U.S. patent application number 12/874489 was filed with the patent office on 2011-03-03 for mattresses with heat dissipation.
This patent application is currently assigned to Denver Mattress Co. LLC. Invention is credited to Jonathan Amendola, Robert L. Rensink.
Application Number | 20110047708 12/874489 |
Document ID | / |
Family ID | 43622660 |
Filed Date | 2011-03-03 |
United States Patent
Application |
20110047708 |
Kind Code |
A1 |
Rensink; Robert L. ; et
al. |
March 3, 2011 |
MATTRESSES WITH HEAT DISSIPATION
Abstract
In one embodiment, a mattress comprises a core and a cushion
layer positioned above the core. A fibrous air spacer layer is
positioned above the cushion layer, and a layer of visco-elastic
foam is positioned above the fibrous layer. This permits the
fibrous layer to be sandwiched between the cushion layer and the
layer of visco-elastic material.
Inventors: |
Rensink; Robert L.; (Denver,
CO) ; Amendola; Jonathan; (Denver, CO) |
Assignee: |
Denver Mattress Co. LLC
Denver
CO
|
Family ID: |
43622660 |
Appl. No.: |
12/874489 |
Filed: |
September 2, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61239386 |
Sep 2, 2009 |
|
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|
Current U.S.
Class: |
5/706 ; 5/690;
5/721; 5/731; 5/740 |
Current CPC
Class: |
A47C 27/22 20130101;
A47C 27/18 20130101; A47C 27/081 20130101; A47C 31/006 20130101;
A47C 27/15 20130101; A47C 27/04 20130101 |
Class at
Publication: |
5/706 ; 5/740;
5/731; 5/721; 5/690 |
International
Class: |
A47C 27/18 20060101
A47C027/18; A47C 27/15 20060101 A47C027/15; A47C 27/04 20060101
A47C027/04 |
Claims
1. A mattress, comprising: a core; a cushion layer positioned above
the core; a fibrous air spacer layer positioned above the cushion
layer; and a layer of visco elastic foam position above the fibrous
layer such that the fibrous layer is sandwiched between the cushion
layer and the layer of visco elastic material.
2. A mattress as in claim 1, wherein the cushion layer comprises
polyurethane.
3. A mattress as in claim 1, wherein the fibrous air spacer layer
comprises multiple strands of fibers positioned between a honey
comb layer.
4. A mattress as in claim 1, wherein the fibrous air spacer layer
comprises a two warp-knitted layers which are connected by pile
mono filaments in single knitting process.
5. A mattress as in claim 1, wherein the fibrous air spacer layer
has a thickness that is in the range from about 1/16 inch to about
2 inches.
6. A mattress as in claim 1, wherein the at least one of the
cushion layer and the layer of visco elastic foam has a surface
that has been modified to be non-planar.
7. A mattress as in claim 1, wherein the core comprises at least
one of a spring coil, a pocket spring, an air bladder, and
latex.
8. A mattress as in claim 1, wherein the layer of visco elastic
foam has a thickness that is in the range from about 0.5 inch to
about 3 inches, and wherein the cushion layer has a thickness in
the range from about 1 inch to about 12 inches.
9. A mattress, comprising: a core; at least one cushion layer
positioned above the core; and a fibrous air spacer layer
positioned between the cushion layer and the core.
10. A mattress as in claim 9, wherein the cushion layer comprises a
layer of visco elastic foam positioned, with the fibrous layer
being sandwiched between the cushion layer and the core.
11. A mattress as in claim 9, wherein the cushion layer comprises a
first cushion layer, and further comprising a second cushion layer,
and wherein the fibrous air spacer layer is positioned between the
first cushion layer and the second cushion layer.
12. A mattress as in claim 11, wherein the first and second cushion
layers are constructed of a material selected from a group
consisting of viscoelastic foam, polyurethane foam, latex, air and
a gel.
13. A mattress as in claim 9, wherein the fibrous air spacer layer
comprises multiple strands of fibers positioned between a honey
comb layer.
14. A mattress as in claim 9, wherein the fibrous air spacer layer
comprises a two warp-knitted layers which are connected by pile
mono filaments in single knitting process.
15. A mattress as in claim 9, wherein the fibrous air spacer layer
has a thickness that is in the range from about 1/16 inch to about
2 inches.
16. A mattress as in claim 9, wherein the at least one of the
cushion layer has a surface that has been modified to be
non-planar.
17. A mattress as in claim 9, wherein the core comprises at least
one of a spring coil, a pocket spring, an air bladder, and latex.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a nonprovisional application and claims
the benefit of U.S. Provisional Application No. 61/239,386, filed
Sep. 2, 2009, the complete disclosure of which is hereby
incorporated by reference
[0002] This application is also related to copending U.S.
application Ser. No. 12/619,286, filed Nov. 16, 2009, the complete
disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0003] This invention relates generally to the field of mattresses,
and in particular with mattresses having various layers, including
a fibrous air circulation layer disposed between separate cushion
layers.
[0004] It is becoming more common to provide cushion layers on top
of a mattress core. Examples of such cushion layers include foam
materials, such as visco, latex and polyurethane. However, when
laminating such layers together, the glue being placed between the
layers may result in a "hard spot" where the two layers are joined
by the glue. Moreover, the glue prevents the layers from adequately
stretching. The mattresses of the invention address these and other
issues.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention provides a wide variety of mattresses having
various cushion layers with a fibrous air spacer layer positioned
between at least one of the cushion layers. For example, in one
embodiment a mattress is constructed of a core and cushion layer
that is positioned above the core. A fibrous air spacer layer (also
referred to as an air spacer layer or spacer fabric) is positioned
above the cushion layer, and a layer of visco-elastic foam is
positioned above the fibrous layer. In this way, the fibrous layer
is sandwiched between the cushion layer and the layer of
visco-elastic material. In some cases, cushion layer may comprise a
polyurethane foam. Also, in certain embodiments, an air spacer
layer could also be positioned between the core and the cushion
layer, and the core in some cases could have a modified surface
layer.
[0006] In certain embodiments, the fibrous air spacer layer may be
positioned between various layers in a mattress. For instance, the
fibrous air spacer layer may be positioned between layers of
cushion layers, such as between two layers of viscoelastic foam. As
another example, the fibrous air spacer layer may sit between two
layers of latex foam, or between combinations of various foams,
such a viscoelastic, latex, polyurethane and the like. As yet
another example, the air spacer layer could sit atop essentially
any type of firm core (spring, foam, latex or the like) and a
topper layer (which may comprise any type of cushioning material
configured to loosely rest on the core). In other embodiments, the
layers between which the fibrous air spacer layer sits could have
their surfaces modified (so that they are not planar). The surfaces
of these layers could be altered using SMT (surface modified
technology) or by profile cutting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a perspective view of one embodiment of a
fibrous air spacer layer according to the invention.
[0008] FIG. 2 is a side view of the fibrous air spacer layer of
FIG. 1
[0009] FIG. 3 is an exploded perspective view of one embodiment of
a mattress having a fibrous air spacer layer according to the
invention.
DETAILED DESCRIPTION OF THE SPECIFIC EMBODIMENTS
[0010] The invention provides a wide variety of mattresses that may
be constructed of a variety of materials. The mattresses may be
constructed of a wide variety of cores, such as box spring cores,
individually wrapped spring cores, spring steel cores, latex rubber
cores, air cores, gel cores, and the like. However, it will be
appreciated that the invention is not limited to the specific type
of core that is used, but rather on the layers that are positioned
above or beneath such a core. Also, it will be appreciated that in
some cases a core may not be needed and the various cushion layers
as described herein may provide adequate cushioning to function as
a mattress or support layer for a user. In most applications, the
mattress will be a typical bed mattress that is long and wide
enough to support a user while sleeping. However, it will be
appreciated that the principles of the invention may be used with
other types of cushioning, such as seat cushions, couches, chairs,
and the like.
[0011] Positioned above or beneath the core are one or more cushion
layers which provide additional comfort to the user. Examples of
such layers are visco-elastic foams, latex foams, polyurethane
foams, gels, coils, air, and the like. Such foam layers may have a
wide variety of densities, hardnesses, indentation deflection
pressures, thicknesses and the like. However, for visco-elastic
layers, the thickness will typically be in the range from about 0.5
inch to about 8 inches. For latex foams, the thicknesses will
generally be in the range from about 0.5 inch to about 6 inches,
and for polyurethane foams, the thickness will typically be in the
range from about 0.25 inch to about 15 inches.
[0012] One important feature of the invention is that the fibrous
air spacer layer is positioned between two of the cushion layers
and/or between the cushion layer and the core. One example of a
fibrous cushion layer 10 is illustrated in FIGS. 1 and 2. As shown,
fibrous air spacer layer 10 is constructed of multiple strands of
fibers 12 and which sit between a honey comb layer 14. The fibers
are loosely arranged so that air may circulate between the fibers.
Also, honey comb layer 14 provides a convenient way to bond the
fibrous air spacer layer 10 between other layers. In one specific
embodiment, fibrous air spacer layer 10 may be constructed of a
three-dimensional spacer or polyester fabric that is constructed of
two warp-knitted layers which are connected by pile mono filaments
in a single knitting process. In another embodiment, fibrous air
spacer layer 10 may be constructed of two covering layers that are
held apart from each other by a pile layer. In turn, the pile layer
is made up of pile threads which provide a degree of elasticity to
the layer. A textile construction process is used to make the
layer, with its physical properties being determined by the
material used to make the pile and the thread composition. One
example of spacer fabrics that can be used include the Space
Air.RTM., Flex and Space Com textiles, available from Pressless
GmbH. Another type of material that can be used for layer 22 is
commercially available from Mueller Textile of Wiehl, Germany.
Further, one specific type of fibrous air spacer layer is described
in published U.S. Application No. 2007/021705, incorporated herein
by reference. Typically, fibrous air spacer layer 10 will have a
thickness in the range from about 1/16 inch to about 2 inches. In
certain embodiments, other fibrous materials may be used. For
example, fiberballs, such as those described in copending U.S.
application Ser. No. 12/619,286, filed Nov. 16, 2009 and
incorporated herein by reference could be used. Also, in some cases
the air spacer layer 10 can be constructed to have different
degrees of firmness. For example, some could be more firm while
others are more plush. This helps with the overall posture of the
mattress, affecting the degree how firm or how plush the mattress
feels to the user. Further, different air spacer layers could be
used in combination, with some being more firm while others are
more plush. In some cases, air spacer layer 10 could include a gel
material incorporated into part of the fibers, such as in a bottom
portion of the layer Such a gel material serves to transfer heat
away from the adjacent cushion layers while also permitting airflow
through the fibers in the air layer that do not have the gel. This
has the benefit of using two heat transfer mechanisms to remove
heat from the adjacent cushion layers.
[0013] Referring now to FIG. 3, one specific embodiment of a
mattress 20 will be described. Mattress 20 is constructed of a
polyurethane layer 22 which may optionally have a surface modified
top surface 24. This may be accomplished using a SMT process, by
profile cutting and the like. Also, it will be appreciated that any
of the layers of mattress 20 could be surface modified or planar or
combinations thereof. Polyurethane layer 22 may be positioned on
top of a core or may alternatively function as the core itself.
Examples of cores to which layer 22 may be attached include
traditional spring coil cores, pocket spring cores, air cores,
latex cores and the like. Typically, polyurethane layer 22 will
have a thickness in the range from about 1 inch to about 12 inches.
Laminated to polyurethane layer 22 is a visco layer 26 which may
have a thickness in the range from about 0.5 inch to about 4 inches
and may optionally have a surface modification. Laminated to visco
layer 26 is a fibrous air spacer layer 28. Optionally, or in
addition to, an air spacer layer may be placed between layers 22
and 26. Finally, laminated to air spacer layer 28 is another visco
layer 30. Air spacer layer 28 will typically have a thickness in
the range from about 1/16 inch to about 2 inches, and visco layer
30 will have a thickness in the range from about 0.5 inch to about
3 inches.
[0014] While one specific embodiment has been described in
connection with FIG. 3, it will be appreciated that fibrous air
spacer layer 28 could be placed in other locations as well, such as
between polyurethane layer 22 and visco layer 26. Also, each of the
cushion layers in FIG. 3 could also be made of different materials.
For example, polyurethane layer 22 could be constructed of latex,
visco, a gel, an inflatable bladder, or the like. Similarly, visco
layers 26 and/or 30 could be constructed on a polyurethane, latex,
gel, an inflatable bladder, or the like. Hence, in one arrangement,
layers 22 and 26 could both be made of latex, with air spacer layer
28 positioned between them. Further, some of these layers could be
eliminated, such as layer 22. As another example, layers 22 and 26
could be used, with layer 28 placed between them, and with layer 30
being eliminated. In other cases, air spacer layer 28 could be
placed between the core and a topper layer. This topper layer is
loosely held on top of a firm core and may comprise one or more
layers of padding materials. In some cases, the air spacer layer 28
could also be included in the topper layer itself.
[0015] By using fibrous air spacer layer 28, a number of
significant advantages are achieved. First, by using fibrous air
spacer layer 28, improved air circulation is provided between the
various layers. With the mattress of FIG. 3, air circulation is
provided between the two visco layers 26 and 28. However, as
previously described, air circulation could be provided between
other layers, such as between a visco layer, latex layer and/or
polyurethane foam layers. This provides for a more hygienic and
comfortable sleeping environment.
[0016] Another significant advantage is that air spacer layer 28
provides improved heat dissipation through and around the various
cushion layers, including layers 22, 26 and 30. This also provides
for a more hygienic and comfortable sleeping environment. Fibrous
air spacer layer is particularly useful when placed adjacent one of
the visco layers as the visco foam material tends to trap the
user's body heat. By providing air circulation beneath the other
surface of the visco layer, heat is able to travel through the
visco foam and to be dissipated from the other surface, thereby
providing a cooler sleeping environment.
[0017] Another feature is that moisture transported and dissipated
through the layers is increased, leading to a more sanitary and
hygienic sleeping environment.
[0018] Further, because most laminating methods involve gluing
multiple layers of foams, viscose and latex together in the cushion
or support layers, "hard spots" result where the two layers are
joined together. This is uncomfortable for the user and also
prevents the layers from stretching. By gluing the various comfort
or support layers to fibrous air spacer layer 28, fibrous air
spacer layer 28 functions as a stretchable spacer fabric and also
eliminates the hard spot where the foams would normally be attached
to each other. Because fibrous air spacer layer 28 is stretchable,
it functions as a stretchable spacer fabric to allow the layers to
be more pliable.
[0019] The invention has now been described in detail for purposes
of clarity and understanding. However, it will be appreciated that
certain changes and modifications may be practiced within the scope
of the appended claims.
* * * * *