U.S. patent application number 11/533178 was filed with the patent office on 2008-03-20 for anti-microbial mattress and improved support core.
This patent application is currently assigned to Boyd Flotation, Inc.. Invention is credited to Dennis Boyd.
Application Number | 20080066237 11/533178 |
Document ID | / |
Family ID | 39187022 |
Filed Date | 2008-03-20 |
United States Patent
Application |
20080066237 |
Kind Code |
A1 |
Boyd; Dennis |
March 20, 2008 |
Anti-Microbial Mattress and Improved Support Core
Abstract
A mattress includes a liquid impermeable layer and at least one
anti-microbial layer. A support core with expanded polystyrene
beads is also disclosed.
Inventors: |
Boyd; Dennis; (Chesterfield,
MO) |
Correspondence
Address: |
HUSCH & EPPENBERGER, LLC
190 CARONDELET PLAZA, SUITE 600
ST. LOUIS
MO
63105-3441
US
|
Assignee: |
Boyd Flotation, Inc.
Maryland Heights
MO
|
Family ID: |
39187022 |
Appl. No.: |
11/533178 |
Filed: |
September 19, 2006 |
Current U.S.
Class: |
5/702 ; 5/690;
5/699; 5/738 |
Current CPC
Class: |
A47C 27/081 20130101;
A47C 31/007 20130101; A47C 27/005 20130101 |
Class at
Publication: |
5/702 ; 5/699;
5/690; 5/738 |
International
Class: |
A47C 27/00 20060101
A47C027/00 |
Claims
1. A mattress comprising: a support core; an anti-microbial fabric
layer for partially covering a portion of the support core; a
liquid impermeable layer below the anti-microbial fabric layer;
said anti-microbial fabric layer being completely removable from
the liquid impermeable layer so that the anti-microbial fabric
layer may be removed from the liquid impermeable layer for
washing.
2. The mattress as set forth in claim 1 further including a
removable, anti-microbial top cover removably secured to one of the
anti-microbial fabric layer or the liquid impermeable layer.
3. The mattress as set forth in claim 2 wherein the anti-microbial
top cover is quilted.
4. The mattress as set forth in claim 3 wherein the top cover
includes anti-microbial fiber batting.
5. The mattress as set forth in claim 3 wherein the top cover
includes a washable foam batting.
6. The mattress as set forth in claim 1 wherein the liquid
impermeable layer is a plastic such as polyvinyl chloride.
7. The mattress as set forth in claim 1 wherein the liquid
impermeable layer constitutes a barrier to body ash.
8. The mattress as set forth in claim 1 further including a
secondary support layer disposed below the liquid impermeable
layer.
9. The mattress as set forth in claim 8 wherein the secondary
support layer consists of a sleep surface unit selected from the
group consisting of an innerspring unit, a foam support unit, an
air support unit, and a flotation support unit.
10. The mattress as set forth in claim 1 wherein the liquid
impermeable layer is disposed above the support core.
11. The mattress as set forth in claim 1 wherein the liquid
impermeable layer is disposed below the support core.
12. The mattress as set forth in claim 1 wherein at least some of
the materials constituting the mattress are fire resistant.
13. The mattress as set forth in claim 1 wherein the support core
includes a plurality of expanded polystyrene beads.
14. The mattress as set forth in claim 13 wherein the expanded
polystyrene beads are partitioned into sections.
15. The mattress as set forth in claim 14 wherein the beads are
partitioned by means of belts.
16. The mattress as set forth in claim 14 wherein the beads are
partitioned by means of baffles.
17. The mattress as set forth in claim 1 wherein the support core
includes a support core component selected from the group
consisting of polyurethane foam, latex foam, memory foam, a fluid
filled chamber, a gel layer, particulated foam, fiber, fiber with
an oxygenating capability, polyethylene foam, an innerspring, and
magnets.
18. A mattress comprising: a resilient container defining an
interior volume, said resilient container having a length and a
width sufficient to support a human user; a plurality of expanded
polystyrene beads filling a substantial part of the interior
volume.
19. The mattress as set forth in claim 18 further including a
conventional mattress disposed below the mattress formed by the
beads in the resilient container.
20. The mattress as set forth in claim 19 wherein the mattress
formed by the beads in the resilient container is removably secured
to the conventional mattress.
21. The mattress as set forth in claim 18 further including a
plurality of baffles disposed in the resilient container to
partition the interior volume into sections.
22. The mattress as set forth in claim 21 wherein at least one of
the baffles has opening formed therein to allow limited movement of
beads from one section to another.
23. The mattress as set forth in claim 18 further including a cover
over the resilient container.
24. The mattress as set forth in claim 18 wherein at least some of
the beads have a first diameter and at least some of the beads have
a second diameter.
25. The mattress as set forth in claim 18 wherein at least some of
the beads have a first density and at least some of the beads have
a second density.
26. The mattress as set forth in claim 18 wherein at least some of
the beads have a first weight and at least some of the beads have a
second weight.
27. The mattress as set forth in claim 18 wherein at least some of
the beads have a first value of a preselected physical
characteristic and at least some of the beads have a second value
of said characteristic, said beads having the first value being
primarily disposed in a first section of the mattress, and said
beads having the second value being primarily disposed in a second
section of the mattress.
28. The mattress as set forth in claim 18 further including a base
for the mattress and at least one belt for removably securing the
mattress to the base, said belt further partitioning the mattress
into at least two sections.
29. The mattress as set forth in claim 28 further including a hook
and pile fastener on the mattress.
30. The mattress as set forth in claim 29 wherein the hook and pile
fastener secures the mattress to the base.
31. The mattress as set forth in claim 29 wherein the hook and pile
fastener secures the mattress to a second mattress.
32. The mattress as set forth in claim 28 wherein the base includes
a layer of support foam.
33. The mattress as set forth in claim 28 further including a cover
surrounding the mattress and at least a portion of the base.
34. The mattress as set forth in claim 33 wherein the cover is
removable.
35. The mattress as set forth in claim 18 wherein the container is
formed with three separate sections to prevent migration of beads
from one section to another.
36. The mattress as set forth in claim 18 wherein the container is
tufted.
37. The mattress as set forth in claim 18 further including a
closeable opening into the container to permit the addition or
removal of beads into and from the interior volume.
38. The mattress as set forth in claim 18 wherein the resilient
container is disposed above a main support core of the
mattress.
39. The mattress as set forth in claim 18 wherein the mattress
includes a top quilted panel, the resilient container being
disposed below the top quilted panel.
40. The mattress as set forth in claim 18 wherein the resilient
container is removably disposed inside a mattress cover.
41. The mattress as set forth in claim 40 wherein the mattress
cover includes a slide fastener which is openable to allow access
to the resilient container.
42. A mattress comprising: a top cover formed of an anti-microbial
material that is permeable to liquid; a liquid impermeable layer
removably secured to the top cover, said liquid impermeable layer
being disposed below the top cover so that a human user does not
lay directly on the liquid impermeable layer; a support core
disposed below the liquid impermeable layer, so that the liquid
impermeable layer prevents liquid moving through the top cover to
the support core.
43. The mattress as set forth in claim 42 wherein the top cover is
washable and removable from the support core.
44. The mattress as set forth in claim 42 wherein the liquid
impermeable layer is removably secured to the top cover by a first
fastener.
45. The mattress as set forth in claim 44 wherein the top cover is
secured to the remainder of the mattress by a second fastener.
46. The mattress as set forth in claim 42 wherein the support core
includes a support core component selected from the group
consisting of polyurethane foam, latex foam, memory foam, a fluid
filled chamber, a gel layer, particulated foam, fiber, fiber with
an oxygenating capability, polyethylene foam, an innerspring, and
magnets.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to a mattress for beds, futons and
the like.
[0005] 2. Prior Art
[0006] There is an increasing awareness of the impact of dust
mites, bacteria, and mold within a mattress and its effects on the
ability to sleep comfortably and efficiently. Dust mites carry
disease and can cause allergic reactions when they (or their
residue) come in contact with the mattress user. Studies have shown
the weight of an innerspring mattress doubles every ten years due
to live dust mites, dead dust mites, and dust mite feces. The
mattress is second only to the garbage disposal in microbiological
growth within the home (toilet is third). Sixty-eight percent (68%)
of those in a recent survey with allergies indicated they had a
difficult time obtaining a restful night's sleep.
[0007] Moisture from perspiration causes a natural environment for
biological growth. This particularly evident in waterbeds and air
mattresses where there is a disparity between the person's body
temperature and the temperature of the water mattress or air
mattress. The average person perspires one pint of fluid during an
8-hour sleep period. A warm moist environment is ideal for microbe
proliferation.
[0008] Dust mites feed on fungus, body ash (dead skin cells flaking
off the body), and natural fibers such as cotton, wool, silk and
rayon. These fibers are ideally used for absorbing moisture to
maintain a dry hygienic sleep surface. Unfortunately these fibers,
while reducing the moisture laden environment that will control
mildew and mold, attract dust mites that feed on these natural
fibers.
[0009] It has also been discovered that mattresses could be
improved in other ways. Many types of materials have been proposed
for use in mattresses, such as various kinds of foams, inner
springs, air and water chambers, and the like. These materials, for
the most part, provide a satisfactory sleep surface. But they are
fairly heavy, which makes them expensive to ship and somewhat
awkward to move or flip. Many people prefer a sleep support that
conforms to their body, which certain of these materials provide in
one form or another. But such conforming supports do not usually
provide a solid "feel" for the user.
[0010] It would be desirable to have a mattress that solves one or
more of these problems, to provide the user a better night's
sleep.
BRIEF SUMMARY OF THE INVENTION
[0011] Briefly, in a first embodiment of the present invention, a
mattress includes a support core, an anti-microbial fabric layer
for partially covering a portion of the support core, and a liquid
impermeable layer removably secured to the anti-microbial fabric
layer to enclose the support core. The anti-microbial fabric layer
is completely removable from the liquid impermeable layer so that
the anti-microbial fabric layer may be removed from the liquid
impermeable layer for washing.
[0012] In a second aspect of the present invention, a mattress
includes a resilient container defining an interior volume, said
resilient container having a length and a width sufficient to
support a human user, and a plurality of expanded polystyrene beads
filling a substantial part of the interior volume.
[0013] In a third aspect of the present invention, a mattress
includes a top cover formed of an anti-microbial material that is
permeable to liquid, a liquid impermeable layer removably secured
to the top cover, said liquid impermeable layer being disposed
below the top cover so that a human user does not lay directly on
the liquid impermeable layer, and a support core disposed below the
liquid impermeable layer, so that the liquid impermeable layer
prevents liquid moving through the top cover to the support
core.
[0014] Among the various objects and features of the present
invention may be noted the provision of an improved mattress with
anti-microbial features.
[0015] A second feature is the provision of such a mattress that
provides a substantially pristine environment conducive to
obtaining a better night's sleep.
[0016] A third feature is the provision of a mattress that provides
a conforming sleep surface with an improved feel.
[0017] A fourth feature is the provision of a mattress than is
substantially lighter than many conventional types of
mattresses.
[0018] A fifth feature is the provision of such a mattress that
includes a light top support surface with improved feel in
combination with an additional support below the top support
surface.
[0019] Other objects and features will be in part apparent and in
part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is an expanded view of a mattress of the present
invention;
[0021] FIG. 2 is an expanded view of a second embodiment of a
mattress of the present invention;
[0022] FIG. 3 is a support core of the present invention having
expanded polystyrene beads;
[0023] FIG. 4 is an alternative embodiment to that of FIG. 3;
and
[0024] FIG. 5 is a third embodiment of an expanded polystyrene bead
support core.
[0025] Similar reference characters indicate similar parts
throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Turning to the drawings, a mattress 11 of the present
invention may include a removable, washable top cover 13, a support
core 15, and a liquid impermeable layer 17 below the top cover. Top
cover 13 is preferably secured to a second portion 19 of the cover
of the mattress by means of a slide fastener or hook and pile
fastener 20 or some other attachment method. Preferably the top
surface material of the top cover 13 is made of an absorbent fabric
such as a Lyocel, rayon, cotton blend, and or a stretch knit
fabric. This portion of the top cover may be quilted using an
anti-microbial fiber or a washable foam such as latex as a batting
material. The bottom (lower fabric) portion of the top cover 13 can
be any fabric, preferably treated to be anti-microbial or using a
genetically engineered fiber that is anti-microbial.
[0027] Second portion 19 is preferably composed of an
anti-microbial fabric that envelops (either alone or in combination
with the top cover) the top and sides of support core 15. The
support core may be formed of any desired material such as
polyurethane foam, latex foam, memory foam, a fluid filled chamber,
a gel layer, particulated foam, fiber, fiber with an oxygenating
capability, polyethylene foam, an innerspring, and magnets. The
expanded polystyrene bead support surface described below makes a
particularly good support core.
[0028] The bottom layer 17 of the envelope that surrounds the
support core is made of a non-porous (to liquids) material such as
polyvinyl chloride. The fabric portion of this surrounding envelop
is attached to the non-porous layer 17 with a slide fastener, hook
and pile fastener, or other detachable mechanism. The fabric
portion is preferably removable and washable. The vinyl or other
non-porous layer 17 is able to be cleaned with a vinyl cleaner or a
household disinfectant. This barrier of non-porous material
prevents dust mites, mold, mildew, and/or other micro-organisms
from penetrating deeper into the mattress. This non-porous material
is also not a food source for the dust mite. It prevents the
further penetration of perspiration or other fluids that could
become lodged deeper into the mattress. The non-porous layer also
stops body ash from sifting deeper into the mattress. This
accumulated body ash on this layer is easier to clean once it has
collected on the surface of the non-porous material. This second
layer could be flipped if desired so that the non-porous layer is
on the top and the fabric layer is on the bottom.
[0029] An optional third component 23 of the mattress of the
present invention is an additional support unit consisting of an
innerspring unit, fiber, visco elastic foam, polyurethane foam,
latex foam, particulated foam, air chamber(s), flotation
chamber(s), or any other sleep support material such as those
listed above. This component does not need to be removable or
washable due to the other layers that would lie between the sleeper
and this support surface. The component 23 shown in FIG. 1 fits
within a recess in a support core retainer 25 (which is, of course,
optional). And the entire mattress 11 rests, if desired on a
platform 27.
[0030] Turning to FIGS. 2, 2A, and 2B, a mattress 31 constitutes a
second embodiment of the present invention. This embodiment differs
from mattress 11 primarily in that the liquid impermeable layer 17
is removably secured directly to top cover 13 by any suitable
fastener such as slide fastener 33 shown. Layer 17 still performs
the functions described above, but it is located adjacent the top
cover 13. The top cover in this embodiment thus includes two
fasteners-fastener 20 to removably secure it to component 19, and
fastener 33 to removably secure it to the liquid impermeable layer
17. It should be appreciated that top cover 13 preferably is
removable and washable, but it need not be removable and washable.
In any event, the top cover may be plain or quilted, and be filled
with a batting such as an anti-microbial fiber batting or a
washable foam batting.
[0031] It should also be realized that at least some of the
materials constituting the mattress can, if desired, be fire
resistant.
[0032] In a preferred embodiment of the present invention, the
support core 15 includes a plurality of expanded polystyrene beads
such as is shown in FIG. 3. In this embodiment, a large number of
expanded polystyrene beads 41 are disposed in a cover or container
43. Optionally, as shown in FIG. 3, the beads may be separated into
various sections, such as sections 15A, 15B, and 15C shown, by
partition baffles 45. Optionally, the partition baffles may be
provided with a plurality of holes 47 to allow some migration of
beads from one section of the support core to another.
[0033] Beads 41 may be of different diameters, densities, and/or
weights, and may be placed in different sections of the support
core as desired. For example, low weight and density beads with a
larger diameter may be placed at the foot of the support core where
there is reduced weight displacement, while denser but smaller
beads may be placed in the middle section 15B to accommodate the
additional weight anticipated for the typical user.
[0034] Although the expanded polystyrene beads construction is
particularly useful in mattress 11, it may be used with other
mattresses. For example, in FIG. 4, an expanded polystyrene bead
support core 51 is provided with downwardly extending side panels
53 which function to keep support core 51 positioned on a mattress
55. (Other methods of securement such as elastic bands, etc. could
be used to secure the support core 51 to mattress 55. In this
embodiment, support core 51 functions as a mattress topper. The
cover of support core 51 (or any of the support cores described
herein) can be formed of multiple layers, such as an outer stretch
knit outer layer 57 and an inner woven or knit fabric layer 59 to
contain the expanded polystyrene beads.
[0035] Turning to FIG. 5, a dual topper support core 61 is shown.
In this embodiment, dual support cores 61A, 61B are disposed over a
foam base 63. One or more belts, bands, or the like 65 may
optionally be used to secure the cores 61A, 61B in place. The belts
may optionally have buckles 67 or other such mechanisms to allow
the belt to be fastened or unfastened. If desired, foam base 63 may
be of various foams, having differing densities and/or layers as
desired, with or without an edge support.
[0036] If desired, sections 61A and 61B may be secured together
with any suitable fastener, including a hook and pile fastener to
reduce the potential for gapping between the two sections.
Similarly, a suitable fastener could be added to the bottom of
these sections and the top of the foam base 63 to help keep dual
support core 61 in place.
[0037] A cover (not shown) could be provided for sections 61A, 61B
and foam base 63 to provide a more conventional look. Preferably
such a cover would have an openable top to allow for manual access
to sections 61A, 61B to allow for adjustment of the placement of
the beads. Such a cover could be totally removable and
washable.
[0038] It should be appreciated that the various objects and
features of the present invention are achieved in the constructions
as set out above. The description and drawings herein are intended
to be illustrative only and not limiting. The present invention is
defined not by this description, but rather by the following
claims.
* * * * *