U.S. patent application number 13/470903 was filed with the patent office on 2012-11-15 for tension relief foam and mattress constructions.
Invention is credited to Andy Beamon, David MORET, Steven Tyree.
Application Number | 20120284927 13/470903 |
Document ID | / |
Family ID | 47139724 |
Filed Date | 2012-11-15 |
United States Patent
Application |
20120284927 |
Kind Code |
A1 |
MORET; David ; et
al. |
November 15, 2012 |
TENSION RELIEF FOAM AND MATTRESS CONSTRUCTIONS
Abstract
Engineered foam components for mattresses reduce tension forces
in the foam and in the horizontal plane or block planar pieces, and
improve the conformance and motion separation characteristics of
foam support systems. The tension relief foam pad is a generally
rectangular piece of foam having a top surface and a bottom
surface. The length and width measurements of engineered foam
pieces are substantially equal to that of a mattress with which it
is to be used. Depending on the arrangement of the tension relief
foam pad within the mattress construction, either the top or bottom
surface contains a plurality of continuous cuts, slits or openings
arranged in a checkerboard or other patterns with an opposite
planar uncut surface.
Inventors: |
MORET; David; (Winston
Salem, NC) ; Tyree; Steven; (High Point, NC) ;
Beamon; Andy; (Jamestown, NC) |
Family ID: |
47139724 |
Appl. No.: |
13/470903 |
Filed: |
May 14, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61485364 |
May 12, 2011 |
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Current U.S.
Class: |
5/716 |
Current CPC
Class: |
A47C 27/064 20130101;
A47C 27/056 20130101 |
Class at
Publication: |
5/716 |
International
Class: |
A47C 23/04 20060101
A47C023/04 |
Claims
1. A tension relief mattress system comprising: an innerspring unit
having a plurality of interconnected coils arranged in rows and
columns; a tension relief pad located directly above the
innerspring, the tension relief pad having a top surface which is
generally planar and a bottom surface, opposite the top surface,
which has a plurality of cuts arranged to form a plurality of
square or rectangles thereon; wherein the tension relief pad is at
least 1 inch thick, the width of the square or rectangles on the
bottom surface is at least 2.5 inches and the distance between each
adjacent square or rectangle is less than 0.75 inches.
2. The tension relief mattress system of claim 1, wherein each of
the plurality of square or rectangles on the bottom surface of the
tension relief pad sits directly above each of the plurality of
interconnected coils of the innerspring.
3. The tension relief mattress system of claim 1, wherein each of
the plurality of square or rectangles on the bottom of the tension
relief pad sits directly above at least one coil of the
innerspring.
4. The tension relief mattress system of claim 1, wherein the
plurality of square or rectangles on the bottom surface of the
tension relief pad are uniform in size.
5. The tension relief mattress system of claim 1, wherein the
plurality of square or rectangles on the bottom surface of the
tension relief pad are non-uniform in size.
6. Then tension relief mattress system of claim 1, wherein a first
group of square or rectangles on the bottom surface of the tension
relief pad are of a first size which corresponds to three coils of
the innerspring unit and a second group of square or rectangles on
the bottom surface of the tension relief pad are of a second size
which corresponds to two coils of the innerspring unit.
7. The tension relief mattress of claim 1, wherein the square or
rectangles located on a short edge of the bottom surface of the
tension relief pad have a larger width than the remainder of the
blocks located therebetween.
8. The tension relief mattress of claim 1, wherein the space
between each adjacent pair of squares or rectangles on the bottom
surface of the tension relief pad is of uniform size.
9. The tension relief mattress of claim 1, wherein the tension
relief pad is made of polyurethane foam.
10. The tension relief mattress of claim 1, wherein a spacer fabric
is located between the tension relief pad and the innerspring
unit.
11. A tension relief mattress system comprising: an innerspring
unit having a plurality of interconnected coils; a tension relief
pad having a top layer which is substantially planar and a bottom
layer, opposite the top layer, which contains a plurality of cuts
formed into a plurality of raised blocks; wherein the thickness of
the plurality of raised blocks is at least one inch, the width of
the plurality of raised blocks is greater than or equal to the
block height and the distance between each adjacent pair of the
plurality of raised blocks is approximately 15% of the smallest
block width.
12. The tension relief mattress system of claim 11, wherein the
size of the plurality of raised blocks is uniform.
13. The tension relief mattress system of claim 11, wherein the
size of the plurality of raised blocks is non-uniform.
14. The tension relief mattress system of claim 11, wherein the
size of the plurality of foam blocks corresponds to one or more
coils of the innerspring unit.
15. The tension relief mattress system of claim 11, wherein the
tension relief pad is made of polyurethane foam.
16. A tension relief mattress system comprising: an innerspring
unit having a plurality of interconnected coils; a comfort unit
comprising two or more foam layers and a tension relief pad
positioned between the two or more foam layers, the tension relief
pad having a top surface which contains a plurality of cuts formed
into a plurality of raised blocks; wherein the thickness of the
tension relief pad is at least one inch, and wherein the tension
relief foam pad is laminated.
17. The tension relief mattress system of claim 11, wherein the
size of the plurality of raised blocks is uniform.
18. The tension relief mattress system of claim 11, wherein the
size of the plurality of raised blocks is non-uniform.
19. The tension relief mattress system of claim 11, wherein the
tension relief pad is made of polyurethane foam.
20. The tension relief mattress system of claim 11, wherein the
height of the plurality of raised blocks is at least 2.5 inches.
Description
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/485,364, filed on May 12, 2011, which is
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is in the field of reflexive support
systems including support systems for humans such as bedding or
seating.
SUMMARY OF THE INVENTION
[0003] The present invention incorporates surface or structurally
modified foam into a mattress for highly localized deformation and
support, independent movement and reduced tension in the horizontal
plane, an improvement in conformance and motion separation
characteristics of the support system. In a representative
embodiment, a tension relief foam pad is a generally rectangular
piece of foam having a top surface and a bottom surface opposite
and parallel to the top surface with four side wall which are
perpendicular to and extend between the top and bottom surface. The
length and width measurements of the pad are substantially equal to
that of a mattress with which it is to be used. Depending on the
arrangement of the tension relief foam pad within a mattress
construction, discussed in greater detail below, either the top or
bottom surface contains a plurality of cuts arranged in a
checkerboard or other pattern, while the opposite surface is
substantially planar. The cuts create a plurality of square or
rectangular blocks on the surface of the pad and independent
modules which have independent support characteristics, and which
may be coupled with other support elements such as springs.
DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1A is a perspective view of a preferred placement of a
tension relief foam topper among other foam layers in a mattress
system.
[0005] FIG. 1B is a perspective view of an alternate placement of a
tension relief foam pad among other foam layers in a mattress
system.
[0006] FIG. 2 is a side view of one embodiment of tension relief
foam pad and innerspring.
[0007] FIG. 3 is a side view of an alternate embodiment of tension
relief foam pad and innerspring.
[0008] FIG. 4 is a chart showing the surface deflection on a
tension relief foam pad in various locations among other foam
layers in a mattress system.
[0009] FIG. 5 is a chart showing the surface strain on a tension
relief foam pad in various locations among other foam layers in a
mattress system.
[0010] FIG. 6A is a perspective view showing the stress
distribution across a tension relief foam pad when the pad is used
as a top layer of a mattress system.
[0011] FIG. 6B is a perspective view showing the stress
distribution across a tension relief foam pad when the pad is used
as a bottom layer of a mattress system.
[0012] FIG. 7 is a side view of an alternate embodiment of tension
relief foam pad and innerspring.
[0013] FIG. 8 is a top view of a tension relief foam pad with
non-uniform sized blocks.
[0014] FIG. 9 is a side view of one embodiment of tension relief
foam pad with non-uniform sized blocks.
[0015] FIG. 10 is a side view of an alternate embodiment of tension
relief foam pad with non-uniform sized blocks.
[0016] FIG. 11 is a side view of an alternate embodiment of tension
relief foam pad with non-uniform sized blocks.
GENERAL DESCRIPTION OF PREFERRED AND ALTERNATE EMBODIMENTS
[0017] The tension relief foam pads, mattresses and support systems
of the present disclosure and related inventions utilize surface
modified foams to achieve independent and localized deformation,
support and movement and reduced tension or shear forces in the
horizontal plane, benefitting the conformance and motion separation
characteristics of the system. The various forms of tension relief
foam pieces and pads described herein (also referred to herein as
"pad" or "foam pad" or "topper") 10 are generally in the form of
rectangular block planar shapes having a top surface and a bottom
surface opposite and parallel to the top surface. For example, the
length and width measurements of the pad 10 are substantially equal
to that of a mattress with which it is to be used. Although
described with reference to particular representative embodiments,
it is understood that the concepts of the present disclosure can be
applied and implemented in other physical forms of foam. As used
herein, the term "tension relief foam" refers generally to each of
the various described foam configurations and constructs, and more
generally to foam body configurations which reduce or eliminate
stress forces within the cellular structure of a body of foam. The
design concepts and configurations are equally applicable to any
type of foam from which such shapes and configurations can be
manufactured, including open cell and closed cell type foams.
Depending on the arrangement of the tension relief foam pad 10
within the mattress construction, set forth in greater detail
below, either the top or bottom surface contains a plurality of
continuous cuts 18 arranged in a checkerboard or other pattern,
while the opposite surface is substantially planar and generally
without cuts. The cuts 18 create a plurality of square or
rectangular blocks 16 on one surface of the pad 10.
[0018] A typical mattress system includes a foundation or box
spring, a support unit and optionally, a comfort unit. The
foundation can be of conventional internal design and construction,
having a rectangular frame on which are mounted a plurality of
spring elements or modules to provide flexible support for an
overlying grid, which defines the foundation surface. The spring
modules in the foundation may be formed of wire or made of a
composite material, or be entirely without individual spring
modules and rather in the form of a flexible support surface.
Foundation units are typically supported by a bed frame which may
further include side boards, a head board and foot board. The
support unit or innerspring of the mattresses of the disclosure are
dimensioned to fit upon the foundation surface and be fully
supported thereby. The support unit or innerspring may be of
conventional design, containing a plurality of interconnected
spring coils. The support unit may alternatively be a high
performance foam core structure without any internal wire or spring
elements. The support surface has relatively few layers of
material, which cover the innerspring, such as one or more layers
of mat or foam or other sheet-like fabric or non-woven material.
The primary purpose of layers is to provide a smooth surface over
the ends of the coils of the innerspring. A comfort unit is
dimensioned to fit upon the support unit. It has a generally
horizontal top and bottom and generally vertical or tapered sides
extending between the top and bottom to define a central space
containing supporting and cushioning components. The comfort unit
contains additional layers of compressible, conformable internal
layers of materials. A comfort unit may contain one or more foam
core layers and intermediate and outer layers made of matted
material, synthetic or organic, such as cotton or wool fibers,
polyester, or hybrid material mats. Extra material layers may also
be used, such as woven cotton, wool or synthetic cloths or hybrids
thereof, or sheet materials such as plastic films, solid or
perforated, which may serve as moisture barriers, aeration
promoters, liners or flame or heat retardants. The feel of the
comfort unit may be adjusted by using different insert materials
such as polyurethane foams, visco-elastic foams, latex foams,
fibers, gels or various combinations thereof. The comfort unit
materials are encapsulated by upholstery, which may include
ticking, for example foam or padding backed woven or embroidered
material, side wall material or ticking, tape edges, and a gusset
which extends from the pillowtop to the top of the support unit.
The upholstery of the comfort unit may be a combination of
materials.
[0019] In a preferred embodiment, the top surface of the tension
relief pad 10 is generally planar while the bottom surface contains
a plurality of cuts 18 arranged in a checkerboard or other pattern.
The cuts or voids 18 between discrete islands of foam can be
uniform in size and spacing or not, generally linear or not, and
dimensioned uniformly or not. The foam structures 16 can be formed
by molding, cutting, water-jet forming or by any other suitable
process. When used in combination with an innerspring 15 or spring
unit, the tension relief foam 10 pad is generally placed directly
above the innerspring 15 and below any other foam layers 12 of the
mattress or comfort unit, as shown in FIGS. 1A, 2 and 3. A thin
fabric or fiber layer or insulation layer may be located between
the tension relief foam pad 10 and the innerspring 15. The
individual blocks 16 on the bottom surface of the pad 10 may be
aligned with or correspond in location to the positions of the
upper terminal convolutions of the coils 14 of the mattress
innerspring 15, as shown in FIGS. 2 and 3. Depending on the size of
the blocks 16, each block may correspond and work in combination
with two or more springs or coils 14 of the innerspring 15 to
provide improved independent movement of the foam 10 and coils 14
accentuating the feel of the coils 14. Each of the individual
blocks 16, in combination with the innerspring 15, is separately
compressible in response to the weight placed directly thereon.
Placing the tension relief pad 10 directly on top of the
innerspring 15, below other foam layers 12, is shown to provide
more local compliance, a lower surface strain and a lower complex
stress state, as shown in the charts of FIGS. 4 and 5 and on the
stress state mapping shown in FIG. 6B.
[0020] Representative and non-limiting examples of springs which
can be used in the tension relief foam mattress system of the
present invention include those disclosed in the commonly assigned
U.S. Pat. Nos. 4,535,978; 4,726,572; 5,558,315; 6,134,729;
6,354,577; 6,406,009; 8,178,187; 7,404,223; 7,908,693 and any other
spring or reflexive device or devices which could be mounted upon a
frame or platform and support a grid or other mattress support
structure over the frame or platform. The springs may be
individually pocketed or Marshall-type coils or the coils may be
without a pocket or encasement. Each of the individual foam blocks
16 may be associated with one or more corresponding spring 14 of a
spring unit 15, as shown in FIGS. 2, 3 and 7. Having an axial upper
end of each coil 14 in direct or indirect physical contact with an
opposing face of a foam block 16 provides a hybrid spring
combination by which a force applied to the area of a particular
foam block 16 is transferred in whole or in part to the
corresponding spring 14, and the matched spring 14 or springs and
foam block 16 respond together to applied forces. The size of each
block 16 in the pattern may be uniform, such as, for example, the
pad 10 shown in FIG. 7 wherein each uniformly sized foam block 16
corresponds to a single coil unit 14 of the innerspring 15. Also,
FIG. 3 shows a pad 10 with uniformly sized foam blocks 16
correspond to every two coil units 14 of the innerspring 15.
Alternatively, the size of the foam blocks 16 in the pattern may be
non-uniform, such as, for example, the pad 10 shown in FIG. 2,
wherein blocks 16 having a first size, which corresponds to three
coil units 14 of the innerspring 15, are interspersed between
blocks 16 having a second size which corresponds to two coil units
14 of the innerspring 15. The individual blocks 16 may be zoned
such that the blocks 16 vary in number or size. For example, the
blocks 16 located along the short edges of the pad 10 may have a
larger width while the remainder of the blocks 16 located
therebetween may have a uniform width, which is less than the width
of the blocks 16 along the short edges of the pad 10. Any pattern
of uniform or non-uniform sized blocks 16, which correspond to any
number of coils 14 may be used to create different zones in the
tension relief foam pad 10 and mattress system of the present
invention.
[0021] In an alternate embodiment, the bottom surface of the
tension relief foam pad 10 is generally planar while the top
surface contains a plurality of cuts 18 arranged in a checkerboard
or other uniform or non-uniform pattern. In this configuration,
shown in FIG. 1B, the tension relief foam pad 10 is typically
placed between additional foam layers 12 of the mattress
construction. To prevent bunching or sticking between the blocks 16
on the top surface of the tension relief foam pad 10 and the bottom
surface of an adjacent foam pad 12, which may result in body
impressions, the tension relief pad 10 may be laminated. The cuts
18 may be of any width or opening (or no opening, such as in the
form of a slit) or any size width from 1 mm to 10 mm or greater.
Also, the cuts 18 may have generally planar and parallel walls or
tapered or other shape, and may be formed in straight and
orthogonal lines as shown or in other arrangements which have the
similar result of relieving tension in the foam piece.
[0022] The tension relief foam pad 10 dimensions, block cut and
geometry affect the surface deformation, surface strain, stress
state upon the layer and deformation modes of the pad 10. For
example, if the height of the blocks 16 is too great, it may cause
weak points between each block 16, which may be subject to tearing
when a force is applied thereto. If the width of the cuts 18 or the
gap between each block 16 is too wide, it may cause local
depressions on the top surface of the mattress. If the gap 18 is
too narrow, there may be too much contact between adjacent blocks
16 preventing independent movement. Also, if the height of the
blocks 16 is too high, it may cause bending or deformation of the
blocks 16. Therefore, as general overall design considerations, the
thickness of the foam pad 10 or the overall solid height of the
foam pad 1--must be greater than or equal to 1 inch; the block 16
width must be greater than or equal to the block 16 height or
greater than or equal to 2.5 inches; the gap width must be 15% of
the smallest block 16 width or less than 0.75 inches.
[0023] As an example, a tension relief foam pad 10 may be
approximately 3 inches thick with cuts 18 between each block 16
being approximately 2 inches deep or extending approximately 2/3 of
the way into the foam pad 10. The individual blocks 16 may have a
uniform size, such as 3.75 inches wide by 3.75 inches long with the
width of the cut or gap 18 between blocks 16 being approximately
0.25 inch wide. Alternatively, the individual blocks 16 may vary in
size such that the blocks 16 located at the short edges are larger
than the blocks 16 located therebetween, wherein the blocks 16
located at the short edges of the pad 10 are approximately 7.35
inches wide and the blocks 16 located therebetween are
approximately 5.2 inches wide. This example tension relief foam pad
10 enables a zoned mattress construction wherein blocks 16 of
different sizes can be formed and located in particular zones or
regions where different support characteristics are desired, such
as the shoulder or lumbar areas of the mattress where blocks 16 of
a relatively larger size may have a relatively greater density and
relatively less freedom of individual movement or deformation to
provide firmer support which still has the enhanced conformance of
the structurally modified foam and a corresponding spring or core
unit support. Tension relief foam pads 10 having various thickness
measurements are shown in FIGS. 9, 10 and 11.
[0024] It will be appreciated by persons skilled in the art that
numerous variations and/or modifications may be made to the
invention as shown in the specific embodiments without departing
from the spirit or scope of the invention as broadly described. The
present embodiments are, therefore, to be considered in all
respects as illustrative and not restrictive. Other features and
aspects of this invention will be appreciated by those skilled in
the art upon reading and comprehending this disclosure. Such
features, aspects, and expected variations and modifications of the
reported results and examples are clearly within the scope of the
invention where the invention is limited solely by the scope of the
following claims.
* * * * *