U.S. patent application number 11/218230 was filed with the patent office on 2007-03-01 for mattress with triple zone topper.
This patent application is currently assigned to The Spring Air Company. Invention is credited to Steve Bryant, Maury O'Brien, Ross Olinski.
Application Number | 20070044245 11/218230 |
Document ID | / |
Family ID | 37802014 |
Filed Date | 2007-03-01 |
United States Patent
Application |
20070044245 |
Kind Code |
A1 |
Bryant; Steve ; et
al. |
March 1, 2007 |
Mattress with triple zone topper
Abstract
A mattress comprises a base unit. A topper is supported above
the base unit. The topper comprises an elongate rectangular body
having a center zone joined between opposite end zones. The topper
is of a select foam material of substantially uniform firmness and
the center zone has a density greater than density of the end
zones. A cover fabric layer surrounds the base unit and the
topper.
Inventors: |
Bryant; Steve; (Loganville,
GA) ; O'Brien; Maury; (Park Ridge, IL) ;
Olinski; Ross; (Bloomingdale, IL) |
Correspondence
Address: |
WOOD, PHILLIPS, KATZ, CLARK & MORTIMER
500 W. MADISON STREET
SUITE 3800
CHICAGO
IL
60661
US
|
Assignee: |
The Spring Air Company
|
Family ID: |
37802014 |
Appl. No.: |
11/218230 |
Filed: |
September 1, 2005 |
Current U.S.
Class: |
5/727 ;
5/730 |
Current CPC
Class: |
A47C 27/146 20130101;
A47C 27/056 20130101; A47C 27/148 20130101; A47C 27/144 20130101;
A47C 27/15 20130101 |
Class at
Publication: |
005/727 ;
005/730 |
International
Class: |
A47C 27/14 20060101
A47C027/14 |
Claims
1. A mattress comprising: a base unit; a topper supported above the
base unit, the topper comprising an elongate rectangular body
having a center zone joined between opposite end zones, the topper
being of a select foam material of substantially uniform firmness
and the center zone having a density greater than density of the
end zones; and a cover fabric layer surrounding the base unit and
the topper.
2. The mattress of claim 1 wherein the topper is of polyethylene
foam construction.
3. The mattress of claim 1 wherein the topper has a planar bottom
surface engaging the base unit and a convoluted upper surface.
4. The mattress of claim 3 wherein the convoluted upper surface has
alternating peaks and valleys arranged in a checkerboard
configuration.
5. The mattress of claim 3 wherein the convoluted upper surface has
a plurality of convolution zones providing different amounts of
support.
6. The mattress of claim 3 wherein the convoluted upper surface has
a different convolution pattern in the center zone than in the end
zones to providing different amounts of support.
7. The mattress of claim 3 wherein the convoluted upper surface has
at least five convolution zones providing different amounts of
support.
8. The mattress of claim 7 wherein the convoluted upper surface has
seven convolution zones providing highest support in a central area
and gradually decreasing support at longitudinal ends of the
topper.
9. The mattress of claim 1 wherein the topper has a planar bottom
surface engaging the base unit and a planar upper surface having a
plurality of upwardly opening slots in a grid pattern of a first
size in the central zone and a second size in the end zones.
10. The mattress of claim 1 wherein the center zone has a density
at least 25% greater than density of the end zones.
11. A mattress comprising: a base unit; a topper supported above
the base unit, the topper comprising an elongate rectangular body
having a center zone joined between opposite end zones, the topper
having a planar bottom surface engaging the base unit and a
patterned upper surface, the center zone having a density greater
than density of the end zones; and a cover fabric layer surrounding
the base unit and the topper.
12. The mattress of claim 11 wherein the topper is of polyethylene
foam construction.
13. The mattress of claim 11 wherein the topper is of elastic
memory foam construction.
14. The mattress of claim 11 wherein the upper surface is
convoluted having alternating peaks and valleys arranged in a
checkerboard configuration.
15. The mattress of claim 11 wherein the upper surface is
convoluted having a plurality of convolution zones providing
different amounts of support.
16. The mattress of claim 11 wherein the upper surface is
convoluted having a different convolution pattern in the center
zone than in the end zones to providing different amounts of
support.
17. The mattress of claim 11 wherein the upper surface is
convoluted having at least five convolution zones providing
different amounts of support.
18. The mattress of claim 17 wherein the convoluted upper surface
has seven convolution zones providing highest support in a central
area and gradually decreasing support at longitudinal ends of the
topper.
19. The mattress of claim 11 wherein the patterned upper surface
has a plurality of upwardly opening slots in a grid pattern of a
first size in the central zone and a second size in the end
zones.
20. The mattress of claim 11 wherein the center zone has a density
at least 25% greater than density of the end zones.
Description
FIELD OF THE INVENTION
[0001] This invention relates to an elongate topper or cushion in a
mattress for supporting a recumbent human body and, more
particularly, to a triple zone topper.
BACKGROUND OF THE INVENTION
[0002] A mattress, in its most basic form, comprises a base unit
surrounded by a cover fabric layer. The base unit may be a
conventional spring assembly having open coils secured internally
and by upper and lower border wires. The spring assembly could
alternatively include individual fabric pocketed coils and could
eliminate the border wire. Another type of mattress, known as foam
encased, includes a bottom foam layer. Four foam side walls are
adhered to an upper surface of the bottom foam layer at its
peripheral edges to provide a rectangular frame or box section. A
support component, such as a spring assembly, foam, or the like, is
loosely positioned in the box section. A top foam layer, pad or
fiber, may be adhered to the tops of the side walls. With any of
these designs, various layers of foam and/or upholstery fabrics may
be included between the cover fabric layer and the base unit to
provide varying degrees of comfort. Firmness of the mattress is
generally determined by firmness of the base unit.
[0003] Various forms of foam cushions or pad, also known as
toppers, have been integrated into mattress designs. Conventional
mattress toppers may be traditional flat foam or may comprise
convoluted cushions which reduces pressure points. An example of a
convoluted foam cushion is shown in Nunez et al. U.S. Pat. No.
6,041,459, assigned to the assignee of the present application. The
convoluted foam cushion described therein comprises an elongate
rectangular body of uniform firmness and density including distinct
comfort and support zones using different patterns of
convolution.
[0004] The present invention is directed to further improvements in
mattress design.
SUMMARY OF THE INVENTION
[0005] In accordance with the invention, there is provided a
mattress including a topper having multiple zones of density and/or
firmness.
[0006] There is disclosed in accordance with one aspect of the
invention a mattress comprising a base unit. A topper is supported
above the base unit. The topper comprises an elongate rectangular
body having a center zone joined between opposite end zones. The
topper is of a select foam material of substantially uniform
firmness and the center zone has a density greater than density of
the end zones. A cover fabric layer surrounds the base unit and the
topper.
[0007] It is a feature of the invention that the topper is of
polyethylene foam construction.
[0008] It is another feature of the invention that the topper has a
planar bottom surface engaging the base unit and a convoluted upper
surface.
[0009] It is a further feature of the invention that the convoluted
upper surface has alternating peaks and valleys arranged in a
checkerboard configuration.
[0010] It is yet another feature of the invention that the
convoluted upper surface has a plurality of convolution zones
providing different amounts of support.
[0011] It is still a further feature of the invention that the
convoluted upper surface has a different convolution pattern in the
center zone than in the end zones to providing different amounts of
support.
[0012] It is yet a further feature of the invention that convoluted
upper surface has at least five convolution zones providing
different amounts of support.
[0013] It is an additional feature of the invention that the
convoluted upper surface has seven convolution zones providing
highest support in a central area and gradually decreasing support
at longitudinal ends of the topper.
[0014] It is yet another feature of the invention that the topper
has a planar bottom surface engaging the base unit and a planar
upper surface having a plurality of upwardly opening slots in a
grid pattern of a first size in the central zone and a second size
in the end zones.
[0015] It is still another feature of the invention that the center
zone has a density at least 25% greater than density of the end
zones.
[0016] There is disclosed in accordance with another aspect of the
invention a mattress comprising a base unit. A topper is supported
above the base unit. The topper comprises an elongate rectangular
body having a center zone joined between opposite end zones. The
topper has a planar bottom surface engaging the base unit and a
patterned upper surface. The center zone has a density greater than
density of the end zones. A cover fabric layer surrounds the base
unit and the topper.
[0017] Further features and advantages of the invention will be
readily apparent from the specification and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is an exploded, partial perspective view, with parts
removed for clarity, of a mattress including a triple zone topper
according to the invention;
[0019] FIG. 2 is a plan view of the topper of the mattress of FIG.
1;
[0020] FIG. 3 is a sectional view taken along a line 3-3 of FIG.
2;
[0021] FIG. 4 is a plan view of a mattress topper according to a
first alternative embodiment of the invention;
[0022] FIG. 5 is a sectional view taken along the line 5-5 of FIG.
4;
[0023] FIG. 6 is a plan view of a mattress topper according to a
second alternative embodiment of the invention;
[0024] FIG. 7 is a sectional view taken along the line 7-7 of FIG.
6; and
[0025] FIG. 8 is a plan view of a mattress topper according to a
third alternative embodiment of the invention;
[0026] FIG. 9 is a sectional view taken along the line 9-9 of FIG.
8.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring initially to FIG. 1, there is illustrated a
mattress 10 including a foam pad or cushion, referred to herein as
a topper, 12 according to the invention. Overall, the mattress 10
is generally conventional in construction and includes a base unit
14. In the illustrated embodiment of the invention, the base unit
14 comprises a conventional spring assembly having open coils
secured internally and by upper and lower border wires. The base
unit 14 could alternatively include individual fabric pocketed
coils and could eliminate the border wire or comprise a foam
encased mattress unit. The invention is not intended to be limited
to any particular construction for the base unit. A plurality of
lower fiber layers 16 rest on the base unit 14. The topper 12 sits
on the lower fiber layers 16. Several additional upper fiber layers
18 are disposed between the topper 12 and a cover fabric layer 20.
As is apparent, the cover fabric layer 20 surrounds the entire
mattress 10.
[0028] As is apparent, the topper 12 can be used in various
mattress configurations. The particular configuration illustrated
in FIG. 1 is but one example of such a mattress. Also, the topper
12 could be provided as a separate unit which can be selectively
placed atop a mattress. Moreover, the topper 12 could also be used
as an insert layer in a quilt top mattress, such as a replacement
for the insert layer shown in Nunez et al. U.S. Pat. No. 5,974,609,
assigned to the assignee of the present application, the
specification of which is incorporated by reference herein.
[0029] The topper 12 is configured to provide comfort and support
to a human body, represented at B. As is apparent, different levels
of comfort and support are advantageously provided for different
portions of the body B. In accordance with the invention, the
topper 12 is provided with three distinct zones providing different
firmness and/or density and/or support.
[0030] Referring to FIG. 2, the topper 12 has a length L and width
W. The length L is typically on the order of 79''. The width W
varies according to the mattress size, such as twin, double, full,
queen or king size. The topper 12 includes a first end zone 22 and
a second end zone 24 on opposite ends of a center zone 26. Each
zone 22, 24 and 26 is made of polyurethane foam, but could be of
latex foam or visco-elastic memory foam. Each zone 22, 24 and 26 is
made separately and then laminated together. Particularly, the
first end zone 22 and center zone 26 are laminated together at a
first joint 28. Similarly, the second end zone 24 and the center
zone 26 are laminated together at a second joint 30. The joints 28
and 30 may comprise butt joints, or overlapping joints, or the
like, as necessary or desired. In the illustrated embodiment of the
invention, each zone 22, 24 and 26 has a similar firmness with the
center zone 26 being of a higher density. For example, the topper
12 may have a firmness of 10 ILD (initial load deflection). The end
zones 22 and 24 may have a density of about 1.2 lbs. per cubic
foot, while the center zone 26 may have a density of about 3 lbs.
per cubic foot. This provides greater cushioning durability in the
center zone 26.
[0031] In an illustrated embodiment of the invention, each end zone
22 and 24 may have a length of about 24'', with the center zone 26
having a length of about 31''. The topper 12 includes a planar top
surface 32 and an opposite planar bottom surface 34. The topper 12
may have a thickness on the order of about 1''. The end zones 22
and 24 being of identical construction, allows the mattress 10 to
be turned so that either end zone 22 or 24 can be used as the head
end or the foot end. As is apparent, the relative lengths of the
zones 22, 24 and 26 could be varied to provide greater or lesser
amounts of enhanced cushioning durability, as is apparent.
Likewise, the firmness in the end zones 22 and 24 could be
different from that in the center zone 26. Likewise, the density in
each zone 22, 24 and 26 could be of a different amount from that
mentioned above.
[0032] Referring to FIGS. 4 and 5, a topper 112 according to a
first alternative embodiment of the invention is illustrated. For
simplicity, the topper 112 will be described using reference
numerals 100 higher than corresponding elements in the topper 12 of
FIGS. 2 and 3.
[0033] The topper 112 is made of polyurethane foam, but could be of
latex foam or visco-elastic memory foam, and includes a first end
zone 122 and a second end zone 124 longitudinally separated by a
center zone 126. The first end zone 122 is joined to the center
zone 126 at a joint 128. The second end zone 124 is joined to the
center zone 126 at a joint 130. The length and width of each zone
122, 124 and 126 is similar to those discussed with respect to the
topper 12 discussed above. The topper 112 includes a generally
planar top surface 132 and a generally planar bottom surface 134.
The topper 112 has a thickness on the order of 21/4''. The firmness
is substantially similar in each zone 122, 124 and 126, while the
density in the center zone 126 is substantially greater than in the
end zones 122 and 124. In an illustrative example, the end zones
122 and 124 have a firmness of 21 ILD and a density of 1.2 lbs. per
cubic foot. The center zone 126 has a firmness of about 23 ILD and
a density of about 1.65 lbs. per cubic foot. As is apparent, other
firmness and densities could be used, including those discussed
above relative to the topper 12.
[0034] The top surface 132 includes surface treatment in the form
of a plurality of slots 140 cut through the top surface 132 in a
grid pattern. A different set of slots 142 is cut through the top
surface 132 of the center zone 126, also in a grid pattern. The
slots 140 and 142 are about 1/2'' in depth. Grid spacing of the
slots 140 in the end zones 122 and 124 is about 3''. Grid spacing
of the slots 142 in the center zone 126 is about 6''. This provides
greater cushioning support in the center zone 126.
[0035] Referring to FIGS. 6 and 7, a topper 212 according to a
second alternative embodiment of the invention is illustrated.
Again, for simplicity, the topper 212 uses reference numerals
similar to those with respect to the embodiments of FIGS. 2 and 3
and 4 and 5, except being in the 200 number series.
[0036] The topper 212 is made of polyurethane foam, but could be of
latex foam or visco-elastic memory foam, and includes first and
second end zones 222 and 224 longitudinally separated from a center
zone 226 by respective joints 228 and 230. The topper 212 includes
a top surface 232 and a bottom surface 234. The bottom surface 234
is planar. The topper 212 differs in that the top surface 232
comprises a surface treatment in the form of a patterned convoluted
surface. The top surface 232 includes what is known as "egg crate"
convolutions throughout. Particularly, the convoluted top surface
232 has alternating peaks 240 and valleys 242 arranged in a
checkerboard configuration. In this embodiment, each of the zones
222, 224 and 226 include a similar pattern of convolutions
throughout.
[0037] Alternatively, the mattress topper 212 could include
different convolution patterns in each of the zones, 222, 224 and
226. Indeed, the convolution patterns could be the same in the end
zones 222 and 224, but different in the center zone 226.
Alternatively, the convolutions could be zoned independently of the
three different foam zones. For example, the top surface 232 could
include seven zones of convolution as shown in U.S. Pat. No.
5,974,609, incorporated by reference above.
[0038] Referring to FIGS. 8 and 9, a topper 312 according to a
third alternative embodiment of the invention is illustrated.
Again, for simplicity, the topper 312 uses reference numerals
similar to those with respect to the previous embodiments, except
being in the 300 number series.
[0039] The principal difference between the topper 212 and the
topper 312 is that a top surface 332 includes seven different zones
of convolution. The convolutions are formed by alternating peaks
340 and valleys 342. The peaks 340 and valleys 342 are arranged in
rows, with adjacent rows being staggered to form a checkerboard
pattern, as is apparent. The topper 312 can be manufactured using
conventional processes for convoluted foam cushions. In the
illustrated embodiment of the invention, the peaks 340 have flat
top surfaces. In an illustrative embodiment of the invention, the
topper 312 has a height of about 2'' measured from the planar
bottom surface 334 to the top of the peaks 340. The topper 312 has
a base thickness of about 11/2'' measured from the planar bottom
surface 334 to the base of the valleys 342. The peaks 340 and
valleys 342 are generally rectangular in shape, albeit having
rounded edges, as is well known. The top surface 332 includes seven
zones of convolution numbered 351, 352, 353, 354, 355, 356 and 357.
The outermost zones 351 and 357 are similar. The next innermost
zones 352 and 356 are similar. The next innermost zones 353 and 355
are similar. In the zones 351 and 357, the peaks and valleys have a
lateral dimension of about 1''. In the zones 352 and 356, the peaks
and valleys have a longitudinal dimension of about 2''. In the
zones 353 and 355, the peaks and valleys have a longitudinal
dimension of about 3''. Innermost zone 354 has peaks and valleys
with a longitudinal dimension of about 5'' in length. As such, the
center most convolution zone 354 provides the greatest amount of
support, with support gradually decreasing moving longitudinally
from the center convolution zone 354 to either end most convolution
zone 351 or 357. As is apparent, the convolution zones do not and
need not correspond to the three foam zones.
[0040] The topper 312 could alternatively be provided with a
different number of convolution zones such as, for example, three
zones or five zones. The borders of the convolution zones need not
match up with the borders of the foam zones.
[0041] The invention is not limited to a particular type of surface
treatment. Also, the surface treatment could be applied to the
bottom surface. The surface treatment could be, for example,
contoured, such as body contouring.
[0042] Each topper described herein can be constructed of
polyurethane foam or of latex. Also, it could be formed of a
visco-elastic memory foam.
[0043] Thus, in accordance with the invention, there is provided a
triple zone mattress topper providing greater durability and
support in a center zone compared to end zone.
* * * * *