U.S. patent application number 13/558092 was filed with the patent office on 2013-01-31 for foam mattress assembly with increased airflow and independent suspension.
This patent application is currently assigned to DREAMWELL, LTD.. The applicant listed for this patent is RICHARD FERRELL GLADNEY, JAMES GERARD RUEHLMANN. Invention is credited to RICHARD FERRELL GLADNEY, JAMES GERARD RUEHLMANN.
Application Number | 20130025069 13/558092 |
Document ID | / |
Family ID | 47595996 |
Filed Date | 2013-01-31 |
United States Patent
Application |
20130025069 |
Kind Code |
A1 |
RUEHLMANN; JAMES GERARD ; et
al. |
January 31, 2013 |
FOAM MATTRESS ASSEMBLY WITH INCREASED AIRFLOW AND INDEPENDENT
SUSPENSION
Abstract
Mattress assemblies that provide user comfort via independent
suspension and increased airflow generally include a first foam
layer; a second foam layer configured with an independent response
system overlaying the first foam layer, wherein the second foam
layer comprises a floor and a plurality of spaced apart support
structures extending at about similar lengths from the floor; and a
third foam layer overlaying the second foam layer having a planar
top surface facing a user resting on the mattress assembly. In some
embodiments, the first foam layer further includes a plurality of
channels extending from a top planar surface to a bottom planar
surface.
Inventors: |
RUEHLMANN; JAMES GERARD;
(CINCINNATI, OH) ; GLADNEY; RICHARD FERRELL;
(FAIRBURN, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
RUEHLMANN; JAMES GERARD
GLADNEY; RICHARD FERRELL |
CINCINNATI
FAIRBURN |
OH
GA |
US
US |
|
|
Assignee: |
DREAMWELL, LTD.
LAS VEGAS
NV
|
Family ID: |
47595996 |
Appl. No.: |
13/558092 |
Filed: |
July 25, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61513091 |
Jul 29, 2011 |
|
|
|
Current U.S.
Class: |
5/740 |
Current CPC
Class: |
A47C 27/15 20130101;
A47C 21/046 20130101; A47C 27/144 20130101; A47C 27/066
20130101 |
Class at
Publication: |
5/740 |
International
Class: |
A47C 27/15 20060101
A47C027/15 |
Claims
1. A mattress assembly comprising: a first foam layer; a second
foam layer configured with an independent response system
overlaying the first foam layer, wherein the second foam layer
comprises a floor and a plurality of spaced apart support
structures extending at about similar lengths from the floor; and a
third foam layer overlaying the second foam layer having a planar
top surface facing a user resting on the mattress assembly.
2. The mattress assembly of claim 1, wherein the first, second and
third foam layers comprise natural latex foam.
3. The mattress assembly of claim 1, wherein the first foam layer
has a density equal to or less than 4 lb/ft.sup.3 and a hardness
equal to or less than about 30 pounds-force.
4. The mattress assembly of claim 1, wherein the spaced apart
support structures comprises a truncated cone.
5. The mattress assembly of claim 1, wherein the first foam layer
is at a thickness within a range of 4 inches to 10 inches; the
second foam layer is at a thickness within a range of 1 inch to 4
inches; and the third foam layer is at a thickness within a range
of 0.5 to 2 inches.
6. The mattress assembly of claim 1, wherein the first foam layer
has a density within a range of 1 pound per cubic foot
(lb/ft.sup.3) to 6 lb/ft.sup.3 and a hardness within a range of 20
to 40 pounds-force; the second foam layer has a density within a
range of 2 to 6 lb/ft.sup.3 and a hardness within a range of 10 to
20 pounds-force; and the third layer has a density within a range
of 1 to 5 lb/ft.sup.3 and hardness within a range of 10 to 20
pounds-force.
7. The mattress assembly of claim 1, further comprising a foam side
rail assembly disposed about a perimeter of the first, second and
third foam layers, wherein the side rail assembly has a thickness
about equal a total thickness of the first, second and third
layers.
8. The mattress assembly of claim 7, wherein the side rail assembly
is formed of natural latex foam.
9. The mattress assembly of claim 1, wherein the first foam layer
includes planar top and bottom surfaces, and a plurality of
channels extending from the planar top surface to the planar bottom
surface.
10. The mattress assembly of claim 1, wherein the second foam layer
comprises a recessed portion defining a perimeter wall about the
floor and the upright support structures.
11. The mattress assembly of claim 1, further comprising a spacer
fabric about a perimeter of the first, second and third foam
layers.
12. The mattress assembly of claim 1, further comprising a spacer
fabric overlaying the third foam layer and extending about a
perimeter of the first, second and third foam layers.
13. The mattress assembly of claim 1, wherein the upright support
structures are oriented to face a user resting on the mattress
assembly.
14. A mattress assembly, comprising: a latex first foam layer
having planar top and bottom surfaces; a latex second foam layer
overlaying the latex first foam layer, the second foam layer
comprising a planar bottom surface and a top surface configured
with a recessed portion defining a perimeter wall, and a plurality
of upright foam support structures extending from a floor of the
recessed portion to a height substantially equal to that of the
perimeter wall, wherein the upright foam support structures
comprise a truncated cone shape to provide motion separation to a
user of the mattress assembly during use thereof; and a latex third
foam layer having top and bottom planar surfaces overlaying the
second foam layer, the third foam layer.
15. The mattress assembly of claim 14, wherein the latex first foam
layer further comprises a plurality of open channels extending from
the top planar surface to the bottom planar surface.
16. The mattress assembly of claim 14, further comprising a side
rail assembly formed of a latex material comprising one or more
layers disposed about a perimeter of the first, second, and third
foam layers.
17. The mattress assembly of claim 14, wherein the layers defining
the side rail assembly and the latex first foam layer are
pre-stressed.
18. The mattress assembly of claim 14, wherein the upright foam
support structures comprise a truncated cone shape to provide
motion separation to a user of the mattress assembly during use
thereof
19. The mattress assembly of claim 14, wherein the first foam layer
further comprises a plurality of channels extending from the planar
top surface to the planar bottom surface.
20. The mattress assembly of claim 14, further comprising a spacer
fabric overlaying the third foam layer and extending about a
perimeter of the first, second and third foam layers.
21. A mattress assembly comprising: a first foam layer comprising
top and bottom planar surfaces, the first foam layer further
comprising a plurality of channels extending from the top to the
bottom planar surfaces; a second foam layer configured with an
independent response system overlaying the first foam layer,
wherein the second foam layer comprises a floor and a plurality of
spaced apart support structures extending at about equal lengths
from the floor; and a third foam layer overlaying the second foam
layer having a planar top surface facing a user resting on the
mattress assembly.
22. The mattress assembly of claim 21, wherein the plurality of
channels are at a density of about 100 to about 800 open channels
per square foot.
23. The mattress assembly of claim 21, wherein each one of the
plurality of channels has circularly shaped cross section.
24. The mattress assembly of claim 21, the first, second and third
foam layers comprise natural latex foam.
25. The mattress assembly of claim 21, wherein the spaced apart
support structures comprises truncated cones.
26. The mattress assembly of claim 21, wherein the first foam layer
is at a thickness within a range of 4 inches to 10 inches; the
second foam layer is at a thickness within a range of 1 inch to 4
inches; and the third foam layer is at a thickness within a range
of 0.5 to 2 inches.
28. The mattress assembly of claim 21, further comprising a foam
side rail assembly disposed about a perimeter of the first, second
and third foam layers, wherein the side rail assembly has a
thickness about equal a total thickness of the first, second and
third layers.
29. The mattress assembly of claim 28, wherein the side rail
assembly is formed of natural latex foam.
30. The mattress assembly of claim 21, further comprising a spacer
fabric about a perimeter of the first, second and third foam
layers.
31. The mattress assembly of claim 30, further comprising a spacer
fabric overlaying the third foam layer and extending about a
perimeter of the first, second and third foam layers.
32. The mattress assembly of claim 21, wherein the upright support
structures are oriented to face a user resting on the mattress
assembly.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/513,091, filed on Jul. 29, 2011, incorporated
herein by reference in its entirety.
BACKGROUND
[0002] The present disclosure generally relates to foam mattress
assemblies exhibiting increased airflow and independent
suspension.
[0003] Foam mattresses such as those formed of polyurethane foam,
latex foam, and the like, are generally known in the art. One of
the ongoing problems associated with foam mattress assemblies is
user comfort. To address user comfort, these mattresses are often
fabricated with multiple foam layers having varying properties such
as density and hardness, among others, to suit the needs of the
intended user. More recently, manufacturers have employed so called
memory foam, also commonly referred to as viscoelastic foams, which
are generally a combination of polyurethane and one or more
additives that increase foam density and viscosity, thereby
increasing its viscoelasticity. These foams are often open cell
foam structures having both closed and open cells but in some
instances may be reticulated foam structures. The term
"reticulated" generally refers to a cellular foam structure in
which the substantially all of the membrane windows are removed
leaving a skeletal structure. In contrast, open cell structures
typically include both open cell (interconnected cells) and closed
cells.
[0004] When used in a mattress, the memory foam conforms to the
shape of a user when the user exerts pressure onto the foam,
thereby minimizing pressure points from the user's body. The memory
foam then returns to its original shape when the user and
associated pressure are removed. However, the return to the
original shape is a relatively slow process because of the
viscoelastic cellular structure of these types of foams.
[0005] Unfortunately, the high density of the various types of
foams used in current mattress assemblies, particularly those
employing memory foam layers, generally prevents proper
ventilation. As a result, the foam material can exhibit an
uncomfortable level of heat to the user after an extended period of
time. Additionally, these foams can retain a high level of
moisture, further causing discomfort to the user and potentially
leading to foul odors.
[0006] Reticulated memory foams, i.e., foams in which the cellular
walls are substantially removed, are known to provide greater
airflow. However, because substantially all of the cellular walls
have been removed leaving behind a skeletal structure, these foams
are inherently weak, provide less load-bearing capabilities
relative to other non-reticulated viscoelastic foams, and are
subject to fatigue at a rate faster than partially or completely
closed cell foam structures. Moreover, reticulated viscoelastic
foams require special processing to remove the cellular walls to
form the skeletal structure making these foams relatively
expensive.
[0007] Still further, as noted above, prior mattress assemblies
generally include multiple stacked layers. The layers typically
have planar top and bottom surfaces. In some instances, these
mattresses may have convoluted surfaces. These surfaces are
generally static in terms of motion response to a user.
[0008] Accordingly, it would be desirable to provide a mattress
assembly, with an improved airflow to effectively dissipate user
heat. Still further, it would be desirable to provide foam mattress
assemblies with motion separation so as to independently respond to
each specific body part for increased user comfort.
BRIEF SUMMARY
[0009] Disclosed herein are mattress assemblies exhibiting
increased airflow and independent suspension. In one embodiment, a
mattress assembly comprises a first foam layer; a second foam layer
configured with an independent response system overlaying the first
foam layer, wherein the second foam layer comprises a floor and a
plurality of spaced apart support structures extending at about
similar lengths from the floor; and a third foam layer overlaying
the second foam layer having a planar top surface facing a user
resting on the mattress assembly.
[0010] In another embodiment, a mattress assembly comprises a first
foam layer comprising top and bottom planar surfaces, the first
foam layer further comprising a plurality of channels extending
from the top to the bottom planar surfaces; a second foam layer
configured with an independent response system overlaying the first
foam layer, wherein the second foam layer comprises a floor and a
plurality of spaced apart support structures extending at about
equal lengths from the floor; and a third foam layer overlaying the
second foam layer having a planar top surface facing a user resting
on the mattress assembly.
[0011] In another embodiment, a mattress assembly comprises a first
foam layer comprising top and bottom planar surfaces, the first
foam layer further comprising a plurality of channels extending
from the top to the bottom planar surfaces; a second foam layer
configured with an independent response system overlaying the first
foam layer, wherein the second foam layer comprises a floor and a
plurality of spaced apart support structures extending at about
equal lengths from the floor; and a third foam layer overlaying the
second foam layer having a planar top surface facing a user resting
on the mattress assembly.
[0012] The disclosure may be understood more readily by reference
to the following detailed description of the various features of
the disclosure and the examples included therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Referring now to the figures wherein the like elements are
numbered alike:
[0014] FIG. 1 illustrates a top down view of a mattress
assembly;
[0015] FIG. 2 illustrates an exploded perspective view of a
mattress assembly in accordance with an embodiment of the present
disclosure;
[0016] FIG. 3 illustrates a perspective view of a foam layer
configured to provide a mattress assembly with motion separation;
and
[0017] FIG. 4 illustrates an exploded perspective view of a
mattress assembly in accordance with an embodiment of the present
disclosure;
DETAILED DESCRIPTION
[0018] Disclosed herein are mattress assemblies that provide user
comfort with improved airflow to effectively dissipate user heat
during use and motion separation to independently respond to each
specific body part for increased user comfort. FIG. 1 illustrates a
top down view representative of the mattress assemblies, which are
generally designated by reference numeral 10. As will be discussed
herein, the various embodiments of the mattress assemblies
disclosed herein have in common the following components: multiple
stacked foam layers, wherein the uppermost foam layer 12 is shown,
a side rail assembly 14 about at least a portion of the perimeter
of the stacked mattress layers, and an optional fabric covering 16
about the side rail assembly as shown, i.e., mattress border. The
uppermost foam layer 12 is generally referred to herein as the
cover layer and has a planar top surface adapted to substantially
face the user resting on the mattress assembly having a length and
width dimensions sufficient to support a reclining body of the
user. In some embodiments, the uppermost foam layer 12 may be
dimensioned to overlay the side rails. Likewise, the optional foam
layer may be configured to cover the side and top surfaces of he
mattress assembly.
[0019] FIG. 2 shows an exploded perspective view of an exemplary
foam mattress assembly in accordance with one embodiment. The
mattress assembly 100 includes a base foam core layer 102
configured with generally planar top and bottom surfaces. For this
as well as the other embodiments disclosed herein, the foam core
layer 102 is chosen to have a thickness less than or equal to the
overall thickness of the mattress assembly. Generally, the
thickness of the foam core layer 102 is within a range of 4 inches
to 10 inches, with a range of about 6 inches to 8 inches thickness
in other embodiments, and a range of about 6 to 6.5 inches in still
other embodiments.
[0020] The core foam layer can be formed of open or closed cell
natural latex foam although other foams can be used, including
without limitation, viscoelastic foams, non-viscoelastic foams,
polyurethane foams, and the like. In one embodiment, the foam core
layer 102 is pre-stressed. That is, the foam core layer is
subjected to a pre-stressing process such as disclosed in U.S. Pat.
No. 7,690,096 to Gladney et al., incorporated herein by reference
in its entirety. By way of example, a force can applied to at least
a section of the foam core layer in an amount sufficient to
temporarily compress its height so as to permanently alter a
mechanical property of the foam layer to provide a pre-stressed
foam layer having a firmness that is different from the firmness of
a similar foam that was not pre-stressed.
[0021] The foam core layer 102 has a density of 1 pound per cubic
foot (lb/ft.sup.3) to 6 lb/ft.sup.3. In other embodiments, the
density is 1 lb/ft.sup.3 to 5 lb/ft.sup.3 and in still other
embodiments, from 1.5 lb/ft.sup.3 to 4 lb/ft.sup.3. By way of
example, the density can be about 1.5 lb/ft.sup.3.
[0022] The hardness of the foam core layer, also referred to as the
indention load deflection (ILD) or indention force deflection
(IFD), is within a range of 20 to 40 pounds-force, wherein the
hardness is measured in accordance with ASTM D-3574 and is
generally defined as the amount of force in pounds required to
indent a 50'' disc into a 15''.times.15''.times.4'' foam sample and
make a 1'' indentation. In other embodiments, the hardness is about
20 to 30 pounds-force.
[0023] Foam layer 104 configured with an independent response
system overlays the base foam core layer 102. Advantageously, the
independent response system as will be described in greater detail
below provides motion separation to an end user of the mattress
assembly as well as improved airflow. The foam layer 104 may be
fabricated from a viscoelastic foam or non-viscoelastic foam
depending on the intended application. The foam itself can be of
any material including without limitation, latex foams, natural
latex foams, polyurethane foams, combinations thereof, and the
like. Foam layer 104 generally has a thickness equal to or less
than 6 inches in some embodiments, equal to or less than 4 inches
in other embodiments, and equal to or less than 3 inches in still
other embodiments. In other embodiments, the thickness is greater
than or equal to 1 inch. The density is generally within a range of
2 to 6 lb/ft.sup.3 in some embodiments, and 3 to 5 lb/ft.sup.3 in
other embodiments. Hardness is generally within a range of 10 to 20
pounds-force.
[0024] As shown more clearly in FIG. 3, foam layer 104 includes a
planar bottom surface 106 and a generally planar top surface 108
configured with a recessed portion 110 defining a perimeter wall
112, and a plurality of upright spaced apart foam support
structures 114 extending from a floor 116 of the recessed portion
110 to a height substantially equal to that of the perimeter wall
112. The upright foam support structures 114 can be of any shape
and dimension including, without limitation, cylindrical shapes,
truncated cones, cubic shapes, polygonal prism shaped, e.g.,
triangular prism, hexagonal prism, combinations thereof, and the
like. The various shapes can be formed using known techniques by
which a plane splitting of a foam block is carried out with
opposing outer sides compressed in a corresponding pattern.
Alternatively, the upright foam support structures may be
individually formed and adhered to the floor, or the like. In these
embodiments, it is generally important that the top surface of each
upright foam support structure have a planar surface. In some
embodiments, the pitch between adjacent upright support structures
is generally equal to or less than a diameter of an individual
support structure. The individual upright support structures 114
may be randomly disposed within the recess or may be configured as
a linear arrangement of rows and columns, or may be configured as
offset rows and/columns Still further, the foam layer 104 may be
configured to include segments of the upright support structures
within the recessed portion that are of a greater density than in
other segments of the recessed portions. In still other
embodiments, the foam layer 104 may include more than one recessed
portion 110 such that recessed portion is divided into multiple
portions defined by a wall (not shown) similar to that of the
perimeter wall except providing compartmentalization of the upright
structures within the interior region defined by the perimeter
wall. For example, in some embodiments, two or more sections may be
defined by an interior foam wall extending from a selected
perimeter wall to an opposing perimeter wall. In still other
embodiments, the two or more sections may be defined by an interior
wall within the confines of the perimeter wall 112. In these
embodiments, the support structures as well as the interior foam
walls have a height about equal to the height of the perimeter wall
122.
[0025] By way of example, which is not intended to be limiting, a
foam layer 104 configured for use in queen sized mattress can have
a thickness of 3 inches, a width of 59.5 inches and a length of
79.5. The perimeter wall has a width of 3 inches and the upright
support structure has a truncated cone shape having a height of 1.5
inches (i.e., the recess floor has a thickness of 1.5 inches) and a
diameter of 2 inches. The upright support structures are equally
spaced apart at a distance of about 1 inch as measured from the
base and linearly arranged by columns and rows.
[0026] Referring back to FIG. 2, a cover panel 106 is shown
disposed on the foam layer 104. The cover panel layer can be formed
from viscoelastic foam or non-viscoelastic foam depending on the
intended application. The foam itself can be of any open or closed
cell foam material including without limitation, latex foams,
natural latex foams, polyurethane foams, combinations thereof, and
the like. The cover panel 106 has planar top and bottom surfaces.
The thickness of the cover panel is generally within a range of
about 0.5 to 2 inches in some embodiments, and less than 1'' in
other embodiments so as to provide the benefits of motion
separation and increased airflow from the underlying foam layer
104. The density of the cover panel layer 106 is within a range of
1 to 5 lb/ft.sup.3 in some embodiments, and 2 to 4 lb/ft.sup.3 in
other embodiments. The hardness is within a range of about 10 to 20
pounds-force in some embodiments, and less than 15 pounds-force in
other embodiments. In one embodiment, the cover panel is at a
thickness of 0.5'', a density of 3.4 lb/ft.sup.3, and a hardness of
14 pounds-force. In some embodiments, multiple foam layers (not
shown) can overlay foam layer 104.
[0027] The various multiple stacked mattress layers 102, 104, and
106 may be adjoined to one another using an adhesive or may be
thermally bonded to one another or may be mechanically fastened to
one another as may be desired for different applications.
[0028] The mattress assembly 100 further includes a side rail
assembly 120 about all or a portion of the perimeter of the
mattress assembly defined by foam layers 102, 104, 106. The side
rails that define the assembly may be attached to or placed
adjacent to at least a portion of the perimeter of the stacked
mattress layers 102, 104, 106, and may include metal springs,
spring coils, encased spring coils, foam, latex, natural latex,
latex w/ gel, gel, viscoelastic gel, or a combination, in one or
more layers. The side rails may be placed on one or more of the
sides of the stacked mattress layers, e.g., on all four sides of
the stacked mattress layers, on opposing sides, on three adjacent
sides, or only on one side of the stacked mattress layers. In
certain embodiments, the side rails may comprise edge supports with
a firmness greater than that provided by the stacked mattress
layers. The side rails may be fastened to the stacked mattress
layers via adhesives, thermal bonding, or mechanical fasteners.
[0029] In one embodiment, the side rail assembly is formed of a
natural latex foam having a density generally less than 3
lb/ft.sup.3 to 0.5 lb/ft.sup.3 and a hardness greater than 30
pounds-force to 80 pounds-force. In one embodiment, the side rails
are formed of natural latex foam having a density of 1.65
lb/ft.sup.3 and a hardness of 45 pounds-force.
[0030] In some embodiments, the side rail assembly 120 may be
formed of multiple layers as is generally shown in FIG. 2. For
example, the side rail assembly may include a core layer 122 having
a higher hardness than an overlaying relatively thinner edge layer
124 having a lower hardness for improved user comfort. By way of
example, the core side rail can have a thickness of 5.5 inches, a
hardness of 45 pounds-force, and a density of 1.65 lb/ft.sup.3. The
edge side rail layer 124, disposed on core side rail layer 122, can
have a thickness of 1 inch, a hardness of 24 pounds-force, and a
density of 1.65 lb/ft.sup.3. Optionally, one or more of the side
rail assembly layers may be pre-stressed in the manner described
above.
[0031] In another embodiment, the side rail assembly 120 is formed
of open cell polyurethane foam having a non-random large cell
structure or a random cellular structure with many large cells. The
large cell structure can be defined by the number of cells per
linear inch. In one embodiment, the large cell structure is about
10 to 40 cells per inch, with about 15 to 30 cells per inch in
other embodiments, and with about 20 cells per inch in still other
embodiments. The open cell foam structure includes a plurality of
interconnected cells, wherein the windows between the adjacent
cells are broken and/or removed. In contrast, in closed cell foam
there are substantially no interconnected cells and the windows
between the adjacent cells are substantially intact. In reticulated
foams, substantially all of the windows are removed. By using an
open cell structure with a large open cellular structure, movement
of moisture and air through a side rail can occur. Also, if the
side rail is adhesively or thermally attached to the mattress
layers, e.g., 102, 104, and 106, the skeletal struts of the open
cell foam will bond to the mattress layers, thereby facilitating
air and moisture transfer from the mattress layers through the side
layers to the environment. In one embodiment, the side rail
assembly includes a natural latex foam, which may be viscoelastic
or non-viscoelastic depending on the intended application.
[0032] For ease in manufacturing the mattress assembly, the side
rail assembly may be assembled in linear sections that are joined
to one another to form the perimeter about the mattress layers.
Alternatively, the ends may be mitered or have some other shape,
e.g., lock and key type shape.
[0033] An optional fabric layer (e.g., 16 in FIG. 1) can be
disposed about the perimeter of the side rail, i.e., serves as a
mattress border. In one embodiment, the fabric border layer is
attached at one end to the top planar surface of the uppermost
mattress layer 106 and at the other end to the bottom planar
surface of the bottom most layer 102. In one embodiment, at least a
portion of the fabric layer can formed of a spacer fabric to
provide a further increase in airflow. As used herein, spacer
fabrics are generally defined as pile fabrics that have not been
cut including at least two layers of fabric knitted independently
that are interconnected by a separate spacer yarn. The spacer
fabrics generally provide increased breathability, crush
resistance, and a three dimensional appearance relative to other
fabrics. The at least two fabric layers may be the same or
different, i.e., the same or different density, mesh, materials,
and like depending on the intended application. When employing the
spacer fabric, a lightweight flame retardant barrier layer may be
disposed intermediate to the mattress foam layers and the spacer
fabric about the perimeter of the side rail assembly.
[0034] By way of example, an exemplary mattress assembly
illustrative of the embodiment shown in FIG. 2 has a 6.5''
pre-stressed foam core layer of natural latex foam having a density
of 1.65 lb/ft.sup.3 and a hardness of 24 pounds-force; a natural
latex foam layer having a density of 3.9 lb/ft.sup.3 and configured
with the independent response system as described above is disposed
on the foam core layer. The independent response system layer
includes a perimeter wall having a width of 3 inches and a
truncated cone shaped upright support structure having a height of
1.5 inches (i.e., the recess floor has a thickness of 1.5 inches)
and a diameter of 2 inches. The upright support structures are
equally spaced apart at a distance of about 1 inch as measured from
the base and linearly arranged by columns and rows. A natural latex
foam cover layer having top and bottom planar surfaces is disposed
onto the foam layer configured with the independent response system
and is at a thickness of 0.5'', a density of 3.4 lb/ft.sup.3, and a
hardness of 14 pounds-force. The side rail assembly is of a two
layer construction of natural latex foam and circumscribes a
perimeter of the mattress layers 102, 104, and 106. The side rail
assembly has a width of 3'', a height of 6.5 inches and is formed
of a core layer having a height of 5.5 inches, a density of 1.65
lb/ft.sup.3 and a hardness of 45 pounds-force. An edge layer having
a height of 1 inch is disposed onto the core layer and has a
density of 1.65 lb/ft.sup.3 and a density of 24 pounds-force. A
mattress border and panel of a spacer fabric is utilized as a
mattress border.
[0035] FIG. 4 shows a cross sectional view of a mattress assembly
in accordance with one embodiment. The mattress assembly 200
includes a base core foam layer 202 configured with planar top and
bottom surfaces. Generally, the thickness of the foam core layer
202 is within a range of 4 inches to 10 inches, with a range of
about 6 inches to 8 inches thickness in other embodiments, and a
range of about 6 inches in still other embodiments. The core foam
layer can be formed of standard polyurethane foam although other
foams can be used, including without limitation, viscoelastic
foams. In one embodiment, the core foam layer is ventilated.
Ventilation can be provided by providing open channels 203
extending from the top planar surface to the bottom planar surface.
The channels are generally circularly shaped although other shapes
can be utilized and have a diameter of less than 2 inches in some
embodiments, less than 1 inch in other embodiments, and less than
0.5 inches in still other embodiments. The density of the open
channels is generally about 100 to about 800 open channels per
square foot in some embodiments, about 300 to about 600 open
channels per square foot in other embodiments, and about 400 to
about 500 in still other embodiments. The core foam layer 202 has a
density of 1 lb/ft.sup.3 to 5 lb/ft.sup.3. In other embodiments,
the density is 1 lb/ft.sup.3 to 3 lb/ft.sup.3 and in still other
embodiments, from 1 lb/ft.sup.3 to 2 lb/ft.sup.3. By way of
example, the density can be 4 lb/ft.sup.3. The hardness of the core
foam layer is within a range of 20 to 40 pounds-force. In one
embodiment, the hardness is about 29 pounds-force.
[0036] Foam layer 204 configured with the independent response
system as described above is disposed on the base core foam layer
202.
[0037] A cover foam layer 206 as described above is disposed on
foam layer 204.
[0038] The mattress assembly may further include the side rail
assembly and the optional fabric border as described above.
[0039] By way of example, an exemplary mattress assembly
illustrative of the embodiment shown in FIG. 4 has a 6'' ventilated
foam core layer of natural latex foam having top and bottom planar
surfaces, a density of 4 lb/ft.sup.3 and a hardness of 29
pounds-force; a natural latex foam layer having a density of 3.9
lb/ft.sup.3 and configured with the independent response system as
described above is disposed on the foam core layer; and a 1'' foam
cover layer of natural latex foam having top and bottom planar
surfaces, a density of 3.4 lb/ft.sup.3 and a hardness of 14
pounds-force. The ventilated foam core has a plurality of equally
spaced open channels extending from the top planar surface to the
bottom planar surface of the core foam layer at a diameter less
than 1 inch and a density of about 400 to 500 channels per square
foot. The independent response system foam layer includes a
perimeter wall having a width of 3 inches and a truncated cone
shaped upright support structure having a height of 1.5 inches
(i.e., the recess floor has a thickness of 1.5 inches) and a
diameter of 2 inches. The upright support structures are equally
spaced apart at a distance of about 1 inch as measured from the
base and linearly arranged by columns and rows. The side rail
assembly is of a two layer construction of natural latex foam and
circumscribes a perimeter of the mattress layers 102, 104, and 106.
The side rail assembly has a width of 3'', a height of 6.5 inches
and is formed of a core layer having a height of 5.5 inches, a
density of 1.65 lb/ft.sup.3 and a hardness of 45 pounds-force. An
edge layer having a height of 1 inch is disposed onto the core
layer and has a density of 1.65 lb/ft.sup.3 and a density of 24
pounds-force. A mattress border and panel of a spacer fabric is
utilized as a mattress border.
[0040] The various mattress layers in the mattress assemblies
described above may be adjoined to one another using an adhesive or
may be thermally bonded to one another or may be mechanically
fastened to one another. The mattress assemblies may further
include one or more upholstery layers to cover mattress assemblies,
which may include an outermost ticking layer.
[0041] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to make and use the invention. The patentable
scope of the invention is defined by the claims, and may include
other examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
* * * * *