U.S. patent application number 12/879114 was filed with the patent office on 2011-03-03 for mattress.
Invention is credited to Allyn Beard.
Application Number | 20110047710 12/879114 |
Document ID | / |
Family ID | 41064660 |
Filed Date | 2011-03-03 |
United States Patent
Application |
20110047710 |
Kind Code |
A1 |
Beard; Allyn |
March 3, 2011 |
MATTRESS
Abstract
A mattress (1) comprises a mattress body (6) and mattress cover
(5) located over the mattress body (6) with the sleep panel (7) of
the cover (5) covering the upper surface of the mattress body (6).
The mattress body (6) comprises a comfort layer (13) disposed
beneath the sleep panel (7) and a resilient support layer (3)
disposed beneath the comfort layer (13). The sleep panel (7) has an
upper cover layer (9) formed of a breathable fabric and a lower
cover layer (10) also formed of a breathable fabric. A resilient
and highly breathable three-dimensional spacer layer (12) is
disposed between the upper and lower cover layers (9, 10). The
upper cover layer (9), spacer layer (11) and lower cover layer (10)
are secured together by quilting or tufting. The cover (5) is
removeable.
Inventors: |
Beard; Allyn; (Gymea Bay,
AU) |
Family ID: |
41064660 |
Appl. No.: |
12/879114 |
Filed: |
September 10, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/AU2009/000281 |
Mar 11, 2009 |
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12879114 |
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Current U.S.
Class: |
5/724 ;
5/737 |
Current CPC
Class: |
A47C 31/10 20130101;
A47C 21/046 20130101; A47C 27/15 20130101; A47C 31/006
20130101 |
Class at
Publication: |
5/724 ;
5/737 |
International
Class: |
A47C 27/00 20060101
A47C027/00; A47G 9/00 20060101 A47G009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 11, 2008 |
AU |
AU2008901189 |
Claims
1. A mattress cover comprising a sleep panel configured to cover an
upper surface of a mattress body, said sleep panel comprising: an
upper cover layer formed of a breathable fabric; a lower cover
layer formed of a breathable fabric; and a resilient and highly
breathable three-dimensional spacer layer disposed between said
upper and lower cover layers; wherein said upper cover layer, said
spacer layer and said lower cover layer are secured by quilting or
tufting; further wherein said cover is removeable.
2. The mattress cover of claim 1, further comprising a peripheral
skirt extending about a periphery of said sleep panel for engaging
side surfaces of the mattress body.
3. The mattress cover of claim 1, wherein said spacer layer
comprises a pair of spaced apart outer mesh elements interconnected
by an array of spacer yarns extending between and separating said
outer mesh elements.
4. The mattress cover of claim 1, wherein said spacer layer is
formed of an open-cell reticulated foam.
5. The mattress cover of claim 1, wherein said spacer layer is
separated into multiple zones of varying resilience.
6. A mattress comprising: a mattress body; and the mattress cover
of claim 1 located over said mattress body with said sleep panel
covering an upper surface of said mattress body; wherein said
mattress body comprises: a comfort layer disposed beneath said
sleep panel; and a resilient support layer disposed beneath said
comfort layer.
7. The mattress of claim 6, wherein said comfort layer comprises a
high density, high resilience foam.
8. The mattress of claim 6, wherein said comfort layer is formed of
visco-elastic foam.
9. The mattress of claim 6, wherein said comfort layer is formed of
latex.
10. A mattress comprising: a resilient support layer; a resilient
and highly breathable three-dimensional lower spacer layer disposed
above said support layer; a comfort layer disposed above said lower
spacer layer, said comfort layer having a plurality of perforations
extending through a thickness thereof; a resilient and highly
breathable three-dimensional upper spacer layer disposed above said
comfort layer; a breathable upper cover layer disposed above said
upper spacer layer.
11. The mattress of claim 10, wherein said comfort layer comprises
a high density, high resilience foam.
12. The mattress of claim 10, wherein said comfort layer is formed
of visco-elastic foam.
13. The mattress of claim 10, wherein said comfort layer is formed
of latex.
14. The mattress of claim 10, wherein said spacer layers each
comprise a pair of spaced apart outer mesh elements interconnected
by an array of spacer yarns sitting between and separating said
outer mesh elements.
15. The mattress of claim 10, wherein said spacer layers are formed
of an open-cell reticulated foam.
16. The mattress of claim 10, wherein said upper spacer layer is
separated into multiple zones of varying resilience.
17. The mattress of claim 10, wherein said lower spacer layer is
laminated to said comfort layer.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of International
Application No. PCT/AU2009/000281, filed Mar. 10, 2009. which
claims the benefit of Australian Application No. 2008901189, filed
Mar. 11, 2008, the entire disclosure of which is hereby
incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates to a mattress, and a mattress
cover therefor.
BACKGROUND OF THE INVENTION
[0003] The use of comfort layers in mattresses has arisen in recent
years due to the comfortable support provided. Such comfort layers
are typically formed of latex, visco-elastic foam or other flexible
high density, high resilience foams. In the field of bedding, high
density foams are usually regarded as those having a density of 20
to 100 kg/m.sup.3, with low density foams generally having a
density of 10 to less than 20 kg/m.sup.3. In the context of the
present specification, the term "high density" has this meaning
High resilience foam grades are generally high density foams in
which the cell structure has been broken down to form a generally
"open cell" construction which is more resilient than the closed
cell structure.
[0004] These comfort layers are typically provided above another,
typically more resilient and harder, support layer to allow a
person lying on the bed to sink into the comfort layer,
distributing pressure more evenly across the person's body, while
still retaining support from the underlying support layer.
Visco-elastic foam support layers have gained particular popularity
as a result of their temperature sensitivity whereby they become
softer when heated by body heat and consequently generally mold to
the form of the body, distributing pressure more evenly.
Visco-elastic foam is also referred to as "memory foam", and is
generally a form of flexible polyurethane foam.
[0005] Visco-elastic foam and latex support layers, however, are
generally unable to readily dissipate heat from the person's body
and, given that there is generally a greater area of surface
contact between the person's body and the molded upper surface of
the mattress, mattresses with such comfort layers are often found
to be uncomfortably hot to sleep on.
[0006] Mattress structures have previously been proposed that
include a resilient, highly breathable spacer layer below the
comfort layer to assist in dissipating heat from the comfort layer
by maintaining an air space between the comfort layer and
underlying support layer. Such a structure, however, relies on the
heat dissipating through the thickness of the comfort layer prior
to escaping via the spacer layer.
[0007] Mattress structures have also been proposed that utilize a
spacer layer laminated to the top surface of the comfort layer in
an effort to dissipate heat from the person's body prior to
reaching the comfort layer. Such structures, however, do not
provide for washability of the spacer layer and do not allow for
retrofitting to existing mattresses with visco-elastic foam or
latex comfort layers that have been found to be uncomfortable due
to overheating.
BRIEF SUMMARY
[0008] A mattress cover is described which includes a sleep panel
configured to cover an upper surface of a mattress body. The sleep
panel includes an upper cover layer formed of a breathable fabric,
a lower cover layer formed of a breathable fabric, and a resilient
and highly breathable three-dimensional spacer layer disposed
between said upper and lower cover layers. The upper cover layer,
the spacer layer and the lower cover layer are secured by quilting
or tufting. The mattress cover further includes a peripheral skirt
extending about a periphery of the sleep panel for engaging side
surfaces of the mattress body. In one form, the spacer layer
includes a pair of spaced apart outer mesh elements interconnected
by an array of spacer yarns extending between and separating the
outer mesh elements. As one option, the spacer layer may be formed
of an open-cell reticulated foam. As another option, the spacer
layer is separated into multiple zones of varying resilience.
[0009] In another embodiment, a mattress is described which
includes a mattress body and a mattress cover located over the
mattress body with a sleep panel covering an upper surface of the
mattress body. In this embodiment the mattress cover is constructed
and arranged as described above. The mattress body includes a
comfort layer disposed beneath the sleep panel and a resilient
support layer disposed beneath the comfort layer. Typically, the
comfort layer comprises a high density, high resilience foam. In
particular embodiments, the comfort layer is formed of
visco-elastic foam. Alternatively, the comfort layer may be formed
of latex.
[0010] In yet another embodiment, a mattress is described which
includes a resilient support layer, a resilient and highly
breathable three-dimensional lower spacer layer disposed above the
support layer, a comfort layer disposed above the lower spacer
layer, a resilient and highly breathable three-dimensional upper
spacer layer disposed above the comfort layer, and a breathable
upper cover layer disposed above the upper spacer layer. The
comfort layer having a plurality of perforations extending through
a thickness thereof.
[0011] Typically, the comfort layer comprises a high density, high
resilience foam. In particular embodiments, the comfort layer is
formed of visco-elastic foam. Alternatively, the comfort layer may
be formed of latex.
[0012] In one alternative form, the spacer layers each comprise a
pair of spaced apart outer mesh elements interconnected by an array
of spacer yarns sitting between and separating the outer mesh
elements.
[0013] Alternatively, the spacer layers may be formed of an
open-cell reticulated foam.
[0014] In one alternative form, the upper spacer layer is separated
into multiple zones of varying resilience.
[0015] Typically, the lower spacer layer is laminated to the
comfort layer.
OBJECT OF THE INVENTION
[0016] It is the object of the present invention to substantially
overcome or at least ameliorate one or more of the disadvantages
briefly mentioned in the Background.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0017] Preferred embodiments of the present invention will now be
described, by way of an example only, with reference to the
accompanying drawings wherein:
[0018] FIG. 1 is an exploded view of a mattress.
[0019] FIG. 2 is a further exploded perspective view of FIG. 1 with
individual layers of each panel laminated.
[0020] FIG. 3 is a fragmentary cross-sectional view of the mattress
of FIG. 1.
DETAILED DESCRIPTION
[0021] For the purposes of promoting an understanding of the
disclosure, reference will now be made to the embodiments
illustrated in the drawings and specific language will be used to
describe the same. It will nevertheless be understood that no
limitation of the scope of the disclosure is thereby intended, such
alterations and further modifications in the illustrated device and
its use, and such further applications of the principles of the
disclosure as illustrated therein being contemplated as would
normally occur to one skilled in the art to which the disclosure
relates.
[0022] Referring to the accompanying drawings, a mattress 1
comprises a base layer 2, support layer 3, intermediate panel 4,
and cover 5. The cover 5 defines the upper face of the mattress 1
forming a sleep surface. The base layer 2 defines the lower face of
the mattress which will typically be located on a mattress
foundation. The support layer 3 and intermediate panel 4 together
define the mattress body 6 and are located between the cover 5 and
base layer 2.
[0023] The cover 5 comprises a sleep panel 7 configured to cover
the upper surface of the mattress body 6 and a peripheral skirt 8
extending about a periphery of the sleep panel 7 for engaging the
side surfaces of the mattress body 6. Referring specifically to
FIG. 3, the sleep panel 7 comprises an upper cover layer 9 formed
of a breathable fabric and a lower cover layer 10 also formed of a
breathable fabric. The breathable fabric may be either knitted or
woven and may, for example, be a stretchable velour fabric. A
resilient and highly breathable three-dimensional upper spacer
layer 12 is disposed between the upper and lower cover layers 9,
10. The upper cover layer 9, upper spacer layer 11 and lower cover
layer 10 are secured together by quilting, so as to form a quilted
sleep surface as depicted in FIG. 1. Alternatively, it is envisaged
that the upper cover layer 9, upper spacer layer 11 and lower cover
layer 10 might be secured by tufting.
[0024] The upper spacer layer 11 is typically formed of a three
dimensional fabric having a pair of spaced apart outer mesh
elements interconnected by an array of spacer yarns (alternatively
referred to as loop piles) extending between and separating the
outer mesh elements. A particularly suitable three dimensional
fabric for forming the spacer layer is Space Flex.RTM. spacer
fabric manufactured by Pressless GmbH of Falkenau, Germany. The
upper spacer layer 11 will typically have a thickness of about 15
to 40 mm. The upper spacer layer 11 may be separated into multiple
zones of varying resilience by varying the spacing (or properties)
of the spacer yarns in each zone. For example, a central zone
extending laterally across the mattress, generally in the area of
the torso of a person lying on the mattress, may be formed of a
more resilient spacer layer, whilst the opposing head and leg ends
of the mattress may be formed with a spacer layer of lower
resilience. Accordingly, such a central zone would provide
additional support to the heavier torso of the person's body.
[0025] As an alternative to the three dimensional fabric of the
spacer layer, a breathable open-cell reticulated foam material may
be utilized, as is available from Joyce Foam Products of Moorebank,
New South Wales, Australia.
[0026] The peripheral skirt 8 is typically formed of a fabric
material, conveniently the same material as the upper cover layer
9. The upper edge of the skirt is stitched to the sleep panel 17.
The lower edge of the peripheral skirt 8 will typically be secured
to the periphery of the base 2 by way of a zipper 12.
[0027] The intermediate panel 4 here comprises a comfort layer 13
that is generally formed of a high density, high resilience foam.
The comfort layer 13 may be formed of a flexible polyurethane foam.
The flexible polyurethane foam may be a visco-elastic foam,
typically having a density of between 40 and 100 kg/m.sup.3.
Alternatively, the comfort layer 13 may be formed of other types of
high resilience flexible polyurethane foam having a density of
between 25 and 50 kg/m.sup.3. In other forms, the comfort layer 13
may be formed of latex, which may either be Talalay or Dunlop
process latex (sometimes referred to as a latex foam). To improve
the breathability of the comfort layer 13, allowing any residual
heat that has passed through the upper spacer layer 11 to pass
through, a series of pin hole perforations 14 may be provided,
extending through the thickness of the comfort layer 13. The
perforations 14 will generally be provided when the comfort layer
13 is formed of latex but they are also applicable to other
compositions of comfort layer 13. The comfort layer 13 will
typically have a thickness of about 50 to 100 mm.
[0028] The intermediate panel 4 also includes a resilient and
highly breathable three-dimensional lower spacer layer 15. The
lower spacer layer 15 will typically be laminated to the comfort
layer 13. The lower spacer layer 15 may be formed of the same
material as the upper spacer layer 11. The lower spacer layer 15
will typically have a thickness of about 10 to 30 mm. The lower
spacer layer 15 enables any heat that has dissipated through the
comfort layer 13 to be readily dissipated by maintaining an air
layer separating the comfort layer 13 from the layers lying
beneath. The lower spacer layer 15 may be configured as a firmer
layer than the upper spacer layer 11, so that the lower spacer
layer 15 will contribute more to supporting a person lying on the
mattress 1 while the upper spacer layer 11 will contribute more to
comfort. In particular embodiments, the firmer lower spacer layer
15 may have a compressive elastic modulus of about 11 to 15 kPa,
with the upper spacer layer 11 having a compressive elastic modulus
of about 2 to 10 kPa.
[0029] The intermediate panel 4 will typically further comprise a
lower layer 16 that is laminated to the underside of the lower
spacer layer 15. The lower layer 16 is typically formed of a high
density flexible polyurethane foam having a density of about 25 to
50 kg/m.sup.3. The lower layer 16 will typically have a thickness
of about 20 to 40 mm. The lower layer 16 provides a foundation for
the lower spacer layer 15 and comfort layer 13 and adds both extra
comfort and support. The lower layer 16 also generally confines the
lower spacer layer 15, which when configured as a spacer fabric can
be a little coarse and may have its ends otherwise sticking through
the skirt 8 of the cover 5.
[0030] The support layer 3 is here formed of two separate support
cores 17, 18 formed of high resilience flexible polyurethane foam
having a density of about 25 to 50 kg/m.sup.3. The support cores
17, 18 may alternatively be formed of latex, such as Talalay
process latex foam or Dunlop process latex. The support cores 17,
18 will typically each have a thickness of about 100 to 200 mm. The
support cores 17, 18 may be configured with different hardness
materials so as to provide different support on the two opposing
sides of the mattress 1 to satisfy the desires of two individuals
lying on the mattress. For example, one support core 17 may be
configured with a particularly firm support core 17, while the
other support core 18 may be configured with a softer material. The
support cores 17, 18 are not laminated to the lower layer 16 and as
such may be readily replaced as desired if the firmness
requirements of persons using the bed change over time. Forming the
support cores 17, 18 separately also enables production of
mattresses with varying hardness properties merely by utilizing
varying hardness support cores.
[0031] The side surfaces of the mattress body 6 are defined by the
edges of the support layer 3 and intermediate panel 4. So as to
maintain a neat side surface in the event that there is some minor
relative displacement between the support layer 3 and intermediate
panel 4, additional foam elements may be located within the skirt 8
adjacent the edges of the mattress body 6. The individual elements
of the mattress body 6, being the support cores 17, 18 and
intermediate panel 4 may be covered in a dust-mite resistant
barrier fabric so as to render the mattress 1 particularly suitable
to asthma and other allergy sufferers.
[0032] The base layer 2 is typically formed of a fabric material
and serves to enclose the mattress body 6 with the cover 5 that is
secured to the base layer 2 by way of a zipper 12 as discussed
above.
[0033] In use, heat generated by the body of a person lying on the
mattress may firstly be dissipated by the air layer provided by the
upper spacer layer 11, separating the person's body from the
comfort layer 13. Whilst the upper spacer layer 11 provides for
dissipation of heat, some residual heat is likely to penetrate
through to the comfort layer 13. The perforations 14 extending
through the thickness of the comfort layer 13 provide passages for
heat to dissipate through the thickness of the comfort layer 13 and
then out of the mattress body 6 via the air gap provided by the
lower spacer layer 15. Embodying the upper spacer layer 11 within
the sleep panel 7 of the cover 5 provides for removal and washing
of the upper spacer layer 11 (within the cover 5). This structure
also allows for retrofitting of the spacer layer 11 embodied within
the cover 5, to mattresses having visco-elastic foam or latex
comfort layers that have previously been purchased, typically at
significant expense, without the need to discard the mattress.
[0034] While the preferred embodiment of the invention has been
illustrated and described in the drawings and foregoing
description, the same is to be considered as illustrative and not
restrictive in character, it being understood that all changes and
modifications that come within the spirit of the invention are
desired to be protected.
* * * * *