U.S. patent application number 11/552768 was filed with the patent office on 2008-05-01 for modular mattress system.
Invention is credited to Thomas C. Erdman.
Application Number | 20080098533 11/552768 |
Document ID | / |
Family ID | 39328398 |
Filed Date | 2008-05-01 |
United States Patent
Application |
20080098533 |
Kind Code |
A1 |
Erdman; Thomas C. |
May 1, 2008 |
MODULAR MATTRESS SYSTEM
Abstract
A modular mattress system having at least one mattress block
which includes an array of resilient coil springs, along with a
foam pad, and a washable/dryable fabric mattress cover. The
components of the modular mattress system are compressible into an
air evacuable bag for purposes of storing, shipping, and disposal.
The size, firmness, type of foam pad, pattern and color of the
fabric mattress cover, and type of securable seam available for the
fabric mattress cover used in the modular mattress system may be
specified by the consumer. Mattress size ranges from Crib size
through King size, with custom sizes available as well. Various
methods of specifying, ordering, and distributing the modular
mattress system are detailed. The care, maintenance, assembly and
usage of the modular mattress system are discussed.
Inventors: |
Erdman; Thomas C.; (Fort
Atkinson, WI) |
Correspondence
Address: |
MARSHALL, GERSTEIN & BORUN LLP
233 S. WACKER DRIVE, SUITE 6300, SEARS TOWER
CHICAGO
IL
60606
US
|
Family ID: |
39328398 |
Appl. No.: |
11/552768 |
Filed: |
October 25, 2006 |
Current U.S.
Class: |
5/722 ;
5/716 |
Current CPC
Class: |
A47C 31/105 20130101;
A47C 27/001 20130101 |
Class at
Publication: |
5/722 ;
5/716 |
International
Class: |
A47C 23/04 20060101
A47C023/04; A47C 17/00 20060101 A47C017/00 |
Claims
1. A mattress comprising: a plurality of mattress blocks, each of
said mattress blocks including an array of resilient coils, the
array of coils being enclosed in a mattress block covering
material.
2. The mattress of claim 1, wherein the mattress blocks are
arranged in a fabric mattress cover having a top layer, a bottom
layer, and at least one sidewall.
3. The mattress of claim 2, wherein the fabric mattress cover
includes a selectively sealable seam, the selectively sealable seam
providing access to an interior of the fabric mattress cover for
inserting or removing the mattress blocks.
4. The mattress of claim 3, wherein the selectively securable seam
is disposed along an intersection of the bottom layer of the fabric
mattress cover and at least one of the at least one sidewalls of
the fabric mattress cover.
5. The mattress of claim 2, further comprising a layer of foam
disposed between the mattress blocks and a surface of the fabric
mattress cover.
6. The mattress of claim 1, wherein each of the mattress blocks is
adapted to be compressed to a compact condition upon sealing the
mattress block in a compressible, air evacuable container and
evacuating air from the air evacuable container.
7. The mattress of claim 1, wherein each of the resilient coils of
each of the mattress blocks is individually wrapped in a
compressible material.
8. The mattress of claim 1, wherein the fabric mattress cover is
machine washable.
9. A method of packaging a mattress, comprising: selecting a fabric
mattress cover having a top layer, a bottom layer, and at least one
sidewall separating the top and bottom layers, the fabric mattress
cover including a selectively securable seam; selecting a plurality
of mattress blocks, each of the mattress blocks including an array
of resilient coils, the array of coils being enclosed in a mattress
block covering material, and the plurality of mattress blocks
configurable to occupy an interior of the fabric mattress cover;
securing at least the plurality of mattress blocks in a
compressible, air evacuable container; and evacuating air from the
air evacuable container, thereby compressing the mattress
blocks.
10. The method of claim 9, further comprising securing the fabric
mattress cover in the air evacuable container with the plurality of
mattress blocks prior to evacuating air from the air evacuable
container.
11. The method of claim 9, further comprising selecting a foam pad
to be disposed in the interior of the fabric mattress cover between
the plurality of mattress blocks and one of the top and bottom
layers of the fabric mattress cover.
12. The method of claim 11, further comprising securing the foam
pad in the air evacuable container with the plurality of mattress
blocks prior to evacuating air from the air evacuable
container.
13. The method of claim 9, further comprising identifying a
mattress size, and wherein, in selecting the fabric mattress cover,
selecting the fabric mattress cover to have dimensions
corresponding to the identified mattress size.
14. The method of claim 9, further comprising identifying at least
one characteristic of a portion of the mattress and wherein, in
selecting the mattress blocks, at least one of the selected
mattress blocks provides the identified characteristic.
15. The method of claim 14, wherein the identified characteristic
is stiffness.
16. The method of claim 14, wherein in selecting the mattress
blocks, the at least one mattress block providing the selected
characteristic includes distinguishing indicia on an exterior of
the mattress block covering material, the indicia indicating that
mattress block provides the selected characteristic.
17. The method of claim 9, further comprising identifying a desired
stiffness of at least a portion of the mattress, and in selecting
at least one of the fabric mattress cover, the mattress blocks, and
the foam pad, the combined stiffness of the selected fabric
mattress cover, the mattress blocks, and the foam pad provides the
desired stiffness.
18. A method of assembling a mattress, comprising: opening a fabric
mattress cover having a bottom layer, a top layer, at least one
side wall separating the bottom and top layers, and a selectively
securable seam; arranging a plurality of mattress blocks in the
fabric mattress cover, each of the mattress blocks including an
array of resilient coils, the array of coils being enclosed in a
mattress block covering material; and securing the selectively
securable seam.
19. The method of claim 18, further comprising, prior to securing
the selectively sealable seam, inserting a foam pad between the
plurality of mattress blocks and one of the layers of the fabric
mattress cover.
20. A method of ordering, packaging, and distributing mattresses,
comprising: providing an interface between a customer and a
mattress distributor; identifying a mattress size; selecting a
fabric mattress cover having a top layer, a bottom layer, and at
least one sidewall separating the top and bottom layers, the fabric
mattress cover including a selectively securable seam, and having
dimensions corresponding to the identified mattress size; selecting
a plurality of mattress blocks from a mattress block supply, each
of the selected mattress blocks including an array of resilient
coils, the array of coils being enclosed in a mattress block
covering material, and the plurality of selected mattress blocks
configurable to occupy an interior of the selected fabric mattress
cover; enclosing at least the plurality of selected mattress blocks
in a compressible, air evacuable container; evacuating the air from
the air evacuable container, thereby compressing the selected
mattress blocks; and inserting the fabric mattress cover and the
compressed air evacuable container having the compressed mattress
blocks therein into a shipping container.
21. The method of claim 20, further comprising identifying a
plurality of additional mattress characteristics selected from the
group of firmness of at least a portion of a mattress, fabric
mattress cover exterior color, fabric mattress cover exterior
pattern, and foam pad type, and wherein in selecting the fabric
mattress cover and plurality of mattress blocks, the selected
fabric mattress cover and selected mattress blocks correspond to
the identified characteristic.
22. A modular mattress system, comprising: a fabric mattress cover
having a top layer, a bottom layer, and at least one sidewall
separating the top and bottom layers, the fabric mattress cover
including a selectively securable seam; a plurality of mattress
blocks arranged in the fabric mattress cover, each of said mattress
blocks including an array of resilient coils, the array of coils
being enclosed in a mattress block covering material; and a foam
pad disposed between the plurality of mattress blocks and one of
the top and bottom layers of the fabric mattress cover.
23. The modular mattress system of claim 22, wherein the stiffness
of the fabric mattress cover, the stiffness of at least one of the
plurality of mattress blocks, and the stiffness of the foam pad are
selectable, whereby the modular mattress system has a selectable
resulting stiffness.
Description
FIELD OF THE DISCLOSURE
[0001] This disclosure relates generally to mattresses and, more
specifically, to a modular mattress system designed for ease of
manufacturing and shipping by the manufacturer, and for ease of
feature selection, handling and assembly or installation by the
consumer.
BACKGROUND OF THE DISCLOSURE
[0002] In the retail mattress market, there are various ways in
which a consumer may purchase a mattress and box spring set,
referred to hereafter as a mattress set. A mattress set may be
purchased, for example, by visiting a retail store, by placing a
telephone order to a retailer, or by placing an order over an
internet website. In each of these purchasing instances, the
specific size of the mattress set, and possibly the firmness of the
mattress set and the type of padding layer covering the mattress,
may be specified by the consumer. If the mattress set is being
delivered to and assembled at the consumer's living space, then
additional fees may be charged for such services. These may be flat
fees or may vary based on, e.g., the size of the mattress set being
delivered and distance from the warehouse to the consumer's living
space.
[0003] The mattress industry promotes certain standard bed sizes,
as follows: Crib size is 28 inches wide by 52 inches long; Twin
size is 38 inches by 75 inches; Full ("Double") size is 53 inches
by 75 inches; Queen size is 60 inches by 80 inches; King size is 76
inches by 80 inches; and California King size is 72 inches by 84
inches. Mattress firmness may typically be specified as soft,
medium, or firm, with other firmness options available depending
upon the manufacturer. Along with industry-standard regular
mattress padding layers, manufacturers may also offer other options
such as a "pillow top" surface consisting of a two to
four-inch-thick cushion of soft material, or a "memory foam"
surface designed to minimize stress that a mattress will exert upon
the sleeper's body.
[0004] For mattress sets ordered via the internet, the consumer may
specify the size, firmness, and padding layer covering the mattress
by choosing these features using their computer in a
point-and-click manner with their mouse devices. Other features,
such as fabric pattern, frame type, etc., may be available for the
consumer to choose as well. Additionally, the consumer may need to
input other information such as the address to which the mattress
set will be delivered, payment information, and other delivery and
assembly particulars (e.g., major intersections, acceptable
delivery times, stairway configurations, elevator dimensions, or
other potential physical obstacles for delivery personnel to
consider).
[0005] Following mattress set specification and an online purchase
transaction, the mattress set may then be shipped from the
website's local warehouse via truck to the consumer's house and
assembled by the delivery crew. Each component of the mattress set,
i.e., a mattress and a box spring, is typically wrapped in a
plastic sheathing, which will be removed by the delivery crew upon
installation. The disposal of the consumer's old mattress set is
often subject to the purchase agreement. Some companies may offer
to discard the old mattress sets (for a disposal fee or free of
charge) or move them to another location within the customer's
living space. Other times, the consumer may be expected to dispose
of their old set.
[0006] For mattress sets purchased via telephone, typically only
the specific size and possibly the firmness of the mattress and
style of the mattress padding layer may be specified by the
consumer. These purchases usually occur on the local level, where
consumers call either a local telephone number or perhaps a
toll-free number and a local company delivers and assembles the
mattress set.
[0007] For those mattress sets purchased directly (in person) from
a retailer, the specific size, the firmness of the mattress set,
and the style of the mattress padding layer may be specified by the
consumer. The consumer interacts with the sales staff to determine
exactly which features are important to him or her in order to make
an informed decision, and at the time of purchase, arrangements are
typically made for home delivery and assembly.
[0008] Consumers who purchase mattress sets hope to get many years
of service out of them. In order to prolong the useable life of a
mattress, the industry suggests rotating and flipping the mattress
on a regular basis. This is done to promote reasonable wear
patterns since most mattresses are manufactured using series of
tightly grouped coil springs. These springs can fatigue or develop
a "memory" if they are subject to the same bodily forces on a
regular basis, as may occur from a consumer sleeping in the same
position each night. The bigger the mattress set, the more
difficult it becomes for the consumer to flip the mattress. For
many mattress sets larger than twin size, it can be difficult, if
not impossible, for one person (particularly an elderly person) to
flip the mattress. In many instances, consumers will forego this
industry-recommended flipping procedure and thus may reduce the
useable life of their mattress. Continued use of a mattress past
its useful life frequently leads to discomfort, poor sleep, and
back problems.
[0009] When a mattress set is installed in a consumer's living
space, that may be the last time that the consumer has help
available to handle their mattress set. The consumer may be
incapable of moving the mattress in order to flip it, to clean
under the bed, or to rearrange the layout of their living
space.
[0010] Over its useable life, the fabric cover of a mattress may
also become stained or otherwise contaminated and may need to be
cleaned. Since mattresses are rather thick and soft, they have a
tendency to absorb any applied cleaning solution. This absorption
may make difficult the thorough drying of the surface of the
mattress. Stain removers are also not very effective. Machine
washing or dry cleaning of just the fabric cover of a mattress
would be preferable, but is not possible with a conventional
mattress, as the fabric cover is not removable. The manner in which
these and other shortcomings of conventional mattresses are
overcome is described in the following Summary of the Disclosure
and Detailed Description of the Preferred Embodiments.
SUMMARY OF THE DISCLOSURE
[0011] A modular mattress system is disclosed in which the spring
structure of a typical marketplace coil spring mattress is divided
into segments of grouped coil springs, hereafter referenced as
mattress blocks, that may be tightly compressed, shipped to a
consumer via common delivery channels in packaging that can be
received by a consumer, brought into their living space, and easily
assembled by the consumer without assistance. The modular mattress
system of the present disclosure, when assembled, has the same
external appearance as a conventional mattress and offers a premium
sleep surface comparable or superior to most conventional coil
spring mattresses.
[0012] A modular mattress system includes mattress blocks that have
the same vertical cross-sectional appearance as that of a standard
coil spring mattress. Each mattress block includes a plurality of
rows and columns of resilient coil springs, which coil springs may
or may not be individually wrapped. The rectangular array of
springs is contained in a thin shell which shell may, by way of
example only, be a woven or non-woven fabric. Mattress blocks may
be manufactured in various sizes that, when assembled together and
secured in an appropriate fabric cover with a selected layering of
foam material above the mattress blocks, create a standard size
mattress such as a Twin size mattress, Queen size mattress, or
other size mattress.
[0013] Due to their coil spring structure and thin shell, all the
mattress blocks necessary for assembly of a mattress of a given
standard size may be compressed, such as in an air evacuable
storage bag or similar packaging material using, for example, an
industrial vacuum cleaner.
[0014] A fabric mattress cover may be provided with each modular
mattress system. This fabric mattress cover may include two fabric
layers (one top and one bottom) with each layer having the same
length and width as that of the associated final mattress size.
These mattress cover pieces may be joined together with other
fabric to cover the sides of the final mattress configuration. A
selectively securable seam, such as a zipper, may be provided
preferably along three sides of the bottom layer of the mattress
cover in order to allow access to the interior of the fabric
mattress cover for insertion or removal of the mattress blocks. It
is recognized that other securement means, such as Velcro.TM.
hook-and-loop fasteners, snaps, or buttons, may alternatively be
used to provide a selectively securable seam to open or close the
fabric mattress cover. For assembly, mattress blocks are arranged
in an open mattress cover. During assembly by the consumer, the
mattress cover is preferably upside down, with the top layer spread
out on the floor or box spring. If desired, one or more foam (or
similar) layers of padding is supplied to cover the arranged
mattress blocks. Once the internal structure of the mattress system
is arranged according to the consumer's final desired
configuration, the mattress cover is closed and the mattress is
ready to be turned right side up, with the selectively securable
seam concealed from sight.
[0015] Mattress blocks may be provided in various degrees of
firmness, including but not limited to soft, medium, and hard. In a
coil spring mattress, the stiffness of the coils is a significant
factor in determining the final firmness experienced by the
consumer. The stiffer the coils, the firmer the mattress will feel
to the consumer. The firmness of mattress blocks employed in a
mattress of the present disclosure may be specified by the
consumer, and indicia and/or color coding of the exterior of the
mattress blocks may be used to differentiate mattress blocks of
different firmness. Though each individual mattress block will be
of uniform firmness throughout the entire block, blocks of
different firmness may be assembled together in the final mattress
configuration to achieve a mattress having regions of varying
firmness. For example, the consumer may choose a different firmness
for the mattress block supporting the back than for the mattress
block supporting the head, or for different sides of the mattress,
so sleepers having different stiffness preferences can share the
same mattress while satisfying their individual, distinct mattress
support preferences.
[0016] The firmness of the modular mattress system at any point, as
felt by the consumer, is a combination of the firmness of not only
the mattress blocks, but also of the firmness of its other
components. Thus, foam pad firmness and fabric mattress cover
firmness may also factor into the overall firmness of the modular
mattress system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a mattress block, including
an array of resilient coil springs;
[0018] FIG. 2 is a top plan view of a mattress block, partially cut
away, exposing an array of resilient coil springs;
[0019] FIG. 3 is a side cut away view of a mattress block, exposing
a plurality of resilient coil springs;
[0020] FIG. 4 is a side cut away view of a single resilient coil
spring and its cloth wrapping;
[0021] FIG. 5 is a perspective view of an open fabric mattress
cover and its selectively securable seam;
[0022] FIG. 6 is a perspective view of a foam pad of a modular
mattress system of the present disclosure;
[0023] FIG. 7 is a perspective view of a plurality of mattress
blocks of a modular mattress system of the present disclosure;
[0024] FIG. 8 is a perspective view of a foam pad and a plurality
of mattress blocks, as installed in an unsecured fabric mattress
cover;
[0025] FIG. 9 is a perspective view of an underside of a modular
mattress system, showing a bottom layer of the fabric mattress
cover of FIG. 8 after securement of the bottom layer of the fabric
mattress cover over the plurality of mattress blocks;
[0026] FIG. 10 is a perspective view of a modular mattress system,
as set into its final assembled position, with a selectively
securable seam of the fabric mattress cover hidden underneath;
[0027] FIG. 11 is a perspective view of a fabric mattress cover
with its selectively securable seam unsecured, and its bottom layer
displayed in the foreground;
[0028] FIG. 12 is a perspective view of a foam pad;
[0029] FIG. 13 is a perspective view of a plurality of mattress
blocks;
[0030] FIG. 14 is a perspective view of a foam pad and a plurality
of mattress blocks, as placed directly on the exposed bottom layer
of the unsecured fabric mattress cover of FIG. 11;
[0031] FIG. 15 is a perspective view of the modular mattress system
shown in FIG. 14, after securement of the selectively securable
seam of the fabric mattress cover;
[0032] FIG. 16 is a comparative illustration of the standard
mattress sizes (in inches) produced for the retail mattress
industry;
[0033] FIG. 17 is a top plan view of a modular mattress system;
with fabric mattress cover, foam pad, and mattress block covering
material cut away, exposing arrays of resilient coil springs of
each mattress block;
[0034] FIG. 18 is a top plan view of a modular mattress system;
with fabric mattress cover, foam pad, and mattress block covering
material cut away, exposing arrays of resilient coil springs of
each mattress block arranged in a different configuration from the
configuration of mattress blocks shown in FIG. 17;
[0035] FIG. 19 is a perspective view, partially cut away, of a
plurality of mattress blocks, as installed in an unsecured fabric
mattress cover, exposing a single coil spring within one of the
mattress blocks, and portion of a foam pad;
[0036] FIG. 20 is a perspective view of an open fabric mattress
cover;
[0037] FIG. 21 is a perspective view of a washer and;
[0038] FIG. 22 is a flowchart of a process of the present
disclosure for ordering, packaging, and distributing a modular
mattress system;
[0039] FIG. 23 is a perspective View of a plurality of mattress
blocks, a foam pad, and a fabric mattress cover for a modular
mattress system of the present disclosure;
[0040] FIG. 24 is a perspective view of a plurality of mattress
blocks, a foam pad, and a fabric mattress cover, as gathered
together in preparation for compressing and shipping;
[0041] FIG. 25 is a perspective view of the plurality of mattress
blocks, the foam pad, and the fabric mattress cover of FIG. 24, in
a stacked arrangement, along with an air evacuable bag large enough
to enclose these modular mattress system components;
[0042] FIG. 26 is a perspective view of the stacked plurality of
mattress blocks, foam pad, and fabric mattress cover enclosed
within the air evacuable bag of FIG. 25, with the air evacuable bag
being attached to an industrial vacuum cleaner;
[0043] FIG. 27 is perspective view of a compressed plurality of
mattress blocks, foam pad, and fabric mattress cover enclosed
within an air evacuable bag, from which air has been removed by an
industrial vacuum cleaner; and
[0044] FIG. 28 is a flowchart of a possible life cycle of a modular
mattress system of the present disclosure in which components of
the modular mattress system are compressed within an air evacuable
bag and shipped from a manufacturer to a consumer, and after the
useful life of the modular mattress system, the components are
recompressed into the air evacuable bag for disposal in the trash,
facilitating transportation and minimizing the space ultimately
occupied by the modular mattress system in a landfill.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] Having reference to the drawings, where like reference
numbers comprise like elements, there is shown in FIG. 1 and FIG. 2
a mattress block, generally denoted by reference number 10. The
mattress block 10 includes a covering material 12 which encloses an
array of resilient coil springs 14, with each coil spring 14
preferably surrounded by a compressible cloth wrapping 16. FIG. 3
shows a cross-sectional view of the mattress block 10, including an
array of coil springs 14, each surrounded by a cloth wrapping 16,
all enclosed within covering material 12. FIG. 4 shows a
cross-sectional view of a typical coil spring 14 surrounded by its
cloth wrapping 16.
[0046] Each coil spring 14, with its cloth wrapping 16, is designed
to move independently of any other coil spring 14. The coil springs
14 are tightly packed adjacent to one another within covering
material 12 such that no gap or crease is felt between rows or
columns of the coil springs 14. For any given size of mattress
block 10, the smaller the diameter of each coil spring 14, the more
coil springs 14 may be packed into the mattress block 10.
Generally, in mattress design, the more springs that can be
inserted into a given size mattress, the better that mattress may
be in conforming to the body shape of the sleeper. The same holds
true for the mattress block 10 design of the present
disclosure.
[0047] FIGS. 5-10 show an embodiment of a modular mattress system
22 of the disclosure, which may include a fabric mattress cover 24,
a foam pad 28, and a plurality of mattress blocks 10. FIG. 5 shows
a fabric mattress cover 24 which may include a top layer 24A, a
bottom layer 24B, and at least one sidewall 24C. A selectively
securable seam 26, such as a zipper, is provided along the
intersection of the bottom layer 24B and at least one sidewall 24C
of the fabric mattress cover 24, in order to allow access to its
interior space for inserting and removing mattress blocks 10 (see
FIG. 2C). FIG. 6 shows a foam pad 28 which may be inserted into the
open fabric mattress cover 24 of FIG. 5 to create the first layer
of padding experienced by the consumer, which may lie underneath
the top layer 24A of the fabric mattress cover 24.
[0048] The second layer of the mattress interior, within the fabric
mattress cover 24, may be created by a plurality of mattress blocks
10, as shown in FIGS. 7 and 8. FIG. 8 shows both the foam pad 28
and the mattress blocks 10 installed in an open fabric mattress
cover 24. FIG. 9 shows the fabric mattress cover 24 secured in the
closed position (enclosing the foam pad 28 and the mattress blocks
10) through the use of the selectively securable seam 26. Upon
securement of the selectively securable seam 26, the modular
mattress system 22 may be flipped over as shown in FIG. 2F, such
that the selectively securable seam 26 is hidden from view,
underneath the modular mattress system 22, as shown in FIG. 2G.
[0049] Advantageously, not only is there no gap or crease felt
between rows or columns of the coil springs 14 of a given mattress
block 10, but because the covering material 12 is sufficiently
thin, no gap or crease is created or felt between adjacent mattress
blocks 10. The only way a person lying on the mattress of the
modular mattress system 22 might feel that the mattress includes
different mattress blocks 10 would be in situations where mattress
blocks 10 of different firmness are arranged in the modular
mattress system 22, as described below.
[0050] FIGS. 11-15 show an alternative way in which a modular
mattress system 22 may be assembled, without the need to flip the
mattress over upon completion of assembly. FIG. 11 shows an open
fabric mattress cover 24. FIG. 12 and FIG. 13 show the insertable
components, a foam pad 28 and mattress blocks 10, respectively.
FIG. 14 shows the mattress blocks 10 abutting the top layer 24A of
the fabric mattress cover 24, and the foam pad 28 abutting the
mattress blocks 10. Also visible is the selectively securable seam
26. FIG. 15 shows the modular mattress system 22, after the fabric
mattress cover 24 has been pulled downward over the foam pad 28 and
the mattress blocks 10 (see FIG. 3D) and secured with the
selectively securable seam 26. This selectively securable seam 26
is hidden away from view along the edge of the bottom layer 24B of
the fabric mattress cover 24 of the modular mattress system 22.
[0051] FIG. 16 shows a comparison of the relative sizes of
mattresses which the mattress industry promotes as standard.
Mattress sizes 29 range from a Crib size of 28 inches wide by 52
inches on the small end to a King size of 76 inches wide by 80
inches long. The main component of the modular mattress system 22
of this disclosure is the mattress block 10. Mattress blocks 10 may
be combined within the modular mattress system 22 in order to
create the standard sizes as shown in FIG. 4, as well as other
non-standard mattress sizes, as necessary. Certain standard
mattress sizes 29 may be replicated using a plurality of mattress
blocks 10 of the same size or of varying sizes. The number of
mattress blocks 10 needed and their size may best be determined by
the manufacturer, in order to balance the comfort of the sleeper
with the cost or ease of manufacturing and supplying the mattress
blocks 10, for example.
[0052] A consumer may purchase a conventional coil spring mattress
with a given firmness, such as soft or firm, that is uniform
throughout the mattress. The firmness is typically consistent
across the entire mattress, from the area where a consumer's head
would rest down through the area where their feet would rest.
However, a consumer may purchase a modular mattress system 22 of
the present disclosure, in which they advantageously may specify
variable firmness levels of mattress blocks 10, and/or foam pad 28
layers.
[0053] FIGS. 17 and 18 show a top view of mattress blocks 30, 32,
34, 36, 38, 40, 42, 44 positioned in a modular mattress system 22.
Any foam pad 28 that may have been covering the mattress blocks 30,
32, 34, 36, 38, 40, 42, 44 has been removed, along with the fabric
mattress cover 24. FIG. 17 shows a modular mattress system 22 in
which mattress blocks 30, 32, 34, 36 are each made of an array of
coil springs 14 having a first stiffness, corresponding, for
instance, to a desired firmness. Also shown are mattress blocks 38,
40, 42, 44, each made of an array of coil springs 14 having a
second stiffness, for example, to provide relatively less support.
Correspondingly, the consumer who sleeps on this modular mattress
system 22 may have a different firmness supporting their head and
back as compared to the firmness supporting the lower portion of
their body.
[0054] Similarly, FIG. 18 shows a modular mattress system 22 in
which mattress blocks 30, 32, 34, 36 are each made of an array of
coil springs 14 having a first stiffness, corresponding, for
instance, to a desired firmness. Also shown are mattress blocks 38,
40, 42, 44, each made of an array of coil springs 14 having a
second stiffness, for example, to provide relatively less support.
Thus, the person who sleeps on the left side (as viewed from above)
of this modular mattress system 22 may have one consistent firmness
(more firm) supporting their entire body as compared to the person
who sleeps on the right side, who will have a different firmness
(less firm) supporting their entire body.
[0055] Another way in which the firmness of the sleeping surface of
the modular mattress system 22 may be varied is in the selection of
the foam pad 28 that may be used to cover the mattress blocks 10.
Consumers may specify that foam pads 28 of different uniform
firmness be included in the modular mattress system 22 that they
purchase. For example, a consumer may specify that all of the
mattress blocks 10 used in their modular mattress system 22 be of
the same firmness, but that they be given two foam pads 28 with
their order. One foam pad 28 may satisfy the firmness requirement
of the person who sleeps on the right side of the bed and covers
the mattress blocks 10 that support that person; and another foam
pad 28 may satisfy the firmness requirement of a second person who
sleeps on the left side of the bed and covers their supporting
mattress blocks 10.
[0056] The firmness felt by a person at any given point on the
surface of the modular mattress system 22 is primarily a
combination of the stiffness of the foam pad 28 at that point,
along with the stiffness of the mattress block 10 and the stiffness
of the fabric mattress cover 24 at that point, given by the
equation:
1/k.sub.foam pad+1/k.sub.mattress block+1/k.sub.fabric mattress
cover=1/k.sub.total
[0057] In this equation, the constant "k" represents the stiffness
of the foam pad 28, the mattress block 10, the fabric mattress
cover 24, or the total, i.e. combined, stiffness. Therefore, the
firmness felt by the consumer at any point on the modular mattress
system 22 may be achieved by varying the firmness of the foam pad
28, by varying the firmness of the mattress blocks 10, by varying
the firmness of the fabric mattress cover 24, or by varying some
combination of these components 28, 10, 24. For example, a desired
firmness for the area that supports a person's head may be achieved
through the use of a "firm" mattress block(s) 10 and a "soft" foam
pad 28, or similarly, by using a "soft" mattress block 10 along
with a "firm" foam pad 28 covering it. Similar firmnesses may be
achieved in different ways. Manufacturers could use this principle
to help them balance their inventories of foam pads 28, mattress
blocks 10, and fabric mattress covers 24, as modular mattress
systems 22 are specified and ordered by consumers.
[0058] Consumers may be offered the option to order modular
mattress system 22 components, such as mattress blocks 10, foam
pads 28, and fabric mattress covers 24, as replacement parts for
components that they may have been damaged, destroyed or lost. The
purchase of replacement component parts has not been practical for
damaged conventional coil spring mattresses, so they are often
discarded in their entirety, and new mattress sets purchased. With
the modular mattress system 22 of the present disclosure, consumers
may also be given an opportunity to purchase replacement parts such
as foam pads 28 or individual mattress blocks 10 if they desire to
change the firmness of their modular mattress system 22, for
example, if they are pregnant or suffered a particular bodily
injury such that they would benefit from a change in the firmness
of a portion of their mattress.
[0059] An important procedure for extending the life of a
conventional inner coil spring mattress is the industry-recommended
act of turning the mattress over at manufacturer-recommended
intervals. In other words, flipping the mattress every six months,
for example, may minimize the development of wear patterns in the
array of resilient coil springs 14. For the modular mattress system
22 of the present disclosure, this procedure may be simplified.
There may be no more struggling on the part of an individual
consumer to lift and turn over their one-piece mattress. Since the
modular mattress system 22 includes a plurality of mattress blocks
10 of separate arrays of coil springs 14, when flipping of the
mattress is desired, the consumer need only open the selectively
securable seam 26 of the fabric mattress cover 24, remove, flip,
and replace each individual mattress block 10, then re-secure the
selectively securable seam 26.
[0060] As seen again in FIGS. 17 and 18, all mattress blocks 30,
32, 34, 36, 38, 40, 42, 44 are exposed upon opening of the fabric
mattress cover 24 and any extra layers of foam pad 28. The consumer
then simply flips each mattress block 30, 32, 34, 36, 38, 40, 42,
44 over and then reassembles the fabric mattress cover 24 and any
layers of foam pad 28 that were temporarily removed to gain access
to the mattress blocks 30, 32, 34, 36, 38, 40, 42, 44.
[0061] As an aid to the consumer, as well as manufacturing and
warehouse personnel, each mattress block 10 may display a label,
tag, or some other sort of indicia which identifies characteristics
such as firmness, size, date of manufacture, country of origin,
etc. Also present may be information regarding the
manufacturer-recommended procedure for flipping the mattress blocks
10 at certain intervals. Similar information may be displayed on
other modular mattress system 22 components such as foam pads 28
and fabric mattress covers 24.
[0062] Another important feature which distinguishes the modular
mattress system 22 disclosed herein from a conventional mattress is
shown in FIGS. 19-22. FIG. 19 shows the modular mattress system 22
with the selectively securable seam 26 of its fabric mattress cover
24 unsecured, exposing a plurality of mattress blocks 10. FIG. 20
shows the fabric mattress cover 24 alone, after the mattress blocks
10 and any foam pad 28 have been removed. As represented in FIG.
21, a consumer may place this fabric mattress cover 24 directly
into a residential or commercial washer 25 and dryer 27, for
cleaning and drying purposes. The fabric mattress cover 24 is
designed to withstand repeated cleaning and drying cycles. In order
for a consumer to clean and dry a conventional mattress, a cleaning
solution would need to be applied to the mattress and the
subsequent wet area would need to be either air dried or, perhaps,
fan dried. This procedure may be considered tedious, especially for
an entire mattress. The ability for this fabric mattress cover 24
to be so easily removed from the mattress system 22 so as to be
independently cleaned and dried may be considered especially
desirable for incontinent individuals, those who provide assistance
to them, and parents of children who are bedwetters.
[0063] Turning to FIG. 22, various methods of specifying, ordering,
and distributing a modular mattress system 22 are also within the
scope of the present disclosure. A consumer may specify and order a
modular mattress system 22 by going to a retail store 60, placing a
telephone call 62, or by using the internet 64. In all cases, the
consumer may choose among such modular mattress system 22
characteristics as size, firmness of individual mattress blocks 10,
fabric mattress cover 24 exterior color, fabric mattress cover 24
exterior pattern, type of foam pad 28 used over or under the
mattress blocks 10, type of selectively securable seam 26 used in
securing the fabric mattress cover 24, etc. At the same time the
consumer may specify such delivery details as the method of
delivery and the timeframe. When ordering a conventional coil
spring mattress, consumers may be able to choose only a few
characteristics such as size, overall firmness, type of foam
padding used for the mattress and the delivery details. Regarding a
conventional mattress set delivery, the consumer may also be
concerned with the extra step of having delivery personnel come
into their residence and assemble the mattress set, whereas with
the mattress system 22 of the present disclosure, with its
comparatively easy assembly, no such extra step is required.
[0064] FIG. 22 is a flow-chart diagram of a ordering, packaging,
and distributing a modular mattress system 22. A consumer may order
their new modular mattress system 22 via a retail store 60, the
telephone 62, or the internet 64. In each case, the consumer's
order may be entered into an order processing computer or CPU 66,
which may forward information regarding the components necessary to
build the specific modular mattress system 22 ordered, to the
appropriate warehouse personnel for fulfillment. The order picker
68 may then obtain the warehouse stocked components necessary to
fulfill the specified order. Each of these stocked components may
be stored in different but convenient supplies, such as a mattress
block supply 70, a mattress pad supply 72, and a fabric mattress
cover supply 74. When all components have been gathered together,
personnel may take an appropriately-sized air evacuable bag 78 and
place the components into this bag 78. They may then proceed to use
an industrial vacuum source 78 to remove air from the bag 78 in
order to compress the contents into a shippable size. It will be
appreciated that all or part of the order-taking, packaging, and
distributing process may be automated, such as by use of conveyor
or robotic technology.
[0065] Individual components of the modular mattress system 22,
such as mattress blocks 10, foam pads 28, and fabric mattress
covers 24, occupy less volume than complete coil spring mattress
sets and are considerably lighter in weight as well. The compact
size of the components of the modular mattress system 22 should be
beneficial in reducing the number of personnel, and the size and
complexity of the storage and handling equipment needed along the
entire supply chain, as compared to that of the conventional coil
spring mattress. Fewer manufacturing personnel, warehouse
personnel, retail stocking personnel, and delivery personnel, along
with the need for less rugged, and thus cheaper, storage and
handling equipment may increase the profit margins for those
companies along the modular mattress system 22 supply chain.
[0066] Since modular mattress systems 22 may require fewer and less
expensive resources to stock, handle, and ship them, as compared to
the resources needed for conventional coil spring mattress sets,
more companies may be interested in selling modular mattress
systems 22. These companies may include those specializing in
internet sales 60, retail stores 62, and catalog merchandisers
specializing in telephone sales 64.
[0067] Since the modular mattress system 22 may include mattress
blocks 10 of arrays of resilient coil springs 14, along with a
fabric mattress cover 24 and a foam pad 28, all of these components
are compressible when surrounded by an appropriately-sized air
evacuable bag 78 and air is removed from the bag 78. The bulky
nature of a conventional coil spring mattress precludes this method
of vacuum packaging for ease of shipping. As indicated in FIG. 22,
after air is removed from the air evacuable bag 78 and the contents
are compressed, the bag 78 may then be placed into an
appropriately-sized shipping container 80, such as a cardboard box.
This box may then be sealed, staged for shipment, and then shipped
to the consumer via selected delivery channels. Since the shipping
container 80 may be of a manageable size and weight, the consumer
is able without assistance to receive the shipment, bring the
shipping container 80 into his or her residence, and unpack the air
evacuable bag 78. The consumer may then proceed to open the air
evacuable bag 78 according to the instructions enclosed. When the
air evacuable bag 78 is opened, the compressed contents of the bag
78 will expand back to their original specifications, and will be
ready for assembly into the modular mattress system 22. Even when
expanded, the mattress blocks 10 and other components of the
mattress system 22 are sufficiently small and manageable for the
individual to move the mattress to any desired location before
assembly, avoiding the problems associated with negotiating
conventional mattresses through corridors, around tight corners, up
or down stairways, or into elevators with low ceilings.
[0068] For retail store 60 transactions, consumers may opt to
purchase a modular mattress system 22 and transport it home by
themselves. To transport a conventional coil spring mattress set
typically requires at least two people to place the mattress set
into a vehicle large enough to contain it, or in many instances, to
secure the mattress set on top of the vehicle, exposing the
mattress to outside elements. The bulkiness of the mattress set,
whether inside or on top of the vehicle, may obstruct the mirrors
and windows of the driver, and may distract the attention of the
driver or other drivers, thus increasing risks while driving. Since
a modular mattress system 22 includes components which individually
occupy much less volume than complete conventional coil spring
mattress sets, and are correspondingly lighter in weight; the
average consumer, without assistance, may be able to pack the
components of the modular mattress system 22 into their vehicle in
a safe configuration, and transport them home without incident. The
mattress systems of the present disclosure occupy so little space
when compressed for transport that a number of the mattress systems
22 may be transported inside a single compact size vehicle.
[0069] The vacuum packaging procedure for the components of a
sample modular mattress system 22 is shown in FIGS. 23-27. FIG. 23
shows the components as a plurality of mattress blocks 10, along
with a fabric mattress cover 24, and a foam pad 28. FIG. 24 shows
these components 10, 24, 28 gathered together and then reoriented
(see FIG. 25) into a vertical stacked arrangement, with the
appropriately-sized air evacuable bag 78 to enclose them located
adjacently. FIG. 26 shows the vertically stacked components 10, 24,
28 enclosed within the air evacuable bag 78, with this air
evacuable bag 78 attached to an industrial vacuum source 79. FIG.
27 shows the air evacuable bag 78 after air has been removed from
it, and it has been disconnected from the vacuum source 78, with
its contents compressed into a shippable size. Within this air
evacuable bag 78 is the compressed modular mattress system 22,
which is ready to place into a shipping container 80 and ship 82 to
the consumer 84.
[0070] FIG. 28 represents a potential life cycle for the modular
mattress system 22 as vacuum packaged in an air evacuable bag 78.
For this particular sample modular mattress system 22, it may be
shipped from the manufacturer 86 to the storage warehouse 88 in an
air evacuable bag 78, and stored in the warehouse 88 in that
manner. It may then be pulled from the shelves of the warehouse 88
and shipped to a consumer 90. The consumer 90 may unpack, assemble,
and use the modular mattress system 22 at their residence for its
useful lifespan, and then the consumer 90 may disassemble the
mattress into its components and place the components back into the
air evacuable bag 78 in which they originally came (or obtain a
replacement air evacuable bag 78 if the original has been damaged,
disposed of, or misplaced). The consumer 90 may evacuate the air
within the air evacuable bag 78 once more (with their own vacuum
cleaner) and place the air evacuable bag 78 into the trash 92. The
air evacuable bag 78 containing the compressed modular mattress
system 22 may then be delivered to the landfill 94, advantageously
occupying substantially less space than a conventional
mattress.
[0071] While various embodiments of modular mattress systems 22
have been described herein, it is recognized that this disclosure
is not limited to these embodiments. Variations may be made thereto
which are still within the scope of the appended claims.
* * * * *