U.S. patent application number 11/223769 was filed with the patent office on 2007-03-15 for mattress with air passageways.
This patent application is currently assigned to Vintage Bedding, Inc.. Invention is credited to Ronald Galardo.
Application Number | 20070056116 11/223769 |
Document ID | / |
Family ID | 37853560 |
Filed Date | 2007-03-15 |
United States Patent
Application |
20070056116 |
Kind Code |
A1 |
Galardo; Ronald |
March 15, 2007 |
Mattress with air passageways
Abstract
A mattress comprises a foam core having therein a plurality of
air passageways extending in different directions and in different
levels within the core.
Inventors: |
Galardo; Ronald; (Industry,
CA) |
Correspondence
Address: |
CONNORS ASSOCIATES
1600 DOVE ST
SUITE 220
NEWPORT BEACH
CA
92660
US
|
Assignee: |
Vintage Bedding, Inc.
|
Family ID: |
37853560 |
Appl. No.: |
11/223769 |
Filed: |
September 9, 2005 |
Current U.S.
Class: |
5/724 |
Current CPC
Class: |
A47C 27/15 20130101;
A47C 21/046 20130101; A47C 27/144 20130101 |
Class at
Publication: |
005/724 |
International
Class: |
A47C 27/15 20060101
A47C027/15 |
Claims
1. A mattress comprising a plurality of foam layers stacked upon
each other, one of said layers having a plurality of parallel air
passageways therein extending in a first direction, and another of
said layers having a plurality of parallel air passageways therein
extending in a second direction that is substantially at 90.degree.
with respect to the first direction.
2. The mattress of claim 1 including at least one connecting air
passageway placing at least one of the air passageways in the one
layer with at least one of the air passageways in the other
layer.
3. The mattress of claim 1 where one of the layers includes a side
having therein a plurality of parallel grooves therein open at said
side to form the air passageways extending in the first direction,
and another of the layers includes a side having therein a
plurality of parallel grooves therein open at said side to form air
passageways extending in the second direction, the sides of each
said layers facing each other so there is direct fluid
communication between the air passageways extending in the first
direction and the air passageways extending in the second
direction.
4. A mattress comprising a foam core having therein a plurality of
air passageways extending in a first direction at first level
within the core, and a plurality of air passageways extending in a
second direction different than the first direction at a second
level within the core that is beneath the first level, at least one
of the air passageways in the first level being in fluid
communication with at least one of the air passageways in the
second level.
5. A foam mattress comprising a first section with a plurality of
parallel air passageways therein extending in a first direction,
and a second section beneath the first section with a plurality of
parallel air passageways therein extending in a second direction
that is substantially at 90.degree. with respect to the first
direction.
6. The mattress of claim 5 including at least one connecting air
passageway placing at least one of the air passageways in the first
section with at least one of the air passageways in the second
section.
7. The mattress of claim 5 where the first section air passageways
are in a first plane and said second section air passageways are in
a second plane that is substantially parallel to the first
plane,
8. A mattress made substantially entirely of foam and comprising a
body member including a first section with a plurality of parallel
air passageways therein extending in a first substantially
horizontal direction with the mattress horizontally oriented, said
first section air passageways being a first plane, a second section
beneath the first section with a plurality of parallel air
passageways therein extending in a second substantially horizontal
direction with the mattress horizontally oriented, said second
direction being substantially at 90.degree. with respect to the
first direction and said second section air passageways being a
second plane that is substantially parallel to the first plane,
said air passageways terminating in opposed ends, said body member
having a substantially rectangular shaped perimeter formed of foam
members having a predetermined thickness substantially from 1 to 6
inches, said foam members encompassing the first and second
sections and covering the ends of the air passageways, and a third
exterior section forming a first side of the mattress covering the
first section and a fourth exterior section forming a second side
of the mattress covering the second section, said third and fourth
sections each having a predetermined thickness substantially from 1
to 10 inches, said third and fourth sections each providing an
exterior surface, one of which a user lies upon when the mattress
is horizontally oriented to thereby compress the mattress and force
air from the passageways and out the passageway ends through the
perimeter foam members.
9. The mattress of claim 8 including at least one connecting air
passageway placing at least one of the air passageways in the one
layer with at least one of the air passageways in the other
layer.
10. The mattress of claim 9 where the mattress has a height of from
3 to 20 inches, the first section has a height substantially from 1
to 10 inches, and the second section has a height substantially
from 1 to 10 inches.
11. A mattress having opposed sides, a predetermined width and a
predetermined length and comprising an internal foam core including
one level having therein in a first plane a plurality of parallel
air passageways extending substantially along the entire width of
the mattress in a first substantially horizontal direction with the
mattress horizontally oriented, and another level having therein in
a second plane that is substantially parallel to the first plane a
plurality of parallel air passageways extending substantially along
the entire length of the mattress in a second substantially
horizontal direction with the mattress horizontally oriented that
is substantially at 90.degree. with respect to the first
direction.
12. The mattress of claim 11 where the air passageways terminated
in opposed open ends at a perimeter of the core.
13. The mattress of claim 12 including foam members along the
perimeter covering the open ends of the passageways.
14. The mattress of claim 13 including at least one connecting air
passageway placing in communication at least one of the air
passageways in the one level with at least one of the air
passageways in the other level, so that upon a user lying on the
mattress when said mattress is horizontally oriented thereby
compresses the mattress to force air from the passageways and out
the passageway ends through the perimeter foam members.
Description
[0001] The words "comprising," "having," "containing," and
"including," and other forms thereof, are intended to be equivalent
in meaning and be open ended in that an item or items following any
one of these words is not meant to be an exhaustive listing of such
item or items, or meant to be limited to only the listed item or
items. "Rectangular shape" includes square shape.
BACKGROUND OF INVENTION
[0002] Mattresses made of foam material, for example, polyurethane
foam, are in common use. The foam is porous and resilient, and
deforms and is compressed when a users seats or lies on a foam
mattress. The mattress, because of the foam material's resiliency,
returns to its non-deformed state upon the user arising from the
mattress. It would be desirable, however, to improve such a
mattress' ability to "breath." Breathing of the mattress is
important because this facilitates conforming to the shape of the
body lying on the mattress.
SUMMARY OF INVENTION
[0003] This invention has one or more features as discussed
subsequently herein. After reading the following section entitled
"DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THIS INVENTION," one
will understand how the features of this invention provide its
benefits. These benefits include, but are not limited to: improved
ability of the mattress to conform to the body of a person lying
thereon.
[0004] Without limiting the scope of this invention as expressed by
the claims that follow, some, but not necessarily all, of its
features are:
[0005] One, the mattress of this invention includes a foam core
with air passageways extending through it. Some air passageways may
extend substantially along the entire width of the mattress in a
first substantially horizontal direction with the mattress
horizontally oriented, and other air passageways may extend
substantially along the entire length of the mattress in a second
substantially horizontal direction with the mattress horizontally
oriented.
[0006] Two, the core may comprise a plurality of foam layers
stacked upon each other. One of the layers may include one side
having therein a plurality of parallel grooves therein open at this
one side to form air passageways extending in a first direction.
Another of the layers may include another side having therein a
plurality of parallel grooves therein open at this other side to
form air passageways extending in a second direction. The sides of
each these layers may face each other so there is direct fluid
communication between the air passageways extending in the first
direction and the air passageways extending in the second
direction.
[0007] Three, the air passageways extending in the first direction
may be at a first level within the core, and the air passageways
extending in the second direction may be at a second level within
the core that is beneath the first level when the mattress is
horizontally oriented, The air passageways in the first and second
levels may be substantially at 90.degree. with respect to each
other. The foam core may include at least one connecting air
passageway placing at least one of the air passageways in the first
level in fluid communication with at least one of the air
passageways in the second level.
[0008] Four, the mattress of this invention may comprise a body
member including first and second sections. The first section may
include a plurality of parallel air passageways therein extending
in a first substantially horizontal direction with the mattress
horizontally oriented, with these first section air passageways
being in a first plane. The second section may be beneath the first
section and include a plurality of parallel air passageways therein
extending in a second substantially horizontal direction with the
mattress horizontally oriented, the second direction being
substantially at 90.degree. with respect to the first direction and
the second section air passageways being in a second plane that is
substantially parallel to the first plane. All the air passageways
may terminate in opposed open ends.
[0009] Five, the body member may have a substantially rectangular
shaped perimeter formed of foam members having a predetermined
thickness substantially from 1 to 6 inches. These foam members
encompass the first and second sections and cover the ends of the
air passageways. The body member may include a third exterior
section forming a first side of the mattress covering the first
section and a fourth exterior section forming a second side of the
mattress covering the second section. The third and fourth sections
may each have a predetermined thickness substantially from 1 to 10
inches, and may each provide an exterior surface. When the mattress
is horizontally oriented and a user lies on one of the surfaces,
the mattress is compressed to force air from the passageways and
out the passageway ends through the perimeter foam members. The
mattress may have a height substantially from 3 to 20 inches, and
the first section may have a height substantially from 1 to 10
inches, and the second section may have a height substantially from
1 to 10 inches.
[0010] In one embodiment, the mattress is made substantially
entirely of foam.
[0011] These features are not listed in any rank order nor is this
list intended to be exhaustive.
DESCRIPTION OF THE DRAWING
[0012] Some embodiments of this invention, illustrating all its
features, will now be discussed in detail. These embodiments depict
the novel and non-obvious mattress of this invention as shown in
the accompanying drawing, which is for illustrative purposes only.
This drawing includes the following figures (Figs.), with like
numerals indicating like parts:
[0013] FIG. 1 is a perspective view of one embodiment of the
mattress this invention, with sections broken away, wherein the
mattress is made from several sheets and numerous small blocks of
foam glued together.
[0014] FIG. 2 is an exploded perspective view of the mattress shown
in FIG. 1.
[0015] FIG. 3 is a plan view taken along line 3-3 of FIG. 2.
[0016] FIG. 4 is a plan view taken along line 4-4 of FIG. 2.
[0017] FIG. 5 is a cross-sectional view taken along line 5-5 of
FIG. 1.
[0018] FIG. 6 is a cross-sectional view taken along line 6-6 of
FIG. 1.
[0019] FIG. 7 is a perspective view showing an alternate
configuration of a core of another embodiment of the mattress this
invention.
[0020] FIG. 8 is an exploded perspective view of the core shown in
FIG. 7.
DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THIS INVENTION
General
[0021] FIGS. 1 through 6 depict one embodiment of this invention,
the mattress 10, comprising a central, foam core C1 including
within this core air passageways P1 at a level L1 and passageways
P2 at level L2. Levels L1 and L2 are substantially parallel, and
level L2 comprises substantially parallel sublevels L2.sub.1 and
L2.sub.2. FIGS. 7 and 8 depict another embodiment of this
invention, a mattress in which a central, foam core C2 includes
multiple foam layers forming air passageways P3 disposed between
air passageways P4.sub.1 and P4.sub.2. Except for the different
types of cores employed, the mattress using the core C2 is
essentially identical to the mattress 10. In both mattresses there
may be fluid communication between at least some of the air
passageways in the different levels or layers, as the case may
be.
FIGS. 1 through 6
[0022] As best illustrated in FIG. 1, the mattress 10 is made
substantially entirely of a foam such as, for example,
polyurethane. The mattress 10 comprises a substantially rectangular
shaped body having opposed exterior sides S1 and S2. The dimensions
of the mattress 10 may correspond to king, queen, double, and twin
size mattresses. Typically, the mattress' width w is from about 39
to about 80 inches, and its length l is from about 72 to about 85
inches, and its height h is from about 3 to about 20 inches.
[0023] As best shown in FIG. 2, the internal foam core C1 has a
substantially rectangular shape formed from a plurality of foam
blocks b1 through b7, four elongated foam strips 14a, 14b, 14c, and
14d that overlie the blocks b1 through b7, and a substantially
rectangular, foam cover sheet 16 that overlies the strips 14a, 14b,
14c, and 14d. The rectangular shaped strips 14a, 14b, 14c, and 14d
are spaced apart to create the parallel passageways P1 between
adjacent strips. As best depicted in FIGS. 2 and 6, between the
adjacent tall blocks b1 and b3, b3 and b4, b4 and b5, b5 and b6,
and b6 and b7 are, respectively, a series of blocks b2.sub.1,
b2.sub.2, b2.sub.3, b2.sub.4, and b2.sub.5, each individual series
including aligned, short, thin, spaced apart blocks A, B, and C.
Each of the blocks A, B, and C is spaced from an adjacent short
block to create connecting air passageways P5 placing at least some
of the air passageways P1 and P2 in fluid communication with each
other directly through the air passageways P5, in contrast to
indirectly though the foam material.
[0024] The foam cover sheet 16 overlies and abuts the top surfaces
of the elongated foam strips 14a, 14b, 14c, and 14d. This cover
sheet 16 and the tall blocks b1, b3, b4, b5, b6, b7, the series of
short blocks b2.sub.1, b2.sub.2, b2.sub.3, b2.sub.4, and b2.sub.5,
and the elongated foam strips 14a, 14b, 14c, and 14d are glued
together to create the core C1, including the passageways P1 and
P2, respectively in levels L1 and L2. The passageways P2 are in
both of the sublevels L2.sub.1 and L2.sub.2. The core C1 has a
thickness t.sub.1 from about 3 to about 10 inches, which is only a
little less than the height h of the mattress 10. The core's C1
width is only a little less (about 1 to 6 about inches) than the
width w of the mattress 10, and its length is only a little less
(about 1 to about 6 inches) than the length l of the mattress. As
discussed subsequently in greater detail, the core's dimensions in
most embodiments will be less than the dimensions of the
mattress.
[0025] In the one level L1 the air passageways P1 are all
substantially parallel, all lie in substantially the same plane,
all extend along the entire length of the core C1, and all are of
substantially equal length. These air passageways P1 extend in a
first substantially horizontal direction with the mattress 10
horizontally oriented. In the other level L2 some of the air
passageways P2 extend along upper rows r1 in the sublevel L2.sub.1
and others of the air passageways P2 extend along lower rows r2 in
the sublevel L2.sub.2. All the air passageways P2 are substantially
parallel and all extend along the entire width of the core C1, and
all are of substantially equal length. The air passageways P2 in
the rows r1 lie in substantially the same plane and the air
passageways P2 in the rows r2 lie in another plane. All the planes
in which the passageways P1 and P2 lie are substantially parallel,
and so are these passageways. With the mattress 10 horizontally
oriented, the passageways P2 extend in a substantially horizontal
direction that is substantially at 90.degree. with respect to the
first direction of the passageways P1. All the air passageways P1
and P2 terminate in opposed open ends E1 and E2 at the perimeter of
the core C1. The connecting air passageways P5, which are
substantially at a right angle with respect to the passageways P1
and P2, allow air to flow directly from the passageway P1 into the
air passageways P2 in both sublevels L2.sub.1 and L2.sub.2.
[0026] The core C1 is enclosed by substantially rectangular, foam
top and bottom sheets 18a and 18b, respectively, and a
substantially rectangular frame 20. The thicknesses of the sheets
18a and 18b and the frame 20 determine how much less the dimensions
of the core C1 are in comparison to the dimensions of the mattress
10. The top and bottom sheets 18a and 18b each have a thickness of
from about 1/2 to about 10 inches, and each provide the exterior
surfaces S1 and S2, respectively, one of which a user lies upon
when the mattress 10 is horizontally oriented. The sheets 18a and
18b, the frame 20, and the core C1 are in registration.
[0027] The frame 20 comprises four blocks 20a, 20b, 20c, and 20d,
each having a height h.sub.2 that is substantially equal to the
thickness t.sub.1 of the core C1. The inside surface of the frame
20 abuts and covers the sides of the core C1, closing the open ends
E1 and E2 of the air passageways P1 and P2. This frame 20 provides
a substantially rectangular shaped perimeter member PM (FIG. 2)
having a uniform predetermined thickness t.sub.2 from about 1 to
about 6 inches. Nevertheless, the different blocks 20a, 20b, 20c,
and 20d may each have a different thickness. The width and length
of the core C1 is almost the same as the width w and length l of
the mattress 10. Consequently, the passageways P1 extend
substantially along almost the entire length l of the mattress 10,
and the passageways P2 extend substantially along almost the entire
width w of the mattress. In this specific embodiment where the
mattress 10 has a substantially rectangular shape and the blocks
20a, 20b, 20c, and 20d have a uniform thickness, the passageways P1
each have a length that is l -2t.sub.2, and the passageways P2 each
have a length that is w-2t.sub.2. The sheets 18a and 18b and the
frame 20 have the same width and length as the mattress 10, and the
top and bottom sheets overlap the frame. Upon assembly, the core
C1, frame 20, and top and bottom sheets 18a and 18b are glued
together.
[0028] The mattress 10 may be considered as including four
sections: (1) a first section with the plurality of parallel air
passageways P1 therein in a first plane and extending in a first
substantially horizontal direction with the mattress 10
horizontally oriented, (2) a second section beneath the first
section with a plurality of parallel air passageways P2 therein
extending in a second substantially horizontal direction with the
mattress 10 horizontally oriented, this second direction being
substantially at 90.degree. with respect to the first direction and
the second section air passageways P2 each being in one or more
second sub-planes that are substantially parallel to the first
plane, (3) a third exterior section formed by the top sheet 18a
that covers the first section, and (4) a fourth exterior section
formed by the bottom sheet 18b that covers the second section. The
first section may have a height of from about 1 to about 10 inches,
which may be equal to the thickness of the sheet 18a, and the
second section may have a height of from about 1 to about 10
inches, which may be equal to the thickness of the sheet 18b.
FIGS. 7 and 8
[0029] Another mattress of this invention using the core C2 is
depicted in FIGS. 7 and 8. The principal difference between the
embodiment illustrated in FIGS. 1 through 6 and that shown in FIGS.
7 and 8 is the core C2 having opposed sides S3 and S4 (FIG. 7). In
essentially the same manner as depicted in mattress 10, this core
C2 is surrounded by the frame 20 (not shown for clarity) and its
opposed sides S3 and S4 are covered, respectively, by the sheets
18a and 18b (not shown for clarity).
[0030] As best shown in FIG. 7, the core C2 includes a plurality of
foam layers 102, 103, and 104 stacked upon each other. As depicted
in FIG. 8, the underside of the layer 102 has parallel,
substantially U-shaped spaced apart grooves 102a therein; the
topside of the layer 103 has parallel, substantially U-shaped
spaced apart grooves 103a therein; and the topside of the layer 104
has parallel, substantially U-shaped spaced apart grooves 104a
therein. The layers 102-104 are assembled so that the grooves 102a
and 104a are at a right angle with respect to the grooves 103a.
This forms the air passageways P4.sub.1 and P4.sub.2 in upper and
lower levels or sections U and L, respectively, with the air
passageways P3 between the air passageways P4.sub.1 and P4.sub.2.
The air passageways P3 are substantially parallel, extend in a
first direction, and lie in the substantially same plane. The air
passageways P4.sub.1 and P4.sub.2 are in different, substantially
parallel planes but extend in the same direction, and are
substantially at 90.degree. with respect to the first direction of
the passageways P3. The plane of the passageways P3 is
substantially parallel to the planes in which the air passageways
P4.sub.1 and P4.sub.2 lie. Because the open sides 102b of the
grooves 102a and the open sides 103b of the grooves 103a overlap
and face each other, there is direct fluid communication between
the air passageways P4.sub.1 and P3 so that air may flow between
these passageways. In this embodiment, the use connecting air
passageways P5 are eliminated because these open sides 102b and
103b are in direct fluid communication.
Operation
[0031] In both embodiments, a user, lying on a horizontally
oriented mattress of this invention, compresses the foam materials
forming the mattress to force air along the passageways P1, P2, and
P5, or P3 and P4, as the case may be, out the passageway ends E1
and E2 through the foam material forming the perimeter member PM.
When the user arises, the mattress decompresses and air is drawn
through the foam material forming the perimeter member PM to expand
the mattress and fill with air the passageways P1, P2, and P5, or
P3 and P4, as the case may be.
SCOPE OF THE INVENTION
[0032] The above presents a description of the best mode
contemplated of carrying out the present invention, and of the
manner and process of making and using it, in such full, clear,
concise, and exact terms as to enable any person skilled in the art
to which it pertains to make and use this invention. This invention
is, however, susceptible to modifications and alternate
constructions from that discussed above which are fully equivalent.
Consequently, it is not the intention to limit this invention to
the particular embodiments disclosed. On the contrary, the
intention is to cover all modifications and alternate constructions
coming within the spirit and scope of the invention as generally
expressed by the following claims, which particularly point out and
distinctly claim the subject matter of the invention:
* * * * *