be slid from one end
of the adjustable pair to the other to alter the stiffness of the
slats in that region. When the adjustor clips are at opposite ends
of the slats (i.e. toward the perimeter frame), the stiffener slat
has little effect on the adjustable pair. As the adjustor clips are
moved toward the center, the adjustable pair of slats is
increasingly stiffened due to the added support of the stiffener
slat. As a result, the overlying mattress will have areas of
differential support that can be adjusted to match the weight
distribution and shape of an individual.
[0053] Unfortunately, typical slat-type support systems do not
provide adjustability for the shoulders. The inventors have
discovered that a mattress support with a 7.sup.th pair of
adjustable slats positioned under the shoulders improves spinal
support. Further, the inventors have discovered that using a
viscoelastic foam mattress, such as that described above, atop this
mattress support provides a combination of the differential
flexibility of the slats and the body conforming properties of the
viscoelastic mattress. This creates a bedding system that provides
better support and comfort for many individuals, including those
with extreme body proportions or back trouble. By replacing the
uniform stiffness of box springs with a system that is capable of
providing varying degrees of support to critical pressure zones of
the neck, shoulders, chest, waist, hips and knees, pressure is more
evenly distributed and the stressors that disturb sleep are
reduced.
[0054] In one embodiment shown in FIG. 2, the invention provides a
slat-type mattress support 20 having a perimeter frame 22 and a
plurality of slats, including nonadjustable slats 24 and adjustable
slats 26, spanning the width of the frame. The slats are attached
to the frame (singly or in pairs) by resilient connectors (31 in
FIG. 3), such as suspension clips. The suspension clips allow the
slats to move down and rotate slightly in response to weight from
above. In the embodiment shown in FIG. 2 there are approximately 13
pairs of slats, though exact number may vary, particularly for tall
individuals (e.g. those over 6'3" tall). The adjustable slats
include 6 pairs of middle adjustable slats 29 (positioned from the
knees to the middle of the back) and a seventh pair of shoulder
support slats 27. One stiffener slat 32 is disposed beneath each of
the seven pairs of "adjustable" slats corresponding to regions of
the body from the knees to the shoulders.
[0055] The stiffener slats 32 are each attached to a corresponding
adjustable pair of slats 26 with an adjustment clip 28. FIG. 3
shows the orientation of the stiffener slat 32 in a side view, and
FIG. 4 shows its orientation in a cross-sectional view. The
location of the adjustment clips 28 relative to the ends of the
adjustable pair of slats determines the flexibility of that region
of the mattress support system. When the adjustment clips are
located near the outer edges of the perimeter frame, the adjustable
slats are more flexible. When the adjustment clips are located near
the middle, the adjustable slats are more stiff, due to the added
support of the stiffener slat. FIG. 4 shows a cross-sectional view
of an adjustable pair of slats 26, a stiffener slat 32, and the
adjustment clip 28. Also shown is a nonadjustable slat 34. The
stiffness of the nonadjustable slats remains constant, while the
stiffness of the adjustable slats is augmented by the adjustment
clips, which press against the stiffener slat.
[0056] When an individual uses this mattress support system 20, the
degree of support of the mattress can be selectively adjusted to
suit the body shape and weight distribution of that individual. For
bed sizes large enough to sleep two individuals, each side may be
adjusted independently, to provide the ideal spinal support for
each user. In this embodiment of the invention, a center support 30
longitudinally bisects the perimeter frame 22 into two functional
mattress supports, each with its own set of slats 24, 26 and
adjustment clips 28.
[0057] One great advantage of this slat-type support system 20 is
the ability to fine-tune the slat configuration to further
accommodate physical alterations due to changes in weight and
health. Compared to the unforgiving stiffness of a box spring or
platform foundation, the slat suspension system has greater ability
to respond specifically to every contour and weight. It
substantially reduces the problems of sag, motion, or rollover
found in conventional mattress/box spring combinations.
[0058] Different types of mattresses may be used with this mattress
support system 20. However, it will be apparent that different
types of mattresses will interact differently with the mattress
support. One type of mattress that appears to work well with this
mattress support system is a viscoelastic foam mattress as
described above. As shown in FIG. 3, the viscoelastic mattress 40
comprises a top layer 42 of viscoelastic foam, and a core layer 44.
These layers can be configured as discussed above. The viscoelastic
layer 42 and the core layer 44 are attached together with a
chemical adhesive and surrounded by a cover 46 to protect the
mattress. The cover contains a zipper 48 for its removal from the
mattress.
[0059] Shown in FIG. 5 is a cross-sectional view of an individual
52 lying on the bedding system 50. The viscoelastic mattress 40
compresses in response to the weight of the body, especially around
the shoulders and hips when the person is lying on tier side.
Similar compression occurs when the person is lying on their back.
As shown, the slat-type mattress support 20 has been fine-tuned to
deflect downwards in areas where the compression of the mattress is
greatest, due to the downward deflection and rotation of the
adjustable slats 16. This allows an even greater degree of
flexibility around the shoulders and hips, complimenting the
body-conforming and supporting properties of the viscoelastic
mattress.
[0060] A bedding system composed of an adjustable slat-type
mattress support and a body conforming viscoelastic mattress can be
a great benefit not only to those with extreme body proportions,
but also to people with mild to severe back pain. For example,
people with specific back pain where a specific area of the back
(e.g. the lumbar region) can be targeted to give greater support
are particularly helped by such a system. By adjusting the mattress
support to match a person's body shape and weight distribution,
further flexibility can be provided to the viscoelastic mattress
without reducing the density of the foam core.
[0061] Another problem in the prior art concerns the tendency of
viscoelastic pillows to allow the head and neck to sag downward out
of alignment with the spine. This is true for the general
population, as well as neck patients under the care of a
chiropractor or physical therapist. Many chiropractors have
complained that the tendency of these pillows to over-compress
makes them undesirable. Not only do they not help maintain proper
curvature of the cervical vertebrae following chiropractic
manipulations, but in many cases they exacerbate the problem and
contradict the treatments.
[0062] To address these problems, the inventors have developed a
pillow that combines the advantages of shape-conforming
viscoelastic foam with structure for increased support for the head
and neck. As shown in FIGS. 6 & 7, the pillow 60 comprises a
body 62 of viscoelastic foam, with a contoured top 64 and a flat
bottom 66. There are two ridges on the contoured top--a larger
ridge 68a for lying on one's side, and a smaller ridge 68b for
lying on one's back. Disposed in the bottom 66 of the pillow under
and parallel to each ridge 68 are two insert pockets 70a, 70b.
Semicylindrical foam inserts 72 are configured to be inserted into
the insert pockets to increase the support provided by the ridges.
In one embodiment, the inserts are a half cylinder about 4 inches
wide and about 2 inches thick. However, the height and width of the
inserts can vary depending upon the size of the pillow. The
viscoelastic foam pillow body and the inserts are surrounded by a
cover 74 with an opening 76 to access the inserts.
[0063] The pillow body is preferably of the same 3510 viscoelastic
foam described above, and thus provides the same advantageous
temperature-related properties noted above. Consequently, the
pillow body will not harden to the same extent as other
viscoelastic materials at lower room temperatures. This can prevent
excessive firmness in colder rooms, and thus prevent the creation
of pressure points on the neck and possible neck pain. In one
embodiment, the inserts 72 can comprise cutouts of the viscoelastic
foam that are created when the insert pockets are cut out of the
pillow body. Alternatively, the inserts can be of other materials,
such as polyurethane foam, and can have a density that is greater
than that of the viscoelastic foam, so as to increase the desired
level of support. Inserts in a variety of densities may be used to
adjust the firmness of the ridges 68. For example, a soft insert
having an indentation force deflection (IFD) of 32.+-.3 (i.e. IFD
of 29-35) can be used. A medium insert having an IFD of 85.+-.5 can
also be used. Finally, a firm insert with an IFD at or above 120
can be used for greatest stiffness. Additionally, it will be
apparent that the pillow could conceivably be used without any
inserts, providing the softest possible configuration. The inserts
are typically made of polyurethane foam, but can be any material
with similar compression properties.
[0064] The inserts 72 used in the pillow 60 limit the amount of
compression in response to the weight of the neck and head, thus
keeping the head in proper alignment with the spine. Fine-tuning of
the firmness of the pillow is accomplished by selecting inserts
with different densities. Unlike traditional foam core pillows that
tend to be too firm and raise the head too far, the viscoelastic
foam allows the head and neck to sink into alignment with the
spine. However, the more dense inserts prevent the head from
sinking too far on larger body builds, as with other memory foam
pillows and many feather pillows. These properties allow optimal
head-spine alignment, reducing neck discomfort and facilitating
restful sleep. FIG. 8 shows how the smaller ridge 68b with the foam
insert 72 assists in keeping the proper curvature of the spine 84
when lying on one's back. FIG. 9 shows how the larger ridge 68a
with the foam insert 72 assists in keeping the spine straight when
lying on one's side.
[0065] It is to be understood that the above-described arrangements
are only illustrative of the application for the principles of the
present invention. Numerous modifications and alternative
arrangements can be devised without departing from the spirit and
scope of the present invention. Thus, while the present invention
has been shown in the drawings and fully described above with
particularity and detail in connection with what is presently
deemed to be the most practical and preferred embodiment(s) of the
invention, it will be apparent to those of ordinary skill in the
art that numerous modifications, including, but not limited to,
variation in size, materials, shape, form, function and manner of
operation, assembly and use may be made without departing from the
principles and concepts set forth herein.
* * * * *