U.S. patent application number 11/789256 was filed with the patent office on 2008-10-30 for flame-resistant mattress rejuvenator.
This patent application is currently assigned to Zinus Inc.. Invention is credited to Youn Jae Lee.
Application Number | 20080263774 11/789256 |
Document ID | / |
Family ID | 39885261 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080263774 |
Kind Code |
A1 |
Lee; Youn Jae |
October 30, 2008 |
Flame-resistant mattress rejuvenator
Abstract
A mattress add-on is placed on top of an existing mattress and
provides a rejuvenated fire-safe mattress. The mattress add-on has
a flame-resistant covering that fits tightly over the sides of the
existing mattress and also has flaps to cover the bottom of the
existing mattress. The mattress add-on in combination with the
flame-resistant covering is an inexpensive means of providing both
more comfort as well as fire protection safety to consumers who
retain their existing mattresses. The mattress add-on does not slip
on the existing mattress because it is held tightly in place by
tightening the flame-resistant covering using straps across the
bottom of the existing mattress. The mattress add-on is customized
to a user's physical profile by using zones of foam having
different densities. In addition, the mattress add-on may include
metal coils or air chambers.
Inventors: |
Lee; Youn Jae; (Pleasanton,
CA) |
Correspondence
Address: |
IMPERIUM PATENT WORKS
P.O. BOX 587
SUNOL
CA
94586
US
|
Assignee: |
Zinus Inc.
|
Family ID: |
39885261 |
Appl. No.: |
11/789256 |
Filed: |
April 24, 2007 |
Current U.S.
Class: |
5/691 ; 5/690;
5/698; 5/716 |
Current CPC
Class: |
A47C 31/001 20130101;
A47C 31/105 20130101 |
Class at
Publication: |
5/691 ; 5/698;
5/690; 5/716 |
International
Class: |
A47C 31/00 20060101
A47C031/00; A47C 27/00 20060101 A47C027/00; A47G 9/00 20060101
A47G009/00 |
Claims
1. A method comprising: placing a mattress add-on on a top surface
of an existing mattress, wherein the existing mattress has a bottom
surface, four side surfaces and the top surface, and wherein the
mattress add-on has a flame-resistant covering; and covering the
bottom surface and the four side surfaces of the existing mattress
with the flame-resistant covering.
2. The method of claim 1, wherein the mattress add-on has a lower
surface, further comprising: tightening the flame-resistant
covering on the bottom surface of the existing mattress such that
the lower surface of the mattress add-on does not slip on the top
surface of the existing mattress.
3. The method of claim 2, wherein the tightening is performed using
straps attached to the flame-resistant covering.
4. The method of claim 1, wherein the mattress add-on has two
layers of foam.
5. The method of claim 4, wherein one of the layers of foam is made
of memory foam.
6. The method of claim 1, wherein the mattress add-on includes
metal coils.
7. An apparatus comprising: a mattress add-on, wherein the mattress
add-on is adapted to lie on a top surface of an existing mattress,
wherein the existing mattress has the top surface, a bottom surface
and four side surfaces; and a flame-resistant covering attached to
the mattress add-on, wherein the mattress add-on has an upper
surface and four add-on side surfaces, and wherein the
flame-resistant covering is adapted to cover the upper surface, the
four add-on side surfaces, the four side surfaces of the existing
mattress and the bottom surface of the existing mattress.
8. The apparatus of claim 7, further comprising: straps attached to
the flame-resistant covering, wherein the straps are adapted to
tighten the flame-resistant covering at the bottom surface of the
existing mattress such that the flame-resistant covering holds the
mattress add-on firmly to the existing mattress.
9. The apparatus of claim 7, wherein the flame-resistant covering
includes bottom flaps, and wherein the bottom flaps are adapted to
fold over the bottom surface of the existing mattress such that
every portion of the bottom surface of the existing mattress is
covered by the flame-resistant covering.
10. The apparatus of claim 7, wherein the mattress add-on includes
metal coils.
11. The apparatus of claim 7, wherein each of the metal coils is
made of a separate piece of metal.
12. The apparatus of claim 10, wherein each of the metal coils in
enclosed in a separate fabric pocket.
13-14. (canceled)
15. The apparatus of claim 13, wherein the mattress add-on has two
layers of foam.
16. An apparatus comprising: a mattress add-on, wherein the
mattress add-on is adapted to lie on a top surface of an existing
mattress, wherein the existing mattress has the top surface, a
bottom surface and four side surfaces, wherein the mattress add-on
includes metal coils; and a covering attached to the mattress
add-on, wherein the mattress add-on has an upper surface and four
add-on side surfaces, and wherein the covering is adapted to cover
the upper surface, the four add-on side surfaces, the four side
surfaces of the existing mattress and the bottom surface of the
existing mattress.
17. The apparatus of claim 16, wherein each of the metal coils in
enclosed in a separate fabric pocket.
18. The apparatus of claim 16, wherein the mattress add-on includes
a layer of memory foam above the metal coils.
19. An apparatus comprising: an existing mattress; a mattress
add-on that lies on a top surface of the existing mattress, wherein
the existing mattress has a bottom surface, four side surfaces and
the top surface; and means for rendering each of the top surface,
the bottom surface and the four side surfaces of the existing
mattress flame resistant, wherein the means covers the mattress
add-on and the existing mattress.
20. The apparatus of claim 19, wherein the means is made of a
fire-barrier fabric.
21. The apparatus of claim 19, wherein the existing mattress is not
flame resistant.
22. The apparatus of claim 19, wherein the mattress add-on includes
metal coils.
23. The apparatus of claim 19, wherein the mattress add-on includes
a layer of memory foam.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to mattresses, and
more particularly to a method of rejuvenating an existing mattress
and rendering the existing mattress flame resistant.
BACKGROUND
[0002] New types and forms of mattresses and mattress accessories
continue to be developed for traditional bedroom use, as well as
for such diverse uses as camping, boating and recreational vehicle
traveling. Where developments continue to emerge, consumers may
expect to spend considerable sums to upgrade their mattresses and
to benefit from those developments. Not all consumers, however,
have the means to spend thousands of dollars on their beds.
[0003] Memory foam was originally developed for NASA in the 1970's.
Since the early 1990's, memory foam has been used in commercially
available mattresses. Mattresses that include memory foam, however,
can be more expensive than mattresses made of other types of foam.
Mattress toppers that include memory foam have allowed consumers to
enjoy many of the benefits of memory-foam mattresses without having
to purchase entirely new mattresses. However, while memory-foam
mattress toppers do provide some ability for consumers to upgrade,
these mattress toppers are not without their attendant
drawbacks.
[0004] One such drawback is the limited ability of some foam
products to breathe. As may be appreciated, foam mattresses are
typically produced from polymeric compounds. For example, memory
foam is made from polyurethane with additional chemicals that add
to its viscosity. And in contrast to regular polyurethane foam,
memory foam has more open cells that allow air to pass to adjoining
cells, for example, when a person lies down on a memory foam
mattress. Sleeping on polymeric compounds, however, is not unlike
sleeping on a plastic tarp. Users of foam mattresses may complain
that their sleep is impaired due to excessive moisture accumulation
as a result of sleeping on a non-breathable mattress.
[0005] In some instances, a simple cover made of terry cloth or
some other natural fiber weave may be implemented to address those
concerns. A simple cover may still not, however, allow sufficient
ventilation to achieve a cool sleep environment. The simple cover
may not absorb all of the perspiration that accumulates during the
hot sleeping period. Moreover, a simple cover may not hold the
mattress topper in place on the existing mattress. Thus, the
mattress topper may skew inside the cover leaving uncomfortable and
unsightly wrinkles. Finally, conventional mattress toppers are not
generally customized to a user's particular physical profile. Some
air mattresses, for example, can be customized by selecting the air
pressure that is pumped into various air chambers. Foam mattress
toppers, however, may lack this ability to be customized, leaving a
user only to select a best average foam density for the topper.
[0006] Although a consumer obtains some of the benefits of a
memory-foam mattress without having to purchase an entirely new
mattress by purchasing a memory-foam mattress topper, the consumer
nevertheless retains at least one significant disadvantage of his
existing mattress, namely its vulnerability to catching on fire. A
newly purchased mattress is likely to be flame resistant. Simply
placing a new mattress topper over an existing mattress does not
provide the fire protection that a new mattress provides.
[0007] Thus, a method is sought for upgrading an existing mattress
and avoiding having to purchase an entirely new mattress, but yet
obtaining the fire-protection benefits associated with a new
mattress. In addition, a method is sought for avoiding the poor
ventilation characteristics of a conventional memory-foam mattress
topper.
SUMMARY
[0008] The following presents a simplified summary of some
embodiments of the invention and is not intended to delineate the
scope of the invention. This summary presents some embodiments in a
simplified form as a prelude to the more detailed description that
is presented below.
[0009] A mattress add-on with a flame-resistant covering is placed
on top of an existing mattress and provides a rejuvenated fire-safe
mattress. The flame-resistant covering of the mattress add-on has a
skirt that fits tightly over the sides of the existing mattress. In
addition, the flame-resistant covering has flaps that cover the
bottom of the existing mattress.
[0010] By purchasing the mattress add-on with the flame-resistant
covering, a consumer can rejuvenate his existing mattress and
obtain many of the benefits of a more-expensive memory foam
mattress. As an added benefit, the consumer obtains fire protection
and renders his existing mattress flame resistant by enclosing all
surfaces of the existing mattress inside the flame-resistant
covering of the mattress add-on.
[0011] Comfort is improved and unsightly wrinkles are avoided by
holding the mattress add-on tightly in place over the existing
mattress. The mattress add-on does not slip on the existing
mattress because it is held in place by tightening the
flame-resistant covering using straps across the bottom of the
existing mattress. In addition, the lower surface of the mattress
add-on is made of slip-resistant fabric.
[0012] The mattress add-on may include metal coils or air chambers
to conform to a user's physical profile. Holding the mattress
add-on firmly in place is an added benefit where the mattress
add-on is an air mattress or a spring mattress. The mattress add-on
can also be customized to a user's physical profile by using zones
of foam having different densities. For example, a zone with foam
having one firmness may be arranged to accommodate the user's head
and torso, while another zone with foam having a different firmness
may be arranged to accommodate the user's legs.
[0013] Other embodiments and advantages are described in the
detailed description below. This summary does not purport to define
the invention. The invention is defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings, where like numerals indicate like
components, illustrate embodiments of the invention.
[0015] FIG. 1 is an illustration of a mattress add-on lying on an
existing mattress, wherein both are covered by a flame-resistant
covering.
[0016] FIG. 2 is a cross-sectional view of the mattress add-on, the
existing mattress and the flame-resistant covering of FIG. 1.
[0017] FIG. 3 is a bottom view of the existing mattress and flame
resistant covering of FIG. 1.
[0018] FIG. 4 is a perspective view of an embodiment of the
mattress add-on of FIG. 1 that includes metal coils.
[0019] FIG. 5 is a perspective view of an embodiment of the
mattress add-on of FIG. 1 that includes multiple layers, wherein
the flame-resistant covering gives the appearance that the mattress
add-on and the existing mattress are once piece.
[0020] FIG. 6 is a perspective view of an embodiment of the
mattress add-on of FIG. 1 that includes multiple layers and that
has a "box-top" appearance on top of the existing mattress.
[0021] FIGS. 7A-D are diagrams of foam layers of mattress add-ons
that have different foam densities in various zones in order to
conform to a user's physical profile.
DETAILED DESCRIPTION
[0022] Reference will now be made in detail to some embodiments of
the invention, examples of which are illustrated in the
accompanying drawings.
[0023] FIG. 1 is an illustration of a mattress add-on 10 lying on
top of an existing mattress 11. Mattress add-on 10 is removably
attached to existing mattress 11, thus allowing a user easily to
upgrade a legacy mattress. Mattress add-on 10 can be placed atop
almost any kind of existing mattress, such as an air mattress, a
coil mattress or a foam mattress without departing from the present
invention. Both mattress add-on 10 and existing mattress 11 are
covered by a flame-resistant covering 12. Flame-resistant covering
12 is attached to mattress add-on 10 at the seams along the edges
of mattress add-on 10. Flame-resistant covering 12 is also attached
to mattress add-on 10 by stitching sewn in a quilting pattern on
the upper surface 13 of mattress add-on 10. The quilting binds
flame-resistant covering 12 to underlying material in mattress
add-on 10, such as batting. Quilting tends to add stability to
coverings and may reduced shifting between coverings and underlying
materials. Selected quilting patterns may contribute to increased
comfort and aesthetic appeal for a user. Any number of quilting
patterns and densities may be utilized without departing from the
present invention. The portion of flame-resistant covering 12 that
covers upper surface 13 of mattress add-on 10 may be composed of a
fabric such as cotton, linen, wool, silk or nylon, depending on
user requirements.
[0024] Flame-resistant covering 12 also hangs down over the sides
of existing mattress 11 and covers the bottom surface of existing
mattress 11 as well. Flame-resistant covering 12 fits tightly over
existing mattress 11 and holds mattress add-on 10 firmly in place.
The lower surface 14 of mattress add-on 10 is prevented from
slipping over the top surface 15 of existing mattress 11 by a
rougher lower surface material of mattress add-on 10 and by the
tension provided by flame-resistant covering 12.
[0025] Mattress add-on 10 may be configured in accordance with any
number of shapes including, but not limited to: a rectangular
shape, a square shape, an ovate shape, a circular shape, and a
free-form shape without departing front the present invention.
Still further, mattress add-on 10 configured in a rectangular shape
may be configured in any number of sizes including, but not limited
to: twin size, full size, queen size, king size, and California
king size, without departing from the present invention.
[0026] FIG. 2 shows a cross-sectional view of mattress add-on 10
lying atop existing mattress 11, with both being covered by
flame-resistant covering 12. In the embodiment of FIG. 2, mattress
add-on 10 includes multiple layers. Mattress add-on 10 has an
underlying layer 16, a core layer 17 made of memory foam, and a
topper layer 18. Underlying layer 16 is made of regular
polyurethane foam and may be formed in any number of shapes and
sizes. Underlying layer 16 provides a first cushioning interface of
mattress add-on 10.
[0027] Memory foam core layer 17 provides a second cushioning
interface of mattress add-on 10 and is sized to conform to
underlying layer 16. The memory foam of core layer 17 has a density
selected for an individual user. For example, high density memory
foam corresponding to a "hard" feel may be selected. Alternatively,
low density memory foam corresponding to a "soft" feel may be
selected. In addition, memory foam core layer 17 is configured to
have a number of zones, each zone having a particular density. In
the embodiment of FIG. 2, memory foam core layer 17 has an egg
crate pattern on its bottom surface. Utilizing an egg crate pattern
on at least one surface provides a softer "feel" normally
associated with low density foam even when higher density foam is
used that is inherently more stable. Although core layer 17 is
illustrated in FIG. 2 as having an egg crate pattern on its bottom
surface, in other embodiments an egg crate pattern may also be
configured on the top surface, or on both the top and bottom
surfaces.
[0028] Topper layer 18 provides a fibrous padding layer for
mattress add-on 10. As noted above, foam mattresses are typically
produced from polymeric compounds. Sleeping on these polymeric
compounds is not unlike sleeping on a plastic tarp. Users of foam
mattresses may complain that their sleep is impaired due to
excessive moisture accumulation as a result of sleeping on a
non-breathable mattress. In some instances, a simple cover made of
terry cloth or some other natural fiber weave may be implemented to
address those concerns. However, a simple cover may still not
provide sufficient breathability to achieve a comfortable sleep
environment because the absorbing ability of a simple cover may not
match a sleeper's expiration of water through sweat during a
sleeping period. In addition, a simple cover may not sufficiently
hold an underlying core layer in place. A foam mattress topper
inside a simple cover may skew cover leaving uncomfortable and
unsightly wrinkles. Thus, topper layer 18 contributes to the
stability of mattress add-on 10.
[0029] Flame-resistant covering 12 tightly encases underlying layer
16, core layer 17 and a topper layer 18 and prevents the three
layers from slipping over each other. The reduction in slippage
adds to the user's comfort. Flame-resistant covering 12 may be made
of one or more fabric materials. For example, flame-resistant
covering 12 may be made of cotton, linen, wool, silk, nylon, an
acrylic or other synthetic fabric that is impregnated with a fire
retardant compound such as, but not limited to, boric acid
(H.sub.3BO.sub.3), zinc borate, antimony trioxide
(Sb.sub.2O.sub.3), vinylidene chloride, decabromodiphenyl oxide
(DBDPO or Deca), Melamine or PVDC. Alternatively, flame-resistant
covering 12 is made of a flame-retardant fabric such as, but not
limited to, a fabric made of para-aramid fibers. In the embodiment
of FIG. 2, topper layer 18 is attached to flame-resistant covering
12 by quilting stitching. In other embodiments, flame-resistant
covering 12 is stitched to a layer of batting on top of topper
layer 18. In addition, lower surface 14 of mattress add-on 10 is
prevented from slipping over top surface 15 of existing mattress 11
by flame-resistant covering 12, which is bound around the bottom of
existing mattress 11 by straps. Moreover, lower surface 14 of
mattress add-on 10 may be composed of a slip-resistant fabric to
provide additional stability of mattress add-on 10 over existing
mattress 11.
[0030] In some embodiments, topper layer 18 comprises a fibrous
woven padding. Materials selected for topper layers include natural
fibers and synthetic fibers. Topper layer 18 also includes a fire
retardant compound. By placing a fibrous layer over a foam core, a
breathable layer is created, which may increase comfort for a user.
Topper layer 18 also provides structural support for underlying
memory foam core layer 17.
[0031] Flame-resistant covering 12 hangs down over the sides of
existing mattress 11 and holds mattress add-on 10 firmly in place.
An elastic band 19 around the bottom of flame-resistant covering 12
holds the sides of flame-resistant covering 12 tight around the
four side surfaces of existing mattress 11. In addition, straps at
the bottom of flame-resistant covering 12 also hold the covering
tight. Finally, bottom flaps 20 and 21 of flame-resistant covering
12 cover all portions of the bottom surface of existing mattress 11
that are not covered by the skirt of flame-resistant covering
12.
[0032] FIG. 3A shows a bottom view of existing mattress 11 in which
elastic band 19 pulls the sides of flame-resistant covering 12
tight around the four side surfaces of existing mattress 11. For
additional tightening, straps 22 with fasteners 23 are used to
tighten flame-resistant covering 12 on the bottom surface of
existing mattress 11 such that lower surface 14 of mattress add-on
10 does not slip on top surface 15 of existing mattress 11.
Although two straps 22 are used to tighten flame-resistant covering
12 over each side surface of existing mattress 11, more straps can
also be used. In one embodiment, straps 22 are made of elastic
bands. Fasteners 23 can be snap type fasteners or belt-buckle type
fasteners. Alternatively, a hook and loop fastener may be used with
a strip of hook material on one strap and a strip of loop material
on the associated strap. FIG. 3A also shows bottom flaps 20 and 21
in a rolled-up position in which the bottom surface of existing
mattress 11 is not completely covered by flame-resistant covering
12.
[0033] FIG. 3B shows a bottom view of existing mattress 11 in which
in which bottom flaps 20 and 21 of flame-resistant covering 12 are
rolled out over the bottom surface of existing mattress 11. Hook
and loop fasteners 24 attach bottom flap 20 to bottom flap 21 and
attach both flaps to the skirt of flame-resistant covering 12. In
FIG. 3B, the bottom surface of existing mattress 11 is completely
covered by flame-resistant covering 12.
[0034] Completely covering all six sides of existing mattress 11
with flame-resistant covering 12 renders the rejuvenated existing
mattress flame-resistant. Federal regulations will soon require all
new mattresses that are sold in the United States to pass an
open-flame standard. For example, new flammability standards are
prescribed for mattresses under 16 C.F.R. .sctn. 1633. A consumer
who avoids the cost of a new mattress and simply places a new
mattress topper over an existing mattress will not benefit from the
new fire-protection safety regulations. Placing mattress add-on 10
over existing mattress 11 and covering all sides of the mattress
add-on and existing mattress with flame-resistant covering 12
rejuvenates the existing mattress and creates a new open
flame-resistant mattress combination. Because the bottom surface of
existing mattress 11 is also covered by flame-resistant covering
12, an open flame on the outside of a fire-resistant covering on a
side of flame-resistant covering 12 will not ignite the bottom of
existing mattress 11 in an open-flame test performed pursuant to 16
C.F.R. .sctn. 1633. Thus, mattress add-on 10 in combination with
flame-resistant covering 12 is an inexpensive means of providing
both more comfort as well as fire protection safety to consumers
who retain their existing mattresses.
[0035] FIG. 4 is an illustration of a mattress add-on 25 that
includes metal coils 26. Each of the metal coils 26 is made of a
separate piece of metal instead of one wire being bent to form
multiple metal coils. Each of the metal coils 26 is enclosed in a
separate fabric pocket 27. Fiber padding may be inserted into each
fabric pocket 27 inside of each metal coil 26. Mattress add-on 25
has a bottom layer 28 that supports the metal coils 26. Bottom
layer 28 is made of rigid polyurethane foam. Mattress add-on 25
includes filler material 29 on top of the metal coils 26. Filler
material 29 is quilted to flame-resistant covering 12. Filler
material 29 can be visco-elastic foam, high density (HD) foam or
fiber padding. Where existing mattress 11 is a coil mattress, it is
rejuvenated with mattress add-on 25 to yield a coil-on-coil
mattress combination. By tightening the covering with straps 22,
mattress add-on 25 with metal coils 26 is held firmly in place over
existing mattress 11.
[0036] FIG. 5 is an illustration of a mattress add-on 30 that
includes multiple layers. Mattress add-on 30 includes a bottom
layer 31, a middle layer 32 and a top layer 33. Bottom layer 31
provides support for the other layers and is made of HD foam.
Middle layer 32 is made of fiber padding or foam. Top layer 33
includes memory foam as well as filling material used for quilting
to upper surface 13 of mattress add-on 30. Flame-resistant covering
12 covers mattress add-on 30 and attaches mattress add-on 30 to
existing mattress 11. The border of flame-resistant covering 12
around the sides of existing mattress 11 is formed to disguise the
presence of mattress add-on 30. The seams on flame-resistant
covering 12 give the appearance that mattress add-on 30 and
existing mattress 11 are one piece. To give this appearance, the
border of flame-resistant covering 12 covering the sides of
existing mattress 11 may be quilted. The foam layers of mattress
add-on 30 are customized by providing different foam
characteristics to different sections of the layers, as described
in further detail below.
[0037] FIG. 6 is an illustration of a mattress add-on 34 that
includes multiple layers of foam. The layers of mattress add-on 34
are thicker than the layers of mattress add-on 30, and mattress
add-on 34 lies on top of existing mattress 11 in a "box-top"
configuration. The border of flame-resistant covering 12 around the
sides of existing mattress 11 has seams that accentuate the
presence of mattress add-on 34. The seams on flame-resistant
covering 12 give a "box-top" appearance to mattress add-on 34 and
existing mattress 11. Mattress add-on 34 includes a bottom layer
35, a middle layer 36 and a top layer 37. Bottom layer 35 provides
support for the other layers and is made of rigid HD foam. Middle
layer 36 is made of memory foam. Top layer 37 may include memory
foam, HD foam or fiber padding that is quilted to upper surface 13
of mattress add-on 30. Flame-resistant covering 12 covers mattress
add-on 34 and attaches mattress add-on 34 to existing mattress 11.
As for the layers of mattress add-on 30, the layers of mattress
add-on 34 are also customized by providing different foam
characteristics to different zones of the layers.
[0038] FIG. 7A shows a representative foam layer 38 of mattress
add-on 10, 30 or 34 in which different zones of the layer have foam
with different qualities, such as density, firmness and softness.
For example, layer 38 represents core layer 17, top layer 33 or
middle layer 36. Layer 38 has multiple zones, each zone having a
corresponding density. In the embodiment of FIG. 7A, layer 38 is
transversely bisected along axis 39 to define zone 1 (40) having a
first density and zone 2 (41) having a second density. By utilizing
separate zones and densities, a more comfortable mattress add-on
may be configured. Thus, for example, zone 1 (40) may be arranged
to accommodate the head and torso of a user while zone 2 (41) may
be arranged to accommodate the legs of a user. As illustrated,
zones 1 (40) and 2 (41) are disposed on either side of axis 39. A
user may select a foam density that more accurately conforms to the
user's physical profile. For example, zone 1 (40) may be composed
of high density foam, while zone 2 (41) may be composed of lower
density foam than in zone 1 (40). At least one reason for utilizing
various zones is to enhance a user's particular needs. In this
example, zone 1 (40) may carry more weight from combined head and
torso of a user, thus requiring high density foam to achieve
adequate cushioning. Zone 2 (41) may carry less weight from legs
and thus require lower density foam with respect to zone 1 (40). In
other embodiments, zone 1 (40) is configured with lower density
foam compared to zone 2 (41). In still other embodiments, foam
density is approximately equivalent across zones 1 (40) and 2 (41).
The zones of core layer 17, for example, may be bonded together
using any conventional means.
[0039] FIG. 7B illustrates another embodiment of a foam layer 42 of
mattress add-on 10, 30 or 34 in which different zones of the layer
have foam with different qualities. Layer 42 is transversely
bisected along axis 43 and medially bisected along axis 44 to
accommodate custom configurations for two users. Thus, zone 1A (45)
may have a first density; zone 1B (46) may have a second density;
zone 2A (47) may have a third density; and zone 2B (48) may have a
fourth density. The densities for each zone are selected in
accordance with user preferences.
[0040] FIG. 7C illustrates yet another embodiment of a foam layer
49 of mattress add-on 10, 30 or 34 in which different zones of the
layer have foam with different qualities. Layer 49 is transversely
trisected along axes 50 and 51 to define zone 1 (52) having a first
density, zone 2 (53) having a second density, and zone 3 (54)
having a third density. By utilizing separate zones and densities,
a more comfortable mattress add-on may be configured. Thus, for
example, zone 1 (52) may be arranged to accommodate the head of a
user; zone 2 (53) may be arranged to accommodate the torso of a
user; and zone 3 (54) may be arranged to accommodate the legs of a
user. In the embodiment of FIG. 7C, axis 50 defines approximately
one sixth of foam layer 49, while axis 51 defines approximately one
half of layer 49. Zones 1 (52) and 2 (53) are disposed on either
side of axis 50, whereas zones 2 (53) and 3 (54) are disposed on
either side of axis 51.
[0041] A user may select a foam density for each zone that more
accurately conforms to the user's physical profile. Zone 2 (53) may
be composed of high density foam, while zone 1 (52) or 3 (54) may
be composed of lower or higher density foam with respect to zone 2
(53). Zone 2 (53) may carry more weight from the torso of a user,
thus requiring high density foam to achieve adequate cushioning.
Zones 1 (52) and 3 (54) may carry less weight from head and legs,
thus requiring lower density foam with respect to zone 2 (53). In
another embodiment, zone 2 (53) may be configured with lower
density foam with respect to zones 1 (52) and 3 (54). In yet
another embodiment, foam density is approximately equivalent across
zones 1 (52), 2 (53) and 3 (54).
[0042] FIG. 7D illustrates another embodiment of a foam layer 55 of
mattress add-on 10, 30 or 34 that allows for still more custom
configuration. Layer 55 is transversely trisected along axes 56 and
57 and medially bisected along axis 58 to accommodate custom
configurations for at least two users. In one embodiment, axis 56
defines approximately a one-sixth portion of layer 55, while axis
57 defines approximately half of layer 55. Thus, zone 1A (59) may
have a first density; zone 1B (60) may have a second density; zone
2A (61) may have a third density; zone 2B (62) may have a fourth
density; zone 3A (63) may have a fifth density; and zone 3B (64)
may have a sixth density. As above, the densities of each zone may
be selected in accordance with user preferences, and the zones of
foam layer 55 may be bonded together using any conventional
means.
[0043] Although certain specific exemplary embodiments are
described above in order to illustrate the invention, the invention
is not limited to the specific embodiments. For example, core layer
17, top layer 33 and middle layer 36 have been described as being
foam layers having different densities in different zones.
Different firmness in different sections of a mattress add-on can
also be achieved, however, by using air bladders that are inflated
to different pressures. In some embodiments, core layer 17, top
layer 33 and middle layer 36 contain multiple air chambers, each
having selectable air pressure that allow a user to customize his
mattress add-on to accommodate his weight, height and sleep
position. A higher air pressure in a section of the layer provides
firmer support in that section. Where the mattress add-on includes
air chambers, tightening flame-resistant covering 12 using the
straps 22 holds the air mattress add-on firmly in place over
existing mattress 11. Accordingly, various modifications,
adaptations, and combinations of various features of the described
embodiments can be practiced without departing from the scope of
the invention as set forth in the claims.
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