U.S. patent application number 11/880952 was filed with the patent office on 2009-01-29 for systems and methods for hinged bedding assemblies.
This patent application is currently assigned to Dreamwell, Ltd.. Invention is credited to Scott H. Smalling, Jack J. Squires.
Application Number | 20090025150 11/880952 |
Document ID | / |
Family ID | 39816615 |
Filed Date | 2009-01-29 |
United States Patent
Application |
20090025150 |
Kind Code |
A1 |
Smalling; Scott H. ; et
al. |
January 29, 2009 |
Systems and methods for hinged bedding assemblies
Abstract
In many aspects, the systems and methods described herein
include mattress having a top sleeping layer disposed on top of a
support layer. The support layer includes polyurethane foam having
channels comprising one or more slits on both sides of a surface to
act as hinges for articulation. The channels may be aligned with
the joints of the articulated sections of the foundation or frame
of the adjustable bedding assembly. When the sections articulate
about the joints, the channels allow the overlying top layer to
conform to the sections while reducing wear and tear therein.
Inventors: |
Smalling; Scott H.; (Roy,
WA) ; Squires; Jack J.; (Gig Harbor, WA) |
Correspondence
Address: |
ROPES & GRAY LLP
PATENT DOCKETING 39/41, ONE INTERNATIONAL PLACE
BOSTON
MA
02110-2624
US
|
Assignee: |
Dreamwell, Ltd.
Las Vegas
NV
|
Family ID: |
39816615 |
Appl. No.: |
11/880952 |
Filed: |
July 24, 2007 |
Current U.S.
Class: |
5/718 ;
5/740 |
Current CPC
Class: |
A47C 27/064 20130101;
A47C 23/005 20130101; A47C 27/144 20130101; A47C 27/20 20130101;
A47C 27/15 20130101; A47C 27/146 20130101 |
Class at
Publication: |
5/718 ;
5/740 |
International
Class: |
A47C 23/04 20060101
A47C023/04 |
Claims
1. A mattress, comprising a top layer, and a support foam layer
disposed below the top layer, having a top surface, a bottom
surface, a first side wall, a second side wall, wherein the support
foam layer includes a first channel extending from the first side
wall to the second side wall along the bottom surface, and a second
channel extending from the first side wall to the second side wall
along the top surface.
2. The mattress of claim 1, further comprising a third layer
disposed between the support foam layer and the top layer.
3. The mattress of claim 1, further comprising a plurality of
layers disposed between the support foam layer and the top
layer.
4. The mattress of claim 3, wherein at least one of the layers
includes at least one of foam or springs.
5. The mattress of claim 3, wherein a layer includes a spring layer
having foam disposed in between a plurality of coil springs.
6. The mattress of claim 5, wherein the spring layer comprises
wrapped coil spring.
7. The mattress of claim 3, wherein at least one of the layers and
support foam layer includes at least one of polyurethane, latex,
and visco foam.
8. The mattress of claim 1, wherein at least one of the first
channel and the second channel comprise a plurality of parallel
slits.
9. The mattress of claim 8, wherein the plurality of slits are
parallel to each other, spaced apart by about 1/3 inch to about 1/2
inch.
10. The mattress of claim 1, wherein at least one of the first
channel and the second channel has a width that allows for
consistent firmness in the top layer.
11. The mattress of claim 10, wherein at least one of the first
channel and the second channel is about 1/3 inch to about 3/4 inch
wide.
12. The mattress of claim 1, wherein at least one of the first
channel and the second channel has a depth that extends partially
into the thickness of the support foam layer.
13. The mattress of claim 12, wherein the depth of at least one of
the first and the second channel extends about 1/3 to about 1/2 of
the thickness of the support foam layer.
14. The mattress of claim 8, wherein at least one of the first
channel and the second channel comprises a plurality of parallel
slits having a depth that extends partially into the thickness of
the support foam layer.
15. The mattress of claim 14, wherein the depth of the parallel
slits are the same as or different from each other.
16. The mattress of claim 12, wherein the depth of at least one of
the first channel and second channel extends perpendicular from the
bottom and top surface, respectively, of the support foam
layer.
17. The mattress in claim 1, wherein the channel is sufficiently
deep to allow flexing and reduce mechanical stress on the point of
articulation of the mattress.
18. The mattress in claim 1, wherein the support foam layer is
sufficiently rigid/firm to accommodate the load of the top layers.
Description
FIELD OF THE INVENTION
[0001] This invention relates to mattresses and mattress assemblies
for adjustable beds, and more generally, assemblies for adjustable
furniture.
BACKGROUND OF THE INVENTION
[0002] Adjustable bed constructions typically include a mattress
placed on top of a rigid foundation having articulating arms that
move the entire mattress or portions thereof. The foundation
includes a plurality of sections that may be adjusted relative to
one another such that mattresses that are disposed on the
foundation, bend and conform with the articulated sections of the
rigid foundation to provide comfort or therapy as needed. However,
repeated bending and articulation of the mattresses near the joints
of the articulated sections often cause wear and tear and reduce
the lifespan of the mattresses.
[0003] For example, in conventional innerspring mattresses, springs
distort near the joints and at the edges from bending. Conventional
innerspring mattresses include stabilizing and reinforcing
structures such as sturdy border wires along top and bottom edges
to prevent sagging and increase lifespan. These stabilizing and
reinforcing structures make the mattress uniformly resilient in the
direction required to support the horizontal body. However, these
structures resist bending as required on an articulated bed.
Consequently, such stabilizing and reinforcing structures are
limited in their use in articulated beds. As a result, articulated
mattresses of the prior art may have a shorter useful life and do
not provide the uniform body support necessary for this
application.
[0004] Conventional foam mattresses that are currently being used
in adjustable bed constructions, also suffer from the similar
drawbacks. In particular, foam mattresses are typically disposed on
top of the rigid articulated foundation and experience significant
wear and tear near the joints that compromise the integrity of the
foam structure and reduce its lifespan. In addition, since the
mattresses are artificially forced to bend along the joints of the
foundation, they tend to not fully conform with the articulated
sections. Consequently, portions of the foam mattress, when
articulated, may be raised or lowered unevenly or slide out of
position.
[0005] Accordingly, there is a need for an improved mattress
construction that can be used in an articulated bed.
SUMMARY OF THE INVENTION
[0006] The systems and methods described herein are directed to
mattresses and mattress assemblies for adjustable beds, and more
generally, articles for adjustable furniture. For purposes of
clarity, and not by way of limitation, the systems and methods may
be described herein in the context of providing mattresses for
adjustable bedding assemblies. However, it may be understood that
the systems and methods described herein may be applied to provide
for any cushioning article associated with any type of adjustable
furniture. For example, the systems and methods of the invention
may be used to provide futon mattresses, seat cushions, including
automotive seat cushions, sofa cushions, pillows and other such
cushions and supports.
[0007] More particularly, the mattresses described herein include a
top layer disposed on top of a support layer of polyurethane foam
having channels including one or more slits on both sides of its
surface to act as hinges for articulation. The channels may be
aligned with the joints of the articulated sections of the
foundation or frame of the adjustable bedding assembly. When the
foundation sections articulate about the joints, the channels allow
the mattress to conform to the sections while reducing wear and
tear therein. The channels are beneficial in that they help
minimize tearing near the bending regions.
[0008] In one aspect, the mattress of the present invention
comprises a top layer, and a support foam layer disposed below the
top layer. The support foam layer has a top surface, a bottom
surface, a first side wall, and a second side wall. Also, the
support layer includes a first channel extending from the first
side wall to the second side wall along the bottom surface, and a
second channel extending from the first side wall to the second
side wall along the top surface. In certain embodiments, the
mattress includes a third layer disposed between the support foam
layer and the top layer, and may further include a plurality of
layers disposed between the support foam layer and the top layer,
wherein at least one of the layers includes at least one of foam or
springs. In addition, the top layer and/or at least one of the
plurality of layers may include a spring layer having foam disposed
in between a plurality of coil springs, wherein the spring layer
comprises wrapped coil spring. Furthermore, the top layer and/or at
least one of the plurality of layers and support foam layer
includes at least one of polyurethane, latex, and visco foam.
[0009] As described above, the support foam layer of the mattress
of the present invention includes a first channel and a second
channel. In certain embodiments, the support foam layer includes
more than two channels. Additionally, at least one of the first
channel and the second channel has a depth that extends partially
into the thickness of the support foam layer, extending about 1/15
to about 13/15 of the thickness of the support foam layer. The
first channel and the second channel may have a depth from about
1/10 to 7/10 of the thickness of the support foam layer, or about
1/4 to about 1/2 of the thickness of the support foam layer. The
depth of at least one of the first channel and second channel
extends perpendicular from the bottom and top surface,
respectively, of the support foam layer. In certain embodiments,
the channel is sufficiently deep to allow flexing and to reduce
mechanical stress on the point of articulation of the mattress.
Further, at least one of the first channel and the second channel
has a width that allows for consistent firmness in the top layer,
and may be about 1/8 inch to about 1.5 inches wide. The width of
the channels may range from about 1/6 inch to about 1 inch, or
about 1/4 inch to about 1/2 inch.
[0010] In certain embodiments, at least one of the first channel
and the second channel in the support foam layer may comprise a
plurality of parallel slits, wherein the slits are spaced apart by
about 1/8 inch to about 2 inches. Alternatively, the distance
between the slits may range from about 1/6 inch to about 1.5
inches, or about 1/3 inch to about 1 inch. Likewise, the plurality
of parallel slits of at least one of the first channel and the
second channel has a depth that extends partially into the
thickness of the support foam layer, wherein the depth of each slit
is the same as or different from each other. The dimensional
requirements that lend to the functional characteristics of the
channels described above also apply to the plurality of slits of
each channel.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT
[0011] The foregoing and other objects and advantages of the
invention will be appreciated more fully from the following further
description thereof, with reference to the accompanying drawings
wherein;
[0012] FIG. 1 is a perspective view of an adjustable mattress,
according to an illustrative embodiment of the invention.
[0013] FIG. 2 illustrates an unassembled view of the mattress of
FIG. 1, according to an illustrative embodiment of the
invention.
[0014] FIG. 3 is a perspective view of the mattress in operation,
according to an illustrative embodiment of the invention.
[0015] FIGS. 4A and 4B depict a cross-section view of mattresses,
according to an illustrative embodiment of the invention.
[0016] FIG. 5 depicts a cross-section view of mattresses, according
to an illustrative embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] To provide an overall understanding of the invention,
certain illustrative embodiments will now be described, including
an articulated hinged mattress having channels in the support foam
layer. However, it will be understood by one of ordinary skill in
the art that the systems and methods described herein may be
adapted and modified for other suitable applications and that such
other additions and modifications will not depart from the scope
hereof.
[0018] In many aspects, the systems and methods described herein
provide an articulated mattress suitable for use with an adjustable
mattress foundation. The mattress described herein includes one or
more padding layers disposed on top of a support foam layer. The
top surface and the bottom surface of the support foam layer
include channels comprising one or more slits that may function as
hinges for articulation. The channels may help to reduce wear and
tear on the hinging portions of the mattress.
[0019] More particularly, FIG. 1 depicts an adjustable mattress
100, according to an illustrative embodiment of the invention.
Although the mattress 100 is depicted as having a rectangular plan,
it will be understood that the mattress may be sized and shaped as
desired without departing from the scope of the invention. The
mattress 100 includes a top layer 106 and a middle layer 104 that
are disposed on a support foam layer 102. The mattress 100 may have
standard dimensions, with a length 114, a width 108, a side 116,
and another side 118 corresponding to at least the dimensions of a
king, queen, double, or twin mattress. The support foam layer 102
includes a channel 110 formed on the bottom surface and a channel
112 formed on the top surface. The channels 110 and 112 may extend
from the sidewall 116 to the sidewall 118 in transverse direction
along the mattress 100. In an exemplary bed assembly, the mattress
100 may be disposed on top of an adjustable foundation or frame
having articulating sections. The channels 110 and 112 may be
aligned with one or more joints of the articulating sections of the
foundation. During operation, as the articulating sections of the
foundation are moved relative to one another, one or more regions
of the support foam layer 102 articulate about the channel 110
and/or channel 112, thereby allowing one or more regions of the top
layer 106 and middle layer 104 to be raised or lowered. In one
example, the channels 110 and 112 are positioned near the head and
foot regions, respectively, of the mattress. In such an example,
the head portion may be raised and the foot portion may be lowered
to bring a person from a laying down position to a sitting
position. In certain embodiments, as described further with
reference to FIG. 4A, the support foam layer 102 includes an
additional channel near the neck region to offer added head/neck
support for the user.
[0020] The support foam layer 102 may be a polyurethane foam. The
support foam layer 102 may be formed from other suitable materials
without departing from the scope of the invention. In certain
embodiments, the support foam layer 102 is formed from a material
having an IFD (or ILD) value from about 30 to about 50. The support
foam layer 102 may have a weight and/or density of about 1 lb to
about 5 lbs. In certain embodiments, the support foam layer 102 may
have a weight and/or density of greater than 2 lbs. The support
foam layer 102 may have weight, rigidity, density, and flexibility
values as desired depending on the nature of the application. In
certain embodiments, the support foam layer 102 includes
polyurethane foam having a substantially consistent and relatively
uniform density across the length and width of the layer. As noted
earlier, the support foam layer 102 includes a channel 110 formed
on the bottom surface and a channel 112 formed on the top surface.
The channels 110 and 112 may be formed by cutting, slicing or
carving portions of the support foam layer 102 as desired, or by
molding foam with channel structures. The channels 110 and 112 may
include one or more slits that allow the support foam layer to
articulate about region of the channels 110 and 112, thereby
minimizing stretching and tearing of the support foam layer 102 or
layers 104 and 106. Certain illustrative characteristics of the
channels in the support layer will be further described with
reference to FIG. 2.
[0021] In certain embodiments, the top layer 106 and/or the middle
layer 104 includes the mattress core. In such embodiments, the
mattress core includes an innerspring mattress comprising coils,
encased coils (such as POCKETED COIL.RTM. springs) or Marshall
Coils. The top layer 106 and/or the middle layer 104 may include
polyurethane materials. In certain embodiments, the top layer 106
and/or the middle layer 104 include foam, visco-elastic foam and/or
latex foam. The top layer 106 and/or the middle layer 104 may
include a combination of an innerspring mattress core combined with
foam material, as described with reference to FIG. 5.
[0022] The top layer 106 and/or the middle layer 104 may be formed
from a sheet of fabric, felt, or polymer, a cotton, nylon, or
polyester batting, or from a layer of foam, plastic, polymer,
natural fiber, synthetic fiber, or any other material or a
combination thereof. In one optional embodiment, the mattress 100
may have cover panel that comprises a non-quilted mattress cover
with an optional smooth sleeping surface. In this embodiment, a
multi-layer, typically three layer, crowned mattress panel may be
provided over the upper surface of the mattress. For example, a
crowned cover panel may be formed from a top fabric layer, an
intermediate filler layer and a backing layer. Optionally, there
may be a layer of flame retardant material or combination of
materials. In either embodiment, the top layer may be a fabric
layer of cotton, linen, synthetic fibers or some other material of
combination of materials.
[0023] The top layer 106, middle layer 104 and any additional
layers may be formed from any suitable materials without departing
from the scope of the invention. In certain embodiments, the
mattress 100 further includes one or more filler layers. The filler
layer can be formed from any padding material, such as foam, cotton
batting, gel, latex foam, visco-elastic foam or other known padding
materials and or combination of padding materials. Optionally, the
filler layer provides a layer of conventional filling and padding
material that may be laid over the mattress.
[0024] An optional fire resistant layer may be disposed in mattress
100 in between at least two of the top layer 106, middle layer 104
and support foam layer 102. The fire resistant layer optionally
extends over the at least entire upper surface of the mattress
panel and around the borders of the panel. The flame resistant
material may be any suitable material, such as for example
polyaramid material (such as KEVLAR.TM.), PET (polyester) binder
fiber, organophosphorous materials, halogenated organic materials
(typically halogenated with chlorine or more popularly bromine) or
nitrogen based compounds. Commercially available materials are sold
under the trade names NOMEX, KEVLAR.TM., INDURA and the actual
material employed may depend upon the particulars of the
application, including mattress type (e.g. open coil, encased coil,
foam, water), mattress size, material costs and other such design
considerations.
[0025] Under the fire resistant layer, a backing layer may be
attached. The backing layer may be formed from a sheet of material,
such as natural fibers such as cotton or linen, aluminum,
fiberglass, synthetic fibers or a mixture thereof. These three
layers may be joined together to form a crowned panel and that
panel may be placed over the upper surface and joined to the
mattress to provide a smooth sleeping surface. In addition, the
mattress 100 typically includes a fabric or plastic covered
structure having an internal construction configured to provide
comfort for a user resting on the surface. Finally, the mattress
100 may also include a removable cover that helps prevent allergens
on the surface.
[0026] FIG. 2 illustrates an unassembled view 200 of the mattress
100 having a top layer 106, a middle layer 104 and a support layer
102. The support layer 102 includes a top surface 224 and bottom
surface 226, and has a thickness 210 which may be about 1 inch to
about 8 inches. In certain embodiments, the support layer 102 has a
thickness from about 2 inch to about 7 inches, or about 3 inches to
about 5 inches. The first channel 110 lies at a distance 206 away
from the edge of the head region 212, and the second channel 112
lies at a distance 208 away from the edge of the foot region 214 of
the mattress 100. In one example, the first channel 110 may be from
about 25 inches to about 40 inches from the head region 212, or
about 29 inches to about 38 inches, or further, about 33 inches to
about 35 inches. Similarly, the second channel 112 may be from
about 22 inches to about 37 inches from the foot region 214, or
about 25 inches to about 34 inches, or further, about 28 inches to
about 31 inches. The distance 206 or 208 may be adjusted to suit
the dimension, mechanical, and/or functional requirements of the
mattress. For example, the distances 206 and 208 may be selected
based on whether the mattress is sized as a king, queen or twin. In
certain embodiments, these dimensions may be customized to an
individual's body size.
[0027] As shown, the first channel 110 extends from sidewall 116 to
sidewall 118 creating a slit 228 along the bottom surface 226.
Likewise, the second channel 112 extends from sidewall 116 to
sidewall 118 creating a slit 230 along the top surface 224 of the
support foam layer 102. In certain embodiments, the channels may
include a plurality of parallel slits which may also further delay
tearing, as will be described with reference to FIGS. 4A and 4B.
Further, the first channel 110 cuts into the support foam layer 102
to a height 202, and therefore depth, from the bottom surface 226.
Similarly, the second channel 112 cuts into the support foam layer
102 to a depth 220 from the top surface 224. In certain
embodiments, the depth of each slit may be about 1/15 to about
13/15 of the thickness of the support foam layer 102.
Alternatively, the range of the depth may be from about 1/10 to
7/10, or about 1/4 to about 1/2 of the thickness of the support
foam layer 102. In one example, a support layer 102 that is about 4
inches thick may have a slit ranging in depth from about 1/4 inch
to about 3.5 inches. The depths 202 and 220 may be selected as
desired to allow for the articulation of the mattress while also
maintaining the integrity of the hinge areas, especially when used
in combination with an articulating platform/foundation. Further,
the depth of each slit 202 and 220 may be the same or different for
one or more slits in either channel 110 and 112.
[0028] The channels 110 and 112 have a width 204 and 222,
respectively, and may be from about 1/8 inch to about 1.5 inches.
The width of the channels may further range from about 1/6 inch to
about 1 inch, or about 1/4 inch to about 1/2 inch. The width 204
and 222 of slits may be selected as desired to allow, among other
things, improved articulation of the mattress by minimizing soft
spots on the top layer 106 of the mattress, and improving the
integrity of the mattress. In certain embodiments, the axes along
which the slits 228 and 230 extend on the top surface 224 and the
bottom surface 226 are perpendicular with respect to the sides 116
and/or 118 of the mattress 100.
[0029] As such, the slits 228 and 230 in channels 110 and 112,
respectively, have a depth and width to allow for ease of
articulation suitable for the dimensions and material of the
mattress. Additionally, the dimensions of the depth and width of
the channels, in combination with their placement at distances 206
and 208 from the head and foot regions, respectively, may be
determined based on the application, degree and nature of the
articulation needed. Moreover, in an alternative embodiment of the
invention, the mattress is suited to offer better conformability
when used in combination with an articulated base, as will be
described with reference to FIG. 3.
[0030] Depicted in FIG. 3 is an adjustable bed assembly 400 in
operation, according to an illustrative embodiment of the
invention. The bed assembly 400 includes a mattress 100 (FIG. 1)
disposed on an adjustable foundation 401 comprising an articulating
platform having articulating sections 402, 412 and 414 connected to
a rigid base 404 via the actuating system 420 and 422. As shown,
the channels 110 and 112 open to allow, among other things,
articulation of the mattress and to reduce the mechanical stress
that results on the pressure points 408 and 410 when the mattress
is caused to articulate. The channels may also act to localize the
pressure points 408 and 410 to the joints of the articulating
sections 416 and 418, thereby minimizing unwanted tearing that may
otherwise happen in several places. Additionally, the channels may
ensure suitable flexing of the mattress to better conform with the
articulating platform. For example, this feature may be
particularly appreciated by users of different weights and sizes.
The channels encourage the full range of articulation without the
need for a heavier user's mass to conform the mattress against the
articulating sections 402, 412, 414, for example. As such, small
and large users may experience similar levels of comfort during
articulation that may be independent of their size and weight. In
certain embodiments, a rubberized material may be sprayed at the
point 408 and 410 to further retard tearing. The rubberized
material may be applied to the channels 110 and 112 at, among other
places, along the interior of the slits.
[0031] In certain embodiments, the mattress 100 may be adjusted to
other possible configurations to allow the user to choose the
position of the head and foot of the bed for maximum comfort. In an
alternative embodiment of the invention, the actuating system 420
and 422 may be programmed to an array of custom configurations.
[0032] FIGS. 4A and 4B illustrate a cross-section views of
mattresses in which the support foam layer 502 or 702 includes
channels having a plurality of parallel slits 504 and 506 or 704
and 706. Mattress 600 and 700 of FIGS. 4A and 4B may be similar to
mattress 100 of FIG. 1. Similarly, the mattress 600 or 700 includes
a top layer 106, a middle layer 104, and a support foam layer 502
or 702 comprised of foam material as described previously.
[0033] More particularly, FIG. 4A depicts the channels 504 and 506
that extend through the support foam layer 502 having a thickness
510 of about 1 inch to about 8 inches. Alternatively, the support
layer 502 may have a range of thickness, from about 1.5 inches to
about 6.5 inches, or about 2 inches to about 5 inches. As shown,
each channel includes two slits: slits 602 and 604 included in
channel 504, and slits 608 and 610 included in channel 506. The
slits included in each channel may be parallel to each other and
are separated by a distance that is measured from the inner
adjacent edges of each slit, as shown in 606 and 612. In one
example, the distance between the slits may be from about 1/8 inch
to about 2 inches. The distance between the slits may range from
about 1/6 inch to about 1.5 inches, or about 1/3 inch to about 1
inch, and may vary according to the dimensions of the mattress, and
the degree of articulation desired. Further, similar to that
described in FIG. 2, each slit of the channel has a height 614 that
is a measure of its depth into the thickness of the support foam
layer. By way of illustration, the height of only one slit 614 is
depicted. However, all slits that comprise the channels have a
height, and therefore depth, in the support foam layer 502. In
certain embodiments, the depth of each slit may or may not be the
same for all slits. Each slit may have a width which may be
determined according to the criteria described in FIG. 2.
Additionally, although two slits are illustrated for each channel
in FIG. 4A, the invention may include a plurality of slits per
channel, as shown in FIG. 4B. In certain embodiments, the support
foam layer 502 may include an additional channel 508. The channel
508, includes two parallel slits 616 and 618, and lies at the
head/neck region of the mattress. However, the placement of
additional channels is not restricted to this configuration;
instead, additional channels may be placed to suit the needs of the
user and/or the configuration of the foundation. Slit dimensions
for all channels may be selected as desired depending on at least
the criteria of the aforementioned descriptions.
[0034] By way of example, FIG. 4B depicts a mattress having three
parallel slits per channel in its support foam layer. Slits 716,
718 and 720 form channel 704 and slits 722, 724, and 726 form
channel 706. As indicated, the middle slit 718 or 724 has a height
710 or 714, respectively, and is flanked by shorter slits 716 and
720 or 722 and 726, respectively. As described previously, since
each height defines the depth of each slit into the support foam
layer, the middle slit in this example forms the deepest groove.
The slits on either side may be of the same or different depths. As
previously described, the distances between slits are designed to
be sufficiently wide to allow flexibility, while adequately narrow
to maintain the integrity of the mattress as well as to prevent
soft spots on the top layer 106. In certain embodiments, the
configuration of the multi-slit channels 704 and 706 may allow for
smaller distances between slits to minimize the likelihood of the
formation of soft spots on its top layer while maintaining the
range of motion needed for the mattress. Moreover, the added slits
may act to reduce the mechanical stress on the points of
articulation since the pressure may be distributed to several
slits.
[0035] In certain embodiments, the one or more top layers disposed
on the support foam layer may include features to ease articulation
of the mattress along the hinge channels. In one example, the top
layer may include reinforcing support structures disposed near the
region of the channels. FIG. 5 illustrates a cross section view of
a mattress 800 having a top layer 801 that includes an innerspring
construction combined with one or more layers of foam 806. In one
example, the top layer 801 is disposed on a middle foam layer 804.
Alternatively, the top layer 801 and the middle foam layer 804 may
be unitarily formed as a composite layer, disposed on top of the
support foam layer 802. The support foam layer 802 includes
channels 814 and 816 to allow articulation of the mattress 800. The
support foam layer 802 may be similar to support foam layer 102 of
FIG. 1.
[0036] The top layer 801 may include an innerspring encased coil
construction having a plurality of coils 812 that are disposed in
pockets 808 and 810. In certain embodiments, the coils 812 may be
arranged in rows along a sheet of pocket material (e.g., upholstery
or fabric). The pocket material may then be wrapped around the
coils 812 and sealed (e.g., by heat-sealing techniques) along lines
818 to seal the coils 812 in the pockets. The encased coils may be
arranged on a foam block 804, which in turn may be disposed on the
support foam layer 802.
[0037] In certain embodiments, foam blocks 806 may be disposed in
between a plurality of coil springs, and may be aligned above one
or more channels 814 and 816 on the support foam layer 802. In
certain embodiments, the encased coils may be attached to the foam
blocks 806 to provide further reinforcement. In other embodiments,
foam material is poured into the innerspring coil construction to
fill one or more gaps between the coils. In such embodiments, the
foam material may be poured in liquid or gel form and may
subsequently cure to provide an integrated foam and spring top
layer 801.
[0038] In certain embodiments, the mattress 800 includes one or
more sidewalls disposed or attached to at least one of the top
layer 801, middle layer 804 and support layer 802. The sidewalls
may include foam. In such embodiments, the sidewalls may include
one or more channels formed thereon. The channels may be configured
so as to form a contiguous channel(s) with the support foam layer.
The sidewalls may be sized, shaped and cut as desired depending on
the dimensions of the mattress. The sidewalls may or may not
include one or more channels that are aligned with the one or more
channels on the support foam layer 802. The sidewalls may or may
not include one or more channels that are not aligned with the one
or more channels on the support foam layer 802. The channels on the
sidewalls may be sized and shaped similar to the channels on the
support foam layer 802.
[0039] Variations, modifications, and other implementations of what
is described may be employed without departing from the spirit and
scope of the invention. More specifically, any of the method,
system and device features described above or incorporated by
reference may be combined with any other suitable method, system or
device features disclosed herein or incorporated by reference, and
is within the scope of the contemplated inventions. The systems and
methods may be embodied in other specific forms without departing
from the spirit or essential characteristics thereof. The foregoing
embodiments are therefore to be considered in all respects
illustrative, rather than limiting of the invention. The teachings
of all references cited herein are hereby incorporated by reference
in their entirety.
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