U.S. patent application number 10/494425 was filed with the patent office on 2005-01-13 for pressure adjustable foam support apparatus.
Invention is credited to Giori, Gualtiero, Janine, Giori.
Application Number | 20050005363 10/494425 |
Document ID | / |
Family ID | 26688985 |
Filed Date | 2005-01-13 |
United States Patent
Application |
20050005363 |
Kind Code |
A1 |
Giori, Gualtiero ; et
al. |
January 13, 2005 |
Pressure adjustable foam support apparatus
Abstract
The present invention concerns a mattress-like apparatus whose
firmness is adjustable by the user. This goal is attained by
enclosing the polyurethane foam core of the mattress within an
airtight cover chamber, and varying the negative air pressure
(vacuum) applied into it. As a result, the mattress is adjustable
as to firmness measured in terms of Indentation Force Deflection
(IFD, or spring-back force) and support (density).
Inventors: |
Giori, Gualtiero; (Fort
Myers, FL) ; Janine, Giori; (Fort Myers, FL) |
Correspondence
Address: |
William E Noonan
PO Box 07338
Fort Myers
FL
33919
US
|
Family ID: |
26688985 |
Appl. No.: |
10/494425 |
Filed: |
April 30, 2004 |
PCT Filed: |
October 7, 2002 |
PCT NO: |
PCT/IB02/04109 |
Current U.S.
Class: |
5/709 ; 5/706;
5/710; 5/910 |
Current CPC
Class: |
Y10S 5/91 20130101; A47C
27/081 20130101; A47C 27/18 20130101; A47C 27/088 20130101; A47C
27/15 20130101; A47C 27/084 20130101 |
Class at
Publication: |
005/709 ;
005/706; 005/910; 005/710 |
International
Class: |
A47C 027/08; A47C
027/15 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 30, 2001 |
US |
10/016,722 |
Jun 5, 2002 |
US |
10/163,041 |
Claims
1-11. (cancelled).
12. A mattress-like support apparatus comprising a core of
open-cell, self-inflating flexible polyurethane foam, said
polyurethane foam core having an Indentation Force Deflection value
within a range of 22 to 50 at standard atmospheric pressure; and an
airtight cover chamber enclosing said foam core, said airtight
cover chamber having at least one valve arrangement for evacuating
air; characterized in that said mattress-like support apparatus is
operated by the user at sub-atmospheric pressure, in that said foam
core has a thickness of at least four inches at standard
atmospheric pressure, and in that said Indentation Force Deflection
value decreases while air pressure within said polyurethane foam
core is lowered.
13. The apparatus of claim 12, wherein said polyurethane foam care
has a density value within a range of 1.2 to 2.5 lbs per cubic foot
at standard atmospheric pressure, and wherein said density value
increases while air pressure within said polyurethane foam core is
lowered.
14. The apparatus of claim 12 wherein said polyurethane foam core
is vertically subdivided into at least two longitudinal or
transversal core sections, and wherein said airtight cover chamber
is replaced by separate individual airtight chambers for each core
section, each individual airtight chamber having at least one valve
arrangement for evacuating air.
15. The apparatus of claim 12, wherein said polyurethane foam core
is vertically subdivided into at least two longitudinal or
transversal core sections, and wherein said airtight cover chamber
is subdivided into individual airtight chambers for each core
section by internal airtight walls, each individual airtight
chamber having at least one value arrangement for evacuating
air.
16. The apparatus of claim 14, wherein at least one of the core
sections has a different Indentation Force Deflection value at
standard atmospheric pressure from the other core section or
sections.
17. The apparatus of claim 15, wherein at least one of the core
sections has a different Indentation Force Deflection value at
standard atmospheric pressure from the other core section or
sections.
18. The apparatus of claim 12, wherein said polyurethane foam core
comprises two or more layers of self-inflating flexible
polyurethane foam.
19. The apparatus of claim 14, wherein said polyurethane foam core
sections comprise two or more layers of self-inflating flexible
polyurethane foam.
20. The apparatus of claim 18, wherein at least one of the foam
layers has a different Indentation Force Deflection value at
standard atmospheric pressure from the other foam layer or
layers.
21. The apparatus of claim 19, wherein at least one of the foam
layers has a different Indentation Force Deflection value at
standard atmospheric pressure from the other foam layer or layers.
Description
FIELD OF THE INVENTION
[0001] The present invention concerns a mattress-like apparatus
whose firmness is adjustable by the user. This goal is attained by
enclosing the polyurethane foam core of the mattress within an
airtight cover chamber, and varying the negative air pressure
(vacuum) applied into it. As a result, the mattress is adjustable
as to firmness, measured in terms of Indentation Force Deflection
(IFD, or spring-back force) and support (density). Indentation
Force Deflection is a measure of the load bearing capacity of
flexible polyurethane foam. IFD is generally measured as the force
(in pounds; 1 pound=0.453 kg) required to compress a 50 square inch
(1 square inch=6.45 square centimeter) circular indenter foot into
a four inch thick sample, typically 15 inches square or larger, to
a stated percentage of the sample's initial height. Common IFD
values are generated at 25 and 65 percent of initial height.
[0002] More specifically, the present invention teaches the
modulation of the principal characteristics of open-cell, flexible
polyurethane foam for use in support devices such as mattresses,
sitting furniture, cushions and all other applications using a
support apparatus. These characteristics are subjective tactile
softness and bodyweight-carrying support firmness, the modulation
of which is effected in a way so as to greatly enhance comfort and
to offer an infinite choice of easily adjustable levels of comfort
to the user at lower comparable cost. On its own, in combination
with multi-chamber arrangements and also integrated with known,
traditional techniques, this invention enhances the versatility of
support devices, allowing for a great number of variations in the
choice and adaptation of materials and mattress architecture to go
together with self-inflating, modulable foam.
BACKGROUND OF THE INVENTION
[0003] Various attempts have been made to control the hardness,
softness, and support of foam within a mattress. This has been
achieved by adding different pieces or zones of foam within a
mattress, each zone having a different density and IFD rating which
corresponds to a body part such as head, shoulders, middle body,
legs and feet. Yet other inventions have interchangeable foam
components which the user may select and arrange as desired. This
process is inconvenient, since bulky foam components have to be
stored and manipulated very often to make the required changes.
Another dilemma with "foam zones" having different IFD ratings for
different parts of the body, is that it is difficult to give
adequate support to a very soft foam component. To achieve this,
mattress manufacturers use a coil, foam base, or compressed air
bases which are firm and offer needed support, subsequently they
layer softer foams above said firm base to offer comfort.
[0004] U.S. Pat. No. 2,779,034 to Arpin discloses a firmness
adjustment for mattresses involving a standard coil spring mattress
wherein standard coil springs are enclosed by a loosely fitting
airtight cover. In Arpin's device, the firmness of the mattress
increases while air pressure within the covered is lowered.
[0005] U.S. Pat. No. 3,872,525 and U.S. Pat. No. 4,025,974 to Lea
discloses a self-inflating air mattress/mat including an airtight
flexible envelope which encloses a core of resilient, open cell,
lightweight foam material, substantially the entire upper and lower
portions of which are bonded to the envelope. The air within can be
removed by compressing the structure whereby the foam layer
collapses, allowing the mat to be rolled up into a compact
package.
[0006] U.S. Pat. No. 4,944,060 illustrates a mattress having a
plurality of discrete, air permeable cells which are to some extent
hydrophobic. The invention uses pressurized air to inflate the
mattress.
[0007] U.S. Pat. No. 6,098,378 discloses a method of packaging a
single mattress to a small size to be conveniently carried. In this
method and apparatus, the foam mattress is compressed to fit into a
hard container for shipment. At the point of sale, the mattress is
extracted and expands to its original shape.
[0008] In recent years, we have seen the advent of higher density
foams such as visco-elastic foam that solves the problem of support
and softness combined in foam of one single piece. Visco-foam
offers support because of its high density (typically over 3 pounds
per cubic foot density-1 cubic foot=0.028 cubic meter) and feels
soft and desirable to the user because it typically has an IFD of
15 lbs or under. However, the high cost, bulk and heavy weight of a
visco-foam core remains a problem. Companies, who sell visco-foam
mattresses, are obliged to deliver and install them at the
customer's home.
DESCRIPTION OF THE INVENTION
[0009] The present invention addresses these difficulties through
controlling softness and support of foam directly, without loss of
support and without excessive weight or bulk of the resulting
mattress.
[0010] The present invention teaches how to control and adjust the
principal characteristics of open-cell flexible polyurethane foam
in a specific integration with airtight covers and pressure valves
for the use in any form of comfort support device, for instance,
mattresses. The principal characteristics pertain to industry
standards of subjective tactile softness in the sense of espousing
body contours so as to optimally distribute pressure points of a
person reclining on a planar surface, and of bodyweight-carrying
support firmness. They are controlled and adjusted in a way to not
only greatly enhance comfort, but particularly to offer an infinite
choice of easily adjustable levels of comfort, defined as a balance
between softness and firmness. This is done at lower comparable
cost and weight compared to high density foam varieties such as
visco-elastic foam, and in combination with known, traditional
techniques, it enhances versatility, allowing for a great number of
variations in the choice and adaptation of materials to go together
with self-inflating, modulable foam into comfort level adjustable
support devices.
[0011] The invention teaches how the Indentation Force Deflection
(IFD) and density properties of a certain quality range of flexible
open-cell polyurethane foam are adjusted by removing some of the
air from within the foam cells and altering the cellular density of
the foam core. Since high density, more expensive foams, such as
visco-elastic foams, are very desirable as to comfort, the main
teaching of the invention is how to modulate comparatively less
expensive, lower density foam to exhibit the feel-characteristics
of high density foam, and also attain support and comfort levels of
a higher density, more expensive foam,- without locking the user
into a single, fixed comfort level.
[0012] IFD and density adjustment are achieved by altering
open-cell, flexible polyurethane foam or material of similar
characteristics within a fixed framework of controllable valves and
airtight bladders. This art teaches that the material is fashioned
in a particular form and that it is of a structure as to permit the
extraction of air in the alveolate structure in a uniform manner
throughout, thus increasing material density equally uniformly. A
further feature of the material is that, by virtue of its
structure, particular manufacturing and finishing processes, it
affords in its low IFD number modulated state a commensurably
higher support stability, heretofore only associated with foam or
similar material of a very much higher density and greatly higher
price. Finally, it is much lighter in weight than the latter and
can also be reduced in size and volume for easy transport and
storage.
[0013] The application of the principles of this teaching extends
to a great number of possible combinations of foam only and foam
plus traditional support devices used in the architecture of, for
example, mattresses, that users may adjust to their personal
preference But in all its combinations, the pivotal point of the
invention is that specifically fashioned types of foam will soften
when air is extracted from their cell structure. Compared to its
original firmness, which is indicated by the manufacturer's IFD
number, its resilience will decrease to about half of its original
value. The density on the other hand increases considerably to
about double its original value, creating the much needed body
support a mattress should have. Density of foam is its weight per
cubic foot, hence the heavier a cubic foot of foam weighs, the
higher will be its density rating.
[0014] The present invention teaches that removing air from a foam
core reduces the volume of the core, hence increases its density
without adding weight to the overall mattress, which would be
undesirable for the user. One of the disadvantages of high density
foams, such as visco-elastic foam, is that they are very heavy and
difficult to fashion in the form of a mattress. In this invention
the single foam core mattress as well as its combination with other
bedding materials are much lighter of weight but yet exhibit the
same comfort and support characteristics as, for instance, a
visco-elastic mattress. It has the additional advantage of being
adjustable. Removing air from visco-elastic foam or similar
materials in the same manner is not possible, because their
cellular structure is very tight and would solidify almost
immediately (densification).
[0015] In the basic configuration, this invention takes the form of
a mattress-like support apparatus comprising
[0016] one core of open-cell, self-inflating flexible polyurethane
foam, said polyurethane foam core having an Indentation Force
Deflection value within a range of 22 to 50 lbs at standard
atmospheric pressure;
[0017] one airtight cover chamber enclosing said foam core, said
airtight cover chamber having at least one valve arrangement for
evacuating air;
[0018] characterized in that said mattress-like support apparatus
is operated by the user at sub-atmospheric pressure, in that said
foam core has a thickness of at least four inches at standard
atmospheric pressure, and in that said Indentation Force Deflection
value decreases while air pressure within said polyurethane foam
core is lowered.
[0019] The apparatus may further comprise at least one vacuum pump
connected to said valve or valves for evacuating air.
[0020] In another embodiment, the polyurethane foam core has a
density value within a range of 1.2 to 2.5 pounds per cubic foot at
standard atmospheric pressure, and said density value increases
while air pressure within the polyurethane foam core is
lowered.
[0021] In still another embodiment, the polyurethane foam core is
vertically subdivided into at least two longitudinal or transversal
core sections, and the airtight cover chamber is replaced by
separate individual airtight chambers for each core section, each
individual airtight chamber having at least one valve arrangement
for evacuating air. In an alternative embodiment, the polyurethane
foam core is vertically subdivided into at least two longitudinal
or transversal core sections, and the airtight cover chamber is
subdivided in individual airtight chambers for each core section by
internal airtight walls, each individual airtight chamber having at
least one valve arrangement for evacuating air. Each core section
may have different Indentation Force Deflection values at standard
atmospheric pressure -from the other core section or sections. In
addition, the polyurethane foam core or core sections may comprise
two or more layers of self-inflating flexible polyurethane foam. In
an embodiment, at least one of the foam layers has a different
Indentation Force Deflection value at standard atmospheric pressure
from the other foam layer or layers.
[0022] The valve arrangement attached to the airtight cover chamber
or to the individual airtight chambers may comprise one or more air
permeable distancing elements, keeping any adjacent materials from
obstructing airflow through said valve arrangement. Said valve
arrangement may also comprises a spring-mounted mechanism that
allows some air to return into the foam core and thereby prevents
compression set within the foam core.
[0023] The following is a description of how a polyurethane foam
core changes in this present invention, demonstrated on a sample of
a twin-size mattress foam core. Such a sample typically contains a
volume of about 13 cubic feet of air, has an initial density rating
of 1.2 and an IFD number of 40, corresponding to a relatively
firm-surface foam weighing 15.6 lbs. In comparison, visco-elastic
foam of the same size would generally weigh about 58 lbs.
[0024] To effect the change in the sample, a fan-style vacuum
generator is connected to an outer airtight cover, drawing
approximately 0.6 cubic feet of air per second. At this rate it
takes 3.5 seconds to double the foams density and to reduce the IFD
value so that it feels like a 2.4 density high resilient foam with
an IFD value of about 22. The vacuum pump is equipped with variable
speed control and remote control memory settings, so that the user
can either set or recall a previous setting of an individual
comfort level at the speed and in increments which suit him. In
laboratory experiments, a user was made to recline on the foam in
it's original configuration. He then adjusted the density and IFD
settings within the foam core. It was observed that the user's
heaviest body-parts sank into the foam and were contoured
progressively as the density increased and the IFD value decreased.
No collapsing of the mattress, bottoming-out or hammock effect
occurred. If no air were allowed to re-enter the foam core and the
user were to be lifted off it, the negative mould of his body with
all corresponding heavy and light pressure points would be
imprinted in the foam permanently.
[0025] The second point of importance to be noted is that the foam
core gains in stability when air is removed, as opposed to an air
chamber which would simply deflate and become wobbly, that is,
unstable. In laboratory experiments a further point has been
addressed, dealing with the undesirable characteristic of open-cell
flexible polyurethane foam to solidify in a full vacuum-state, the
so-called `compression set` (CS). If too much air is removed from
the cellular structure of foam, it will harden in its densest state
and subsequently no longer be able to self-inflate and regain its
loft, even partially. CS becomes critical when foam has been
compressed for an extended period of time. If, however, a residual
amount of air could be left in a foam core and be controlled, it
would not suffer CS nearly as much as opposed to a fully deflated
foam core.
[0026] The chamber's vacuum in this example is controlled by valves
which operate under spring pressure. When air is evacuated from a
self-inflating foam core within a hermetically sealed cover, the
foam material's cellular elasticity exerts pressure to expand to
its original form by drawing air back into its open cells,
developing a measurable suction force. The more air is removed from
the foam cells, the higher the foam core's re-inflation force.
Springs in the valve assemblies connected to the partially emptied
chamber oppose the re-inflation force reciprocally. Hence a balance
between the opposing forces can be established, depending on the
spring force and the suction force. Tests conducted in a laboratory
environment show that CS can be prevented in a totally deflated
foam core if the re-inflating force is slightly greater than the
closing force of the valve spring. In this manner, air is drawn
back into the mattress at a very slow rate, and stops entering the
mattress when the re-inflation force of the foam equals the
compression force of the spring in the valve. A fixed spring-force
setting, allowing foam to re-inflate to a specific degree greatly
reduces the occurrence of CS and preserves the deflated product
from malfunctioning when allowed to re-inflate after extended
storage periods. The principle of residual air retention to off-set
CS has been validated in laboratory experiments for polyurethane
foam used in a wide variety of mattress architectures, be it by
itself or in a combination with other arrangements. To balance the
closing force of the valve spring within the valve assembly against
the re-inflating force of the various foams, a great number of
specific compression values are being used to adapt to foams having
different IFD and density ratings.
[0027] Thus, controlling compression set forms integral part of the
invention, which would not be able to perform satisfactorily over
long periods of time if intentional or accidental excessive
deflation took place, destroying the specific characteristics of
open cell, flexible polyurethane foam, which are the basis of
comfort level adjustment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 4 shows a hermetically sealed, modulable foam core in
its simplest form, one or more valves and a distancing element.
[0029] FIG. 5 shows the effect of pressure on a chamber containing
a self-inflating foam core;
[0030] FIG. 6 shows the effect of removing weight from the core in
FIG. 5
[0031] FIG. 7 shows one autonomous airtight chamber two foam cores,
a single valve and a distancing element;
[0032] FIG. 8 shows two airtight individual chambers, one or more
foam cores, an internal airtight wall, two valves and two
distancing elements;
[0033] FIG. 9 shows two separate individual airtight chambers, one
or more foam cores an outer attachment, two valves and two
distancing elements;
[0034] FIG. 10 shows three airtight individual chambers, one or
more foam cores, two internal airtight walls, three valves and
three distancing elements;
[0035] FIG. 11 shows five airtight individual chambers, one or more
cores of foam in each chamber, four internal airtight walls, five
valves and five distancing elements;
[0036] FIG. 12 shows three separate individual airtight chambers, a
fastening element, one or more foam cores, three valves and three
distancing elements;
[0037] FIG. 13 shows an overall valve assembly installed in a
chamber wall;
[0038] FIG. 14 shows a vacuum hose engaged in a valve with an air
permeable distancing element behind the valve, and a foam core with
an exploded outer cover;
[0039] FIG. 15 shows an exploded view of the valve subassembly in
combination with a vacuum hose;
DETAILED DESCRIPTION OF THE DRAWINGS
[0040] FIG. 4 shows one airtight cover chamber (40) and one foam
core (41). Chamber (40) contains a self-inflating foam core (41)
and is fitted with one or more valves (42), penetrating wall (44)
of the chamber. The valves, when opened, either serve to let the
core self-inflate rapidly or to evacuate some air, contracting the
foam core(41) in a uniform manner and changing both its density and
IFD values as the cellular volume of the foam cells changes. Air
can be extracted with a vacuum pump (not shown) connected to the
valves (42) which contain an air permeable distancing element (43).
This element is essential to the proper functioning of the mattress
and keeps wall (44) and valve (42) distanced from the foam core
(41), hence permitting an effective airflow to and from the foam
core.
[0041] As to the vacuum pump, no particular specifications are put
forward for such an apparatus other than that it has to be
efficient in extracting the air contained in the foam core. The
utilization of a vacuum pump is stated here once and not repeated
in subsequent descriptions of mattress configurations, but
implied.
[0042] FIG. 5 shows the advantage of modulating a self-inflating,
open-cell, flexible polyurethane foam core in support structures
such as mattresses when weight is placed upon it. Compared to
traditional mattress architecture with coils and air chambers, the
weights (V) are causing a quite different reaction or counter
pressure. When they are placed on a partially deflated foam core
(FS1), which is enclosed in a chamber (51) fitted with a valve
(52), through which air can be evacuated selectively and uniformly,
the foam core resists the pressure of the weights W without sagging
(hammock-effect) and deforms at local pressure points only. If more
air is evacuated from the core, the weights slowly sink deeper into
the surface, still confined locally and precisely in the area where
they are exerting downward pressure, without deforming adjacent
areas. Because of an increase in density and a decrease of the IFD
value within the foam, the surface will become softer and offer
continuous support--unlike standard coil spring mattresses, where
any weight deposited on the surface tends to tension and harden the
coil springs, which want to return to their original, more relaxed
state.
[0043] FIG. 6 demonstrates the effect with reference to FIG. 5.
Foam core (FS1) is enclosed in a hermetically sealed chamber (as is
shown in FIG. 4), from which some air has been uniformly removed,
and the valve or plurality of valves (62) were then closed. The
depressions on the top surface, where one of the weights (W1) has
been removed, can still be seen, because the self-inflating foam
recovers slowly, reacting to the reduction in pressure by
rearranging the internal air distribution with a flow through its
open-cell structure towards the indented area. If additional air
were to be removed from the foam core, the depression (W1) would
remain, because the resilience force of the foam cells in the
depressed area would not be strong enough to extract air from the
open-cell structure of the adjacent foam cells for an even
distribution. In this state the foam core has a very reduced IFD
and a greatly increased density, thus adopting the properties of a
visco-elastic memory foam. This example can be translated directly
to the effect of a person reclining on top of the foam core, as air
is removed uniformly from the chamber. The heaviest pressure points
of the body are modulated first, provided the foam core is fully
enclosed. Any evacuation of air out of the core will result in a
softer surface behaving in the manner shown in FIG. 6. For the
invention at hand to perform in a satisfactory manner, foam cores
should be at least 4 inches thick.
[0044] FIG. 7 illustrates a mattress consisting of one airtight
cover chamber (71) with two self-inflating pieces of foam (72)
placed inside, one on top of the other, forming a single foam core.
At least one valve (73) with air permeable distancing element (74)
is fitted to the outer wall of chamber (71), through which air can
be exhausted or admitted. When the valve is opened, air can be
withdrawn from the chamber by means of a vacuum pump, which will
change the air volume within the foam core. When the foam pieces
(72) are compressed, their surfaces will soften as a result of
decreasing IFD. Provided foam pieces are used with different
factory pre-set density and IFD values, their characteristics will
change differentially upon air evacuation. A harder pre-set foam on
the bottom will soften less and provide more stability, while a
softer pre-set foam on top will soften more readily under the
conditions of an identical partial vacuum. More comfort modulation
levels are thus provided to the user. The foam core in each chamber
can be subdivided into two or more core pieces, each piece of foam
may or may not have a different pre-set foam density. All foam
pieces within the same core and in the same chamber will react
differently on extraction of air.
[0045] Additionally, having multiple and diverse factory-preset
foam pieces within a chamber, signifies that the user can choose
which surface of the mattress he prefers to recline upon before any
modulation takes place. Versatility is thus increased. Using, for
example in the two chamber configuration, one or more foam pieces
per chamber, it is possible to achieve a comfort modulation level
of very soft to softer in the first chamber, and hard to very firm
in the second chamber. For clarity's and brevity's sake, the
possibility of using multiple core foam pieces per chamber and
multiple chambers is implied in the subsequent descriptions of
chamber configurations, and not limited to the present
examples.
[0046] FIG. 8 shows a mattress (81) comprising an airtight cover
chamber subdivided in two individual airtight chambers (A and B) by
an internal airtight wall (83), each containing one or more
self-inflating foam pieces (84). The chambers (A&B) are both
fitted with one or more valves (85) to exhaust air selectively and
independently from within the foam cores. The valves penetrate the
wall (81) to the interior of their respective chamber and both have
an air permeable distancing element (86) attached to their inward
end to prevent foam or cover material from clogging the air
passage. When the air is exhausted from the chambers selectively,
the two cores increase in density, so there is no loss of support,
and they will soften because of a decrease in IFD. They will do so
differentially when foam types of a different factory pre-set
density and IFD value are used, so that the foam in chamber (A),
for example, can be independently modulated to give a harder
surface feeling than the lower piece of foam or vice versa. On the
other hand, when only the air is evacuated from the foam core of
chamber (A), only this chamber will be rendered softer because the
core (B) will remain unaffected. This mattress combination can be
used on both sides, and is intended for use by two users who wish
to modulate their own side of the bed selectively.
[0047] FIG. 9 shows a mattress comprising two individual airtight
chambers (A and B), both containing one or more foam pieces (92).
Both chambers (A and B) are removably connected by an exterior
element (93) such as a zipper or hook and loop. Although the
modulation capabilities of this mattress are identical to the
previous in FIG. 8, it has the added advantage of separating into
two mattresses which can be used in a different location.
[0048] FIG. 10 shows a mattress comprising an airtight cover
chamber subdivided in three individual airtight chambers (A,B,C)
with two internal walls (101). Each individual airtight chamber
contains one or more foam pieces (102, 103, 104) to form three foam
cores within the three chambers which may or may not contain foams
of similar IFD and density ratings. Three chambers thus organized,
represent a comfort zone for the head (A), middle body (B), and
feet (C). Each section may be modulated by removing some air
through the valves (106) (one shown) which each contains an air
permeable distancing element (107) (one shown) directly behind it,
to prevent any occlusion and to increase airflow to and from the
chambers. The top foam pieces in chambers (A,B and C) (108) may be
softer IFD factory-preset rated foam, and the bottom pieces (109)
may be firmer factory-preset rated foams. In this manner, the user
may chose to recline on either side of the mattress (arrows
110,111), before modulation with a vacuum pump is commenced.
[0049] FIG. 11 shows a mattress comprising an airtight cover
chamber subdivided in five individual airtight chambers (A,B,C,D
and E) with four internal walls (1101-1104). Each individual
airtight chamber contains one or more foam pieces (1105) (only one
foam core shown) to form five foam cores within the five chambers
which may or may not contain foams of similar IFD and density
ratings. Five chambers thus organized represent comfort zones for
the head (H) and shoulders (S), middle body (M), and feet (F). Each
chamber may be modulated by removing some air through the valves
(1106) (one shown) which contains a permeable distancing element
(1107) (one shown) directly behind it, to prevent any occlusion and
to increase airflow to and from the chamber. As in FIG. 10, the top
foam pieces in chambers (A,B C,D and E) may be softer IFD
factory-preset rated foam, and the bottom pieces may be firmer. In
this manner, the one may use the mattress on either side.
[0050] FIG. 12. shows a mattress comprising three individual
airtight chambers (A, B and C), each containing one or more foam
pieces (1201) (only one core shown). All three chambers (A, B and
C) are removably connected by an exterior element (1202) such as a
zipper or hook and loop at the edges of the chambers. As with
previous foam combinations, this mattress can be modulated by
removing some air through the valves from either chamber resulting
in a higher density, lower IFD more desirable foam feel. The
chambers are zoned for head (H), middle body (M) or feet (F), and
have the added advantage of separating into three sections.
Moreover, both foot and head sections may be inclined at different
angles if placed on an adjustable bed frame.
[0051] FIG. 13 shows an example of valve assembly as installed in
the walls of any of the chambers referenced above, with an air
permeable distancing element behind the valve. To this end, chamber
wall (1308) is placed between two elements (1304-and 1305) of the
overall valve assembly. The flange (1304) is a truncated, inverted
cone. Flange (1305) is also a truncated, but outward facing cone,
which exactly matches inverted cone (1304). Once these elements are
screwed together they will securely clamp the chamber wall. Welding
or gluing can also be used, while a clamped valve could be taken
apart again for servicing, if necessary. Also shown is a lateral
cylindrical extension (1 303) which interconnects to the valve and
acts as an air-permeable distancing element (1301). The element has
an air-permeable opening (1302), essential for the modulation of
the foam core, since air can pass to and from the foam core. When
air is rapidly evacuated through the assembly, foam and outer cover
material is prevented from occluding or touching the valve, because
the air-permeable distancing element keeps the foam and outer cover
material at a distance from the inner valve. When not in use, the
valve assembly can be closed by a plug (1306) which is inserted
into the interior of the valve assembly. The plug is attached to
the valve housing by a loss-prevention cord (1307). It also
prevents any undesirable foreign particles or liquids from
entering.
[0052] FIG. 14 shows the air-permeable distancing element (1401)
that may contain additional frontal openings (1402). When the
vacuum is activated, air is drawn through the valve (V) and from
within the foam core (1403). This causes the valve, distancing
element (1401), and outer cover (1405) to be drawn towards the foam
core (1403). By contrast, air also passes through openings (1402)
from within the distancing element (1401), thus sucking the outer
cover (1405) through the openings (1402) only in that area. The
outer cover wall (1405) is pulled towards the openings (1402) and
because of this vacuum effect the outer cover (1405) pulls the
distancing element and the valve back towards itself. The two
opposing forces (the valve and distancing element being pulled
towards the foam, and the outer cover pulling these components
back) allow for a perfect vacuuming effect to be formed and they
create a perfect airflow. Thanks to this functionality the airflow
within a vacuum pump is more efficient, causing less heat and
fatigue to the electrical motor. It also increases the speed at
which a mattress can be modulated. When a vacuum pump is activated
to remove some air without an air-permeable distancing element,
valve (V) and outer cover (1405) would be drawn towards the foam
wall (1403) and form a counter vacuum whereby very little air would
be removed from the foam core. Also shown in FIG. 14 is a vacuum
hose (1406) and nipple (1407), which can be disengaged from the
valve, or may be permanently attached to the valve extending
towards a vacuum pump (not shown), and may be removably connected
to that vacuum pump.
[0053] FIG. 15 shows the structure of the example valve assembly in
an exploded view. The chamber material is clamped between flanges
(1304) and (1305). Flange (1304) is connected to a cylindrical
extension (1501), which has lateral air apertures (1502) so that
the air being evacuated can easily enter the inner valve assembly.
The cylindrical extension (1501) fits tightly within the
air-permeable distancing element and extends laterally (1401).
Behind the valve stem-head (1503) is a compression spring (1504)
and a protective plug (1306), which has a forward cylindrical
extension (1505) with a locking slot (1506), allowing plug (1306)
to be engaged into interior receptacle (1509). When air is
evacuated from any of the chambers referenced above, plug (1306) is
removed from the valve assembly and nipple (1507) is being inserted
into the interior receptacle (1509) with its forward end (1508) in
a press fitting manner. A vacuum hose (1510) is attached to the
nipple (1507) by way of screw threads (1511).
* * * * *