U.S. patent application number 13/857563 was filed with the patent office on 2013-10-31 for mattress assemblies and components employing passageways for ventilation and airflow.
This patent application is currently assigned to Nomaco Inc.. The applicant listed for this patent is Nomaco Inc.. Invention is credited to Michael Allman, Christopher Dean Page, Mark Stearley, Brian Towne, Julian Thomas Young.
Application Number | 20130283538 13/857563 |
Document ID | / |
Family ID | 49476031 |
Filed Date | 2013-10-31 |
United States Patent
Application |
20130283538 |
Kind Code |
A1 |
Young; Julian Thomas ; et
al. |
October 31, 2013 |
MATTRESS ASSEMBLIES AND COMPONENTS EMPLOYING PASSAGEWAYS FOR
VENTILATION AND AIRFLOW
Abstract
Embodiments disclosed herein include mattress assemblies and
components employing passageways for ventilation and airflow. A
mattress may contain a mattress core to provide cushioning and
support. For example, the mattress core may comprise an
innerspring, air bladder(s), and/or foam layer(s). A mattress
assembly may include a foam base and/or at least one foam side
support member to at least partially surround a mattress core to
provide cushioning and structure. The foam base and/or at least one
foam side support member may include at least one passageway for
facilitating diffusion and air exchange between an exterior
environment and an interior space of the enclosure containing the
mattress core. In this manner, as stagnant air and humidity
developing in the mattress core may be avoided or reduced from the
mattress core, which may otherwise cause unhealthy conditions or
unpleasant odors for users.
Inventors: |
Young; Julian Thomas;
(Zebulon, NC) ; Page; Christopher Dean;
(Nashville, NC) ; Allman; Michael; (Wilson,
NC) ; Stearley; Mark; (Cary, NC) ; Towne;
Brian; (Zebulon, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nomaco Inc. |
Zebulon |
NC |
US |
|
|
Assignee: |
Nomaco Inc.
Zebulon
NC
|
Family ID: |
49476031 |
Appl. No.: |
13/857563 |
Filed: |
April 5, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13738391 |
Jan 10, 2013 |
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13857563 |
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61791842 |
Mar 15, 2013 |
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61620649 |
Apr 5, 2012 |
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Current U.S.
Class: |
5/724 |
Current CPC
Class: |
A47C 27/146 20130101;
A47C 27/20 20130101; A47C 27/144 20130101; A47C 21/046 20130101;
A47C 27/053 20130101; B68G 11/06 20130101 |
Class at
Publication: |
5/724 |
International
Class: |
A47C 21/04 20060101
A47C021/04 |
Claims
1. A mattress assembly, comprising: a mattress core comprising a
first support surface configured to face a user applying a weight
of the user to the mattress core, a second support surface opposite
the first support surface, and a side periphery extending between
the first support surface and the second support surface; a foam
base configured to support the weight of the user transmitted
through the mattress core; and at least one foam side support
member disposed along the side periphery, wherein the at least one
foam side support member is configured to allow an airflow to exit
from and enter into an interior space formed by an inner side
surface of each of the at least one foam side support member and a
portion of an inner base surface of the foam base, wherein the
portion of the inner base surface faces the mattress core.
2. The mattress assembly of claim 1, wherein the at least one foam
side support member comprises: a first opening in the inner side
surface; a second opening in an outer side surface of the at least
one foam side support member, the outer side surface is opposite
the inner side surface; and a passageway surface surrounding a
passageway coupling the first opening to the second opening,
wherein the passageway is configured to allow the airflow to exit
from and enter into the interior space.
3. The mattress assembly of claim 2, wherein the passageway is not
disposed perpendicular to the inner side surface.
4. The mattress assembly of claim 2, wherein the inner side surface
and the outer side surface comprise mainly closed cell foam.
5. The mattress assembly of claim 2, wherein the passageway is not
disposed parallel to an extrusion direction of the at least one
foam side support member.
6. The mattress assembly of claim 5, wherein the at least one foam
side support member comprises polyethylene.
7. A mattress assembly, comprising: a mattress core comprising a
first support surface configured to face a user applying a weight
of the user to the mattress core, a second support surface opposite
the first support surface, and a side periphery extends between the
first support surface and the second support surface; a foam base
configured to support a weight of the mattress core, and the foam
base further comprises an inner base surface facing the mattress
core; and at least one foam side support member configured to be
disposed along the side periphery, the at least one foam side
support member comprises an inner side surface facing the mattress
core and an outer side surface opposite the inner side surface, the
at least one foam side support member is configured to allow an
airflow to exit from and enter into an interior space formed by the
inner side surface of each of the at least one foam side support
member and a portion of the inner base surface, wherein the inner
side surface and the outer side surface comprise closed cell
foam.
8. The mattress assembly of claim 7, wherein the at least one foam
side support member comprises: a first opening in the inner side
surface; a second opening in the outer side surface of the at least
one foam side support member opposite the inner side surface; and a
passageway surface surrounding a passageway connecting the first
opening to the second opening, wherein the passageway is configured
to allow the airflow to exit from and enter into the interior
space.
9. The mattress assembly of claim 8, wherein the passageway is not
perpendicular to the inner side surface.
10. The mattress assembly of claim 8, wherein the inner side
surface and the outer side surface include closed cell
polyethylene.
11. The mattress assembly of claim 8, wherein the passageway is not
parallel to an extrusion direction of the at least one foam side
support member.
12. A mattress assembly, comprising: a mattress core comprising a
cushioning structure including a first support end configured to
receive a weight of a user, a second support end opposite the first
support end, and a side periphery; an enclosure forming an interior
space to contain the mattress core, the enclosure comprising: a
foam base including a first surface and a second surface opposite
the first surface, the first surface disposed adjacent to the
second support end of the mattress core and configured to receive
the weight of the user from the mattress core; at least one foam
side support member including an inner surface and an outer surface
opposite the inner surface, the at least one foam side support
member is disposed along the side periphery and is in communication
with the foam base; and an inner surface of the at least one foam
side support member forming at least one passageway to permit an
airflow between the interior space and an exterior environment.
13. The mattress assembly of claim 12, wherein the at least one
passageway comprises an orifice through the foam base, the orifice
including a first base opening in the first surface of the foam
base and a second base opening in the second surface of the foam
base and an inner base surface of the foam base connecting the
first base opening and the second base opening.
14. The mattress assembly of claim 12, wherein the first surface of
the foam base comprises a channel extending across the foam base,
and the channel in combination with the at least one foam side
support member forms a passageway of the at least one
passageway.
15. The mattress assembly of claim 12, wherein the foam base
comprises an inner base passageway formed from an internal base
surface extending across the foam deck, the internal base surface
connecting a first exterior opening to a second exterior opening,
and the inner base passageway forming at least a portion of a
passageway of the plurality of passageways.
16. The mattress assembly of claim 15, wherein the first surface of
the foam base is partially formed by a plurality of protrusions
extending from a foam deck and extending across the foam deck, the
inner base passageway is at least partially disposed within at
least one of the plurality of protrusions.
17. The mattress assembly of claim 15, wherein the inner base
passageway exchanges airflow through the first surface with a
secondary passageway, the secondary passageway extending from a
secondary opening in the first surface of the foam base to a
secondary opening in the internal base surface.
18. The mattress assembly of claim 16, wherein each of the
plurality of protrusions comprises opposing sidewalls and a distal
end, and the secondary passageway is through at least one of the
opposing sidewalls.
19. The mattress assembly of claim 16, wherein each of the
protrusions comprises opposing sidewalls and a distal end, and the
secondary passageway is through the distal end.
20. The mattress assembly of claim 17, wherein the secondary
passageway exchanges airflow with a hollow portion of the at least
one foam side support member through a lower surface opening of the
at least one foam side support member.
21. The mattress assembly of claim 20, wherein the hollow portion
extends longitudinally across the at least one foam side support
member to form at least one longitudinal side support passageway
between opposite external openings of the at least one foam side
support member.
22. The mattress assembly of claim 20, wherein the hollow portion
traverses across a width of the at least one foam side support
member to form at least one latitudinal side support passageway
between opposite external openings of the at least one foam side
support member.
23. The mattress assembly of claim 20, wherein the hollow portion
in the at least one foam side support member further exchanges the
airflow though a tertiary opening through the inner surface of the
at least one foam side support member.
24. The mattress assembly of claim 20, wherein the hollow portion
in the at least one foam side support member further exchanges the
airflow though a tertiary opening through the outer surface of the
at least one foam side support member.
25. The mattress assembly of claim 20, wherein the hollow portion
in the at least one foam side support member further exchanges the
airflow through a tertiary opening in an upper surface of the at
least one foam side support member.
26. The mattress assembly of claim 12, wherein the at least one
foam side support member comprises: at least one hollow portion;
and a first opening in the inner side surface configured to
exchange airflow between the hollow portion and the mattress
core.
27. The mattress assembly of claim 26, wherein the at least one
foam side support member further comprises a second opening in the
outer side surface configured to exchange airflow between the at
least one hollow portion and the exterior environment.
28. The mattress assembly of claim 25, wherein the at least one
foam side support member further comprises an upper opening in the
upper surface configured to exchange airflow between the at least
one hollow portion and the exterior environment.
29. The mattress assembly of claim 26, wherein the at least one
hollow portion extends longitudinally across the at least one foam
side support member to form at least one longitudinal side support
passageway between opposite external openings of the at least one
side support.
30. A foam side support member to support a side periphery of a
mattress core, comprising a foam body, the foam body comprising: a
first surface configured to receive a weight of a user, a second
surface opposite the first surface to transfer the weight of the
user to a foam base, an inner side surface configured to face an
inner space containing a mattress core, the inner side surface
connects the first surface to the second surface, an outer side
surface opposite the inner side surface and facing an exterior
environment, and an inner surface forming a passageway configured
to exchange airflow between the inner space and the exterior
environment.
31. The foam side support member of claim 30, wherein the
passageway extends from an opening in the inner side surface to an
opening in the outer side surface.
32. The foam side support member of claim 30, wherein the
passageway extends from an opening in a second side surface to an
opening in the outer side surface.
33. The foam side support member of claim 30, wherein the
passageway is not perpendicular to the inner side surface.
34. The foam side support member of claim 30, wherein the inner
side surface and the outer side surface comprise mainly closed cell
foam.
35. The foam side support member of claim 30, wherein the
passageway is not parallel to an extrusion direction of the foam
side support member.
36. The foam side support member of claim 30, wherein the foam side
support member comprises polyethylene.
37. A side rail assembly for supporting an edge of a mattress,
comprising: a layer of foam comprising at least one channel and/or
a plurality of orifices, wherein the layer is configured to be
disposed about a perimeter of an inner core of the mattress,
wherein the at least one channel extends through a length of the
layer and the plurality of orifices extend through a width of the
layer, and wherein the at least one channel and/or the plurality of
orifices are configured to permit the flow of fluid from and to the
inner core through the layer.
38. The side rail assembly of claim 37, wherein the layer comprises
at least one foam side support member.
39. The side rail assembly of claim 37, wherein the at least one
channel comprises at least one longitudinal passage.
40. The side rail assembly of claim 37, wherein the plurality of
orifices comprises at least one passageway formed by an inner
surface of the at least one foam side support member to permit an
air exchange between the interior space and an exterior
environment.
41. The side rail assembly of claim 37, wherein the inner core
comprises the mattress core.
42. The side rail assembly of claim 38, wherein the width of the
layer comprises a distance between an inner side surface of the at
least one foam side support member and the outer side surface of
the at least one foam side support member.
43. The side rail assembly of claim 37, wherein the flow of fluid
comprises an air exchange.
44. The side rail assembly of claim 39, further comprising at least
one inter-level channel connecting the at least one channel.
45. The side rail assembly of claim 38, further comprising at
opening at a bottom surface or a second side of the at least one
foam side support member, the opening is configured to be in fluid
communication with a hollow portion of the at least one foam side
support member and an inner base passageway of a foam base.
46. The mattress assembly of claim 12, wherein the at least one
passageway comprises a plurality of passageways which are
horizontally aligned and vertically offset.
Description
PRIORITY APPLICATIONS
[0001] The present application claims priority to co-pending U.S.
Provisional Patent Application Ser. No. 61/791,842 entitled
"Mattress Assemblies and Components Employing Passageways for
Ventilation and Airflow," filed on Mar. 15, 2013, which is hereby
incorporated herein by reference in its entirety.
[0002] The present application also claims priority to co-pending
U.S. Provisional Patent Application Ser. No. 61/620,649 entitled
"Mattress Assemblies And Methods Employing Foam Side Support
Members With Attachment Members," filed on Apr. 5, 2012, which is
hereby incorporated herein by reference in its entirety.
[0003] The present application is a continuation-in-part
application of co-pending U.S. patent application Ser. No.
13/738,391 entitled "Mattress Assemblies and Methods Employing
Cloth Member(s) Thermally Bonded To Foam Side Support Member(s) To
Form Mattress Encasements," filed on Jan. 10, 2013, which claims
priority to U.S. Provisional Patent Application Ser. No. 61/585,021
entitled "Mattress Assemblies And Methods Employing Foam Side
Support Members With Attachment Members," filed on Jan. 10, 2012,
both of which are incorporated herein by reference in their
entireties.
FIELD OF DISCLOSURE
[0004] The technology of the disclosure relates generally to foam
mattress assemblies, mattresses, and related methods providing
ventilation and airflow, which may be employed in bedding and
seating applications.
BACKGROUND
[0005] Mattress cores 10 are one of many components contributing
support and cushioning characteristics to a mattress or seating
structure. Mattress cores 10 may be available in many varieties,
for example, innerspring assemblies ("innersprings"), one or more
foam layers, and air baffles. An exemplary innerspring 12 is
depicted in FIG. 1A and provided as part of a mattress assembly 14.
The innerspring 12 is comprised of a plurality of spring coils 16
arranged proximate to each other. The mattress core 10 may be
located atop a foam base 18 to support a user's weight. The foam
base 18 may contribute cushioning to the mattress assembly 14. The
foam base 18 is used below the mattress core 10 and, in combination
with at least one side support 20(1), 20(2) located around the side
periphery of the mattress core 10, to form an enclosure 22 around
the mattress core 10.
[0006] The enclosure 22 may serve many useful functions. The
enclosure 22 may protect the mattress core 10 during transportation
and installation by providing a more rugged exterior structure. The
enclosure 22 may also provide additional support around the side
periphery of the mattress core 10 where an individual user may
disproportionally place weight on the mattress core 10, for
example, during mounting onto and dismounting from the mattress
assembly 14. The enclosure 22 may also prevent the mattress core 10
from separating from the mattress assembly 14.
[0007] The mattress assembly 14 in FIG. 1 may include a plurality
of cushion layers 24 disposed atop the mattress core 10 and the
enclosure 22. The plurality of cushion layers 24 typically closes
off a top opening 26 of the enclosure 22 while providing soft
cushioning to the user. However, stagnant air and humidity may
collect within the enclosure 22 contributing to development of
bacterial counts. There is a need for mattress assemblies and
associated components that avoid stagnant air and humidity.
SUMMARY OF THE DETAILED DESCRIPTION
[0008] Embodiments disclosed herein include mattress assemblies and
components employing passageways for ventilation and airflow. A
mattress may contain a mattress core to provide cushioning and
support. For example, the mattress core may comprise an
innerspring, air bladder(s), and/or foam layer(s). A mattress
assembly may include a foam base and/or at least one foam side
support member to at least partially surround a mattress core to
provide cushioning and structure. The foam base and/or at least one
foam side support member may include at least one passageway for
facilitating diffusion and air exchange between an exterior
environment and an interior space of the enclosure containing the
mattress core. In this manner, as stagnant air and humidity
developing in the mattress core may be avoided or reduced from the
mattress core, which may otherwise cause unhealthy conditions or
unpleasant odors for users.
[0009] In this regard in one embodiment, a mattress assembly is
provided. The mattress assembly may include a mattress core
comprising a first support surface configured to face a user
applying a weight of the user to the mattress core. The mattress
core may also include a second support surface opposite the first
support surface. The mattress core may also include a side
periphery extending between the first support surface with the
second support surface. The mattress assembly may include a foam
base configured to support the weight of the user transmitted
through the mattress core. The mattress assembly may further
include at least one foam side support member disposed along the
side periphery. The at least one foam side support member is
configured to allow an airflow to exit from and enter into an
interior space formed by an inner side surface of each of the at
least one foam side support member and a portion of an inner base
surface of the foam base. The portion of the inner base surface
faces the mattress core. In this manner, stagnant air and humidity
may be removed from the interior space.
[0010] In another embodiment, a mattress assembly is disclosed
comprising a mattress core. The mattress core comprises a first
support surface configured to face a user applying a weight of the
user to the mattress core, a second support surface opposite the
first surface, and a side periphery extending between the first
support surface and the second support surface. The mattress core
further comprises a foam base configured to support a weight of the
mattress core. The foam base further comprises an inner base
surface facing the mattress core. The mattress core further
comprises at least one foam side support member configured to be
disposed along the side periphery. The at least one foam side
support member comprises an inner side surface facing the mattress
core and an outer side surface opposite the inner side surface. The
at least one foam side support member is configured to allow an
airflow to exit from and enter into an interior space formed by the
inner side surface of each of the at least one foam side support
member and a portion of the inner base surface. The inner side
surface and the outer side surface comprise closed cell foam. In
this manner, stagnant air and humidity may be removed from the
interior space.
[0011] In another embodiment, a mattress assembly is disclosed
comprising a mattress core. The mattress core comprises a
cushioning structure including a first support end configured to
receive a weight of a user, a second support end opposite the first
support end, and a side periphery. The mattress assembly further
comprises an enclosure forming an interior space to contain the
mattress core. The enclosure comprises a foam base including a
first surface and a second surface opposite the first surface. The
first surface is disposed adjacent to the second support end of the
mattress core and configured to receive the weight of the user from
the mattress core. The enclosure further comprises at least one
foam side support member including an inner surface and an outer
surface opposite the inner surface. The at least one foam side
support member is disposed along the side periphery and is in
communication with the foam base. The mattress core further
comprises an inner surface forming at least one passageway to
permit airflow between the interior space and an exterior
environment. In this manner, stagnant air and humidity may be
removed from the interior space.
[0012] In another embodiment, a foam side support member is
disclosed. The foam side support member is disposed along a side
periphery of a mattress core. The foam side support member
comprises a foam body. The foam body comprises a first surface
configured to receive a weight of a user. The foam body also
comprises a second surface opposite the first surface to transfer
the weight of the user to a foam base. The foam body also comprises
an inner side surface configured to face an inner space containing
a mattress core. The inner side surface connects the first surface
to the second surface. The foam body also comprises an outer side
surface opposite the inner side surface and facing an exterior
environment. The foam body also comprises an inner surface forming
a passageway configured to exchange airflow between the inner space
and the exterior environment. In this manner, the stagnant air and
humidity may be removed from the interior space.
[0013] In another embodiment, side rail assembly for supporting an
edge of a mattress is disclosed. The side rail assembly including
layer of foam comprising at least one channel and/or a plurality of
orifices. The layer is configured to be disposed about a perimeter
of an inner core of the mattress. The at least one channel extends
through a length of the layer and the plurality of orifices extend
through a width of the layer. The at least one channel and/or the
plurality of orifices are configured to permit the flow of fluid
from and to the inner core through the layer. In this manner,
stagnant air and humidity may be removed from the interior
space.
[0014] Additional features and advantages will be set forth in the
detailed description which follows, and in part will be readily
apparent to those skilled in the art from that description or
recognized by practicing the embodiments as described herein,
including the detailed description that follows, the claims, as
well as the appended drawings.
[0015] It is to be understood that both the foregoing general
description and the following detailed description present
embodiments, and are intended to provide an overview or framework
for understanding the nature and character of the disclosure. The
accompanying drawings are included to provide a further
understanding, and are incorporated into and constitute a part of
this specification. The drawings illustrate various embodiments,
and together with the description serve to explain the principles
and operation of the concepts disclosed.
BRIEF DESCRIPTION OF FIGURES
[0016] FIG. 1 is a perspective partial cutaway view of a mattress
in the prior art including a mattress core of an innerspring type
surrounded by an enclosure comprising at least one foam side
support member and a foam base as is known in the art, illustrating
the enclosure wherein stagnant air and humidity may have a tendency
to collect;
[0017] FIG. 2A is a top perspective view of an exemplary mattress
assembly including at least one foam side support member, a foam
base, and a mattress core, illustrating one embodiment of at least
one passageway to facilitate air exchange between the interior
space and an exterior environment and thereby avoid or reduce
stagnant air and humidity from the interior space;
[0018] FIGS. 2B and 2C are side sectional views along a width and a
length, respectively, of the mattress assembly of FIG. 2A;
[0019] FIG. 2D is an exploded side sectional view of the mattress
assembly of FIG. 2A including a cushion layer and the mattress core
removed from an enclosure comprising the at least one side support
and the foam base, illustrating an interior space with which the at
least one passageway will exchange airflow to and from an exterior
environment;
[0020] FIGS. 3A and 3B depict side sectional views of a mattress
assembly which is a second embodiment of the mattress assembly of
FIG. 2A, wherein a foam side support member allows an airflow
A.sub.1 to exit from and enter into the interior space according to
diffusion;
[0021] FIGS. 4A and 4B depict side sectional views of a mattress
assembly which is a second embodiment of the mattress assembly of
FIG. 2A, wherein a foam side support member allows an airflow
A.sub.2 to exit from and enter into the interior space when the
mattress assembly is subject to a weight of the user;
[0022] FIGS. 5A and 5B are a partial side view and a partial top
view, respectively, of passageways through the foam side support
member of FIGS. 3A-4B;
[0023] FIGS. 6A-6D are a top perspective, front side, and two right
sectional views, respectively, of another embodiment of the
mattress assembly including at least one side support and a foam
base, illustrating at least one passageway to exchange airflow
between the interior space and the exterior environment;
[0024] FIGS. 7A-7D are a top perspective, front side, and two right
sectional views, respectively, of another embodiment of the
mattress assembly including at least one side support and a foam
base, illustrating at least one passageway to exchange airflow
between the interior space and the exterior environment;
[0025] FIGS. 8A-8D are a top perspective, front side, and two right
sectional views of another embodiment of the mattress assembly
including at least one side support and a foam base, illustrating
at least one passageway to exchange airflow between the interior
space and the exterior environment;
[0026] FIG. 8E is a top perspective view of the passageways of the
mattress assembly of FIG. 8A with the at least one side support
member and the foam base in phantom lines;
[0027] FIG. 8F is a bottom view of the at least one side support of
FIG. 8A illustrating bottom openings of inter-level channels to
communicate with inner base passageways of the foam base;
[0028] FIG. 8G is a top view of the foam base of FIG. 8A
illustrating top interface openings of the foam base configured to
communicate with the bottom openings of the at least one side
support;
[0029] FIGS. 9A-9D are a top perspective, front side, and two right
sectional views of another embodiment of the mattress assembly
including at least one side support and a foam base, illustrating
at least one passageway to exchange airflow between the interior
space and the exterior environment;
[0030] FIGS. 10A-10D are a top perspective, front side, and two
right sectional views of another embodiment of the mattress
assembly including at least one side support and a foam base,
illustrating at least one passageway to exchange airflow with the
exterior environment;
[0031] FIGS. 11A-11D are a top perspective, front side, and two
right sectional views of another embodiment of the mattress
assembly including at least one side support and a foam base,
illustrating at least one passageway to exchange airflow with the
exterior environment;
[0032] FIG. 11E is a bottom view of the at least one side support
of FIG. 11A illustrating bottom openings of inter-level channels to
communicate with inner base passageways of the foam base;
[0033] FIG. 11F is a top view of the foam base of FIG. 11A
illustrating top interface openings of the foam base configured to
communicate with the inter-level channels of the at least one side
support; and
[0034] FIG. 11G is a close-up front side view of the foam base of
FIG. 11B showing passageways through sidewalls of the protrusions
and a foam deck of the foam base.
DETAILED DESCRIPTION
[0035] With reference now to the drawing figures, several exemplary
embodiments of the present disclosure are described. The word
"exemplary" is used herein to mean "serving as an example,
instance, or illustration." Any embodiment described herein as
"exemplary" is not necessarily to be construed as preferred or
advantageous over other embodiments.
[0036] Embodiments disclosed herein include mattress assemblies and
components employing passageways for ventilation and airflow. A
mattress may contain a mattress core to provide cushioning and
support. For example, the mattress core may comprise an
innerspring, air bladder(s), and/or foam layer(s). A mattress
assembly may include a foam base and/or at least one foam side
support member to at least partially surround a mattress core to
provide cushioning and structure. The foam base and/or at least one
foam side support member may include at least one passageway for
facilitating diffusion and air exchange between an exterior
environment and an interior space of the enclosure containing the
mattress core. In this manner, as stagnant air and humidity
developing in the mattress core may be avoided or reduced from the
mattress core, which may otherwise cause unhealthy conditions or
unpleasant odors for users.
[0037] In this regard, FIGS. 2A, 2B, 2C, and 2D are a top
perspective view, two side sectional views, and an exploded view,
respectively, of an exemplary mattress assembly 30(1). The mattress
assembly 30(1) comprises at least one passageway 32A to facilitate
an exchange of airflow A.sub.1 between an exterior environment 34
and an interior space 36 of the mattress assembly 30(1). The
interior space 36 is disposed within an enclosure 38 comprised of
at least one foam side support member 40A(1)-40A(4) supported by a
foam base 42(1). The airflow A.sub.1 may occur through a force F
applied by a user on the mattress assembly 30(1). It is also noted
that an airflow A.sub.2 may be exchanged through the passageways
32A through diffusion in the absence of the force F. The
passageways 32A may be formed by an inner surface 45 of the foam
side support members 40A(1)-40A(4) connecting opposite openings
47A, 47B in the foam side support members 40A(1)-40A(4). In this
manner, as a non-limiting example, stagnant air and humidity may be
avoided or reduced from the interior space 36 which may otherwise
cause unhealthy conditions or unpleasant odors for users.
[0038] The mattress assembly 30(1) comprises a mattress core 44,
the foam base 42(1), and the foam side support members
40A(1)-40A(4). It is noted that the foam side support members
40A(1)-40A(4) may be secured to the foam base 42A with at least one
first cloth member 43(1)-43(4), an adhesive, cohesive, mechanical
means, or thermal bonding to form the enclosure 38. The foam base
42A and the foam side support members 40A(1)-40A(4) may be made of
any polymeric foam material, for example, an extruded or molded
closed-cell polyethylene foam.
[0039] The mattress core 44 is at a center of the mattress assembly
30(1) providing primary support to a user. The mattress core 44 may
include a first support end 46, second support end 48, and a side
periphery 50. The first support end 46 may be configured to face a
user applying a weight F (or "force") of the user to the mattress
core 44. The second support end 48 may be opposite the first
support end 46. The side periphery 50 may be formed by the lateral
outward bounds of the mattress core 44 between the first support
end 46 and the second support end 48. The mattress core 44 may
further comprise at least one cushioning structure 52. Embodiments
of the cushioning structure 52 may comprise, for example, a
non-pocketed spring coil, a pocketed spring coil 54 (also referred
to as a "Marshall coil"), or an air bladder. FIGS. 2B and 2C depict
the exemplary cushioning structure 52 as a pocketed spring coil 54
in a sleeve 56.
[0040] With continuing reference to FIGS. 2A through 2C, the foam
base 42(1) is a structural component which supports the mattress
core 44 and also forms a portion of the enclosure 38A that
surrounds the mattress core 44. The enclosure 38(1) protects the
integrity of the mattress core 44 by, for example, preventing the
at least one cushioning structure 52 of the mattress core 44 from
separating. The mattress assembly 30(1) may include the foam base
42(1) configured to support the weight F of the user transmitted
through the mattress core 44.
[0041] Next, the foam side support members 40A(1)-40A(4) provide an
optional perimeter support structure around the mattress core 44 to
thereby provide additional support when a user mounts or dismounts
from the mattress assembly 30(1). The foam side support members
40A(1)-40A(4) also form another portion of the enclosure that
surrounds the mattress core 44 and thereby may be attached to the
foam base 42(1).
[0042] Each of the at least one foam side support member
40A(1)-40A(4) comprises a first surface 58(1)-58(4), a second
surface 60(1)-60(4) opposite the first surface 58(1)-58(4), and an
inner side surface 62(1)-62(4) facing the mattress core 44. The
second surface 60(1)-60(4) of the foam side support member
40A(1)-40A(4) or any other part of the foam side support member
40A(1)-40A(4) may be attached to the first cloth member
43(1)-43(4). Further, the inner side surface 62(1)-62(4) of the
foam side support member 40A(1)-40A(4) may abut the mattress core
44. This abutment enables the mattress core 44 to be vertically
positioned and minimizes localized pressure experienced by the user
by distributing the user's weight over a larger quantity of
cushioning structures 52.
[0043] The attachments between the first cloth member 43(1)-43(4)
and the foam side support member 40A(1)-40A(4) and the foam base
42(1) may be made with an adhesive or thermal bonding. The adhesive
may be, for example, hot melt, a water-based adhesive, or a
solvent-based adhesive. As such, the first cloth member 43(1)-43(4)
may be attached in situations when thermal bonding is not
available.
[0044] With continuing reference to FIGS. 2A through 2D, the
mattress assembly 30(1) may further include a second cloth member
64 that may be configured to prevent the mattress core 44 from
departing from an interior space 36 formed by the inner side
surface 62(1)-62(4) of each of the foam side support member
40A(1)-40A(4) and a portion 66 of an inner base surface 68 of the
foam base 42(1). The portion 66 of the inner base surface 68 faces
the mattress core 44. The enclosure 38 forming the interior space
36 (see FIG. 2D) may comprise an opening 70. The opening 70 may be
opposite the portion 66 of the inner base surface 68 to enable the
mattress core 44 to abut against the inner base surface 68 when not
departing the opening 70.
[0045] The second cloth member 64 may be attached to at least
portions 72 (see FIG. 2A) of the foam side support member
40A(1)-40A(4) to at least partially close the opening 70 and
thereby prevent the mattress core 44 from departing the interior
space 36. As shown in FIG. 2A, the portions 72 may be close to the
corners 74 of the mattress assembly 30(1) to enable the second
cloth member 64 to more easily straddle the mattress core 44
between two portions that are relatively close together. The second
cloth member 64 may be a multi-piece or single-piece structure to
reduce cost.
[0046] With continuing reference to FIGS. 2B and 2C, instead of
merely closing the opening 70 to prevent the mattress core 44 from
departing the interior space 36, the second cloth member 64 may
also be attached to the foam side support members 40A(1)-40A(4) and
the mattress core 44 to prevent the mattress core 44 from departing
the interior space 36.
[0047] Next, as shown in FIG. 2D, a padding material 76 may be
included as part of the mattress assembly 30(1). The padding
material 76 may be disposed between the user and the mattress core
44 to provide more comfort to the user. The padding material 76 may
be made of a soft resilient material, for example, viscoelastic
foam. Ticking 78 may be added to form an exterior surface that
surrounds the other components, as well as the padding material 76
disposed between the ticking 78 and the mattress core 44.
Alternatively, the mattress assembly 30(1) may optionally not
include the ticking 78 and/or the padding material 76 to lower
material costs and thereby enable lower prices to be provided to
consumers.
[0048] Other embodiments of the mattress assembly are possible to
facilitate air exchange between the exterior environment 34 and the
interior space 36 and thereby avoid or reduce stagnant air and
humidity within the interior space 36. FIGS. 3A-4B depict a side
view of a mattress assembly 30(2) in another embodiment of the
mattress assembly 30(1). The mattress assembly 30(2) may comprise a
foam side support member 40B(1)-40B(4), which is another embodiment
of the foam side support member 40A(1)-40A(4). The mattress
assembly 30(2) may comprise the ticking 78 surrounding the foam
side support member 40B(1)-40B(4), the first cloth member
43(1)-43(4), and the foam base 42(1). The ticking 78 may be
configured to be permeable to the airflow A.sub.1. The ticking 78
may be made of a strong flexible material that is permeable to the
airflow A.sub.1, A.sub.2, for example, a woven fabric.
[0049] The foam side support member 40B(1)-40B(4) may be configured
to allow the airflow A.sub.1 to exit from and enter into the
interior space 36 using diffusion when the mattress assembly 30(2)
is not subject to either the force F.sub.1 or the force F.sub.2 of
the user as shown in FIGS. 3A-3B. The foam side support member
40B(1)-40B(4) may also be configured to allow the airflow A.sub.2
to exit from and the airflow A.sub.2 to enter into the interior
space 36 when the mattress assembly 30(2) is subject to non-zero
forces F.sub.1, F.sub.2 of the user as shown in FIGS. 4A-4B. It is
noted that the mattress core 44 may be disposed within the interior
space 36, but the mattress core 44 is not shown in FIGS. 3A-4B to
merely simplify the drawings. The airflow A.sub.1 and the airflow
A.sub.2 may remove moisture and stagnant air from the interior
space 36 and the mattress core 44 that may otherwise promote
unhealthy conditions, for example, mold growth within the
mattress.
[0050] The force F.sub.1 may be positively created directly by the
user in the direction of gravity. The force F.sub.2 is a responsive
force created by elements of the mattress assembly 30(2) to restore
its original shape while not subject to force F.sub.1. One or more
of the foam side support members 40B(1)-40B(4) may include a first
opening 80 in one or more of the inner side surfaces 62(1)-62(4).
One or more of the foam side support members 40B(1)-40B(4) may also
include a second opening 82 in one or more outer side surfaces
84(1)-84(4) of the foam side support members 40B(1)-40B(4) opposite
the inner side surfaces 62(1)-62(4). As shown in FIGS. 5A and 5B
the foam side support members 40B(1)-40B(4) may further include
passageway surface 86 forming one or more passageways 32 connecting
the first opening 80 to the second opening 82. The passageway 32
may be configured to allow the airflows A.sub.1, A.sub.2 to exit
from the interior space 36, and the airflows A.sub.1, A.sub.2 to
enter into the interior space 36. The passageway 32 may or may not
be perpendicular to the inner side surface 62(1)-62(4), although
the exemplary embodiment shown in FIG. 5B is perpendicular.
Airflows A1, A2 may be directed on an angle if the passageway 32 is
not perpendicular to avoid obstacles (not shown) within the
interior space 36, for example, adjacent ones of the foam side
support members 40B(1)-40B(4).
[0051] In order to reduce noise related to open cell foam surfaces
rubbing against the ticking 78 and the mattress core 44, the inner
side surface 62(1)-62(4) and the outer side surface 84(1)-84(4) may
comprise mainly closed cell foam. The closed cell foam may be
created, for example, through an extrusion process where the
surfaces at issue are parallel to a direction of extrusion.
[0052] The passageway 32 may be non-parallel to an extrusion
direction for the foam side support member 40B(1)-40B(4). In this
case, the passageway 32 may be created through the foam side
support member 40B(1)-40B(4) without use of extrusion, but instead
by, for example, boring the passageway 32 through the foam side
support member 40B(1)-40B(4). The foam side support member
40B(1)-40B(4) may comprise, for example, polyethylene to enable a
boring process or other material removal process to create the
passageway 32.
[0053] With reference back to FIGS. 3A-4B, at least one
longitudinal passageway 88 may be created through the foam side
support member 40B(1)-40B(4). The longitudinal passageway 88 may be
created as part of an extrusion process, for example, and thereby
may be parallel to an extrusion direction of the extrusion process.
The longitudinal passageway 88 may be optionally angled to the
passageway 32 and may be unconnected so as to prevent the airflow
A.sub.1, A.sub.2 from entering the longitudinal passageway 88.
Preventing the airflow A.sub.1, A.sub.2 to pass between the
longitudinal passageway 88 and the passageway 32 may improve
product safety by limiting oxygen flow to a localized area of the
foam side support member 40B(1)-40B(4). Otherwise, a greater
availability of oxygen may propagate flames in a situation known as
"chimney effect" as may be measured by a product safety burn
test.
[0054] It is noted that the foam side support member 40B(1)-40B(4)
may be utilized in mattress assemblies 30(2) with or without
flexible cloth-shaped members. This flexibility enables the
airflows A.sub.1, A.sub.2 to ventilate mattresses assemblies that
utilize other attachment techniques.
[0055] Other embodiments of the mattress assembly 30 are possible
to reduce stagnant air and humidity in the interior space 36. FIGS.
6A-6D are a top perspective, front side, and two right sectional
views of a mattress assembly 30(3) which is another embodiment of
the mattress assembly 30(2) of FIG. 3A-4B. Accordingly, only the
details of differences will be discussed for clarity and
conciseness.
[0056] The mattress assembly 30(3) comprises at least one foam side
support member 40C(1)-40C(4) supported by the foam base 42(1). The
foam side support members 40C(1)-40C(4) comprise the passageways 32
therethrough. The foam side support members 40C(1)-40C(4) also
comprise at least one top groove 90 as part of the first surface
58(1)-58(4) of the foam side support members 40C(1)-40C(4). The top
grooves 90 are configured pass at least a portion of the airflows
A1, A2 to be exchanged between the exterior environment 34 and the
interior space 36 of the mattress assembly 30(3). The top grooves
90 may be curved and up to a distance D.sub.1 deep. The distance
D.sub.1 may be between 0.125 inches and 0.75 inches deep, and
preferably a quarter (0.25) inches deep. The top grooves 90 may be
formed with a router or other cutting tool. In this manner,
stagnant air and humidity may be eliminated or reduced from the
interior space 36 which may otherwise cause unhealthy conditions or
unpleasant odors for users.
[0057] With continued reference to FIGS. 6A-6D, the foam base 42(1)
of the mattress assembly 30(3) may include at least one inner base
passageway 92 formed by at least one inner base surface 94
extending across the foam base 42(1). The at least one inner base
passageway 92 may reduce stiffness of the foam base 42(1) and
thereby contribute cushioning to the mattress assembly 30(3).
However, the inner base passageways 92 are not connected to the
passageways 32. In this manner, the mattress assembly 30(3) is less
complex and easier to manufacture.
[0058] The passageways 32 of the foam side support members
40C(1)-40C(4) may also be unconnected to the longitudinal
passageways 88 of the foam side support members 40C(1)-40C(4). The
lack of a connection may allow the foam side support members
40C(1)-40C(4) to retain a higher level of stiffness and thereby
provide more support to the mattress assembly 30(3). In this
manner, the foam side support members 40C(1)-40C(4) may be made of
a low density foam to save material costs yet still contribute
sufficient support for the mattress assembly 30(3).
[0059] Other embodiments of the mattress assembly 30 are possible
to reduce stagnant air and humidity in the interior space 36. FIGS.
7A-7D are a top perspective, front side, and two right sectional
views of a mattress assembly 30(4) which is another embodiment of
the mattress assembly 30(2) of FIGS. 3A-4B. Accordingly, only the
details of differences will be discussed for clarity and
conciseness.
[0060] The mattress assembly 30(4) comprises at least one foam side
support member 40D(1)-40D(4) supported by the foam base 42(1). The
foam side support members 40D(1)-40D(4) comprise the passageways 32
extending between the first openings 80 on the inner side surfaces
62(1)-62(4) and the second openings 82 on the outer side surfaces
84(1)-84(4) of the foam side support members 40D(1)-40D(4).
However, the passageways 34 may be connected to a plurality of
longitudinal passageways 88(1)-88(3) that extend respective lengths
L.sub.S of the foam side support members 40D(1)-40D(4). The
longitudinal passageways 88(1)-88(3) may be respectively disposed
at different heights H.sub.1, H.sub.2, H.sub.3 of the foam side
support members 40D(1)-40D(4) which may be equidistant. In this
manner, the foam side support members 40D(1)-40D(4) may have
reduced stiffness and thereby contribute cushioning to the mattress
assembly 30(4).
[0061] For purposes of terminology it is noted, that as used
herein, a hollow portion 99 (see FIG. 5B) or "hollow portion" of
any foam side support member means any passageway or portion of a
passageway to allow airflow to pass internally within the foam side
support member and between any two openings disposed at different
locations on a full periphery of the foam side support member. For
example, if a foam side support member has a rectangular prism
shape, then the full periphery of the foam side support member is
formed by all six sides of the rectangular prism shape.
[0062] With continued reference to FIGS. 7A-7D, the mattress
assembly 30(4) may also comprise at least one inter-level channel
96A connecting the longitudinal passageways 88(1)-88(3) of the foam
side support members 40D(1)-40D(4). The inter-level channel 96A may
be directed parallel to an axis A.sub.3 (FIGS. 7B and 7D) which may
be disposed vertically. The inter-level channel 96A may allow
airflow exchange between the longitudinal passageways 88(1)-88(3)
and the inter-level channel 96A. In this manner, the foam side
support members 40D(1)-40D(4) may have more uniform stiffness
characteristics along the length L.sub.S of the foam side support
members 40D(1)-40D(4) while providing airflow exchange throughout
the side supports.
[0063] The inter-level channels 96A may also include at least one
opening 98 on the first surfaces 58(1)-58(4) of the foam side
support members 40D(1)-40D(4). In this manner, stagnant air and
humidity may be more effectively eliminated or reduced from the
interior space 36 by increasing the quantities of the possible
directions the airflow could exit or enter the interior space
36.
[0064] With continued reference to FIGS. 7A-7D, the foam base 42(1)
of the mattress assembly 30(3) may include the at least one inner
base passageway 92 formed by the at least one inner base surface 94
extending across the foam base 42(1). The at least one inner base
passageway 92 may reduce stiffness of the foam base 42(1) and
thereby contribute cushioning to the mattress assembly 30(3).
However, the inner base passageways 92 are not connected to the
passageways 32. In this manner, the mattress assembly 30(4) is less
complex and easier to manufacture.
[0065] Other embodiments are possible to reduce stagnant air and
humidity in the interior space 36. FIGS. 8A-8D are a top
perspective, front side, and two right sectional views of a
mattress assembly 30(5) which is another embodiment of the mattress
assembly 30(4) of FIG. 7A. The mattress assembly 30(5) comprises at
least one side support 40E(1)-40E(4) supported by a foam base
42(2). The mattress assembly 30(5) is similar to the mattress
assembly 30(4). Accordingly, only details of differences will be
discussed for clarity and conciseness.
[0066] The mattress assembly 30(5) comprises at least one
inter-level channel 96B connecting the longitudinal passageways
88(1)-88(3) of the foam side support members 40E(1)-40E(4), similar
to the inter-level channel 96A of the mattress assembly 30(4).
However, the inter-level channels 96B extend along an axis A.sub.4
to bottom openings 100 (FIG. 8F) at the second surface 60(1)-60(4)
of the foam side support members 40E(1)-40E(4). The bottom openings
100 of the foam side support members 40E(1)-40E(4) connect with the
inner base passageways 92 of the foam base 42(2) via top interface
openings 102 on the inner base surface 68 of the foam base 42(2)
(FIG. 8G). In this manner, the stagnant air and humidity may be
more efficiently eliminated or reduced from the interior space 36
by exiting out the inter-level channels 96B to the foam base 42(2).
It is noted that FIG. 8E is a top perspective view of the inner
base passageways 92 within the mattress assembly 30(5) with
outlines of the foam side support members 40E(1)-40E(4) and the
foam base 42(2) in phantom lines for convenient reference.
[0067] Other embodiments are possible to reduce stagnant air and
humidity in the interior space 36. FIGS. 9A-9D are a top
perspective, front side, and two right sectional views of a
mattress assembly 30(6) which is another embodiment of the mattress
assembly 30(5) of FIG. 8A. The mattress assembly 30(6) comprises at
least one foam side support member 40F(1)-40F(4) supported by the
foam base 42(2) of FIG. 7A. The mattress assembly 30(5) is similar
to the mattress assembly 30(4). Accordingly, only details of
differences will be discussed for clarity and conciseness.
[0068] The mattress assembly 30(6) comprises at least one
inter-level channel 96C connecting the longitudinal passageways
88(1)-88(3) of the foam side support members 40F(1)-40F(4) and
extend to openings 98 at the first surface 58(1)-58(4), similar to
the inter-level channel 96A of the mattress assembly 30(4).
However, the inter-level channels 96C of the foam side support
members 40F(1)-40F(4) are offset horizontally from the passageways
32. In this manner, the foam side support members 40F(1)-40F(4) are
stronger because the passageways are spread more uniformly within
an interior of the foam side support members 40F(1)-40F(4).
[0069] The foam side support members 40F(1)-40F(4) further comprise
secondary channels 104 to connect the longitudinal passageway 88(1)
with the inner base passageway 92 of the foam base 42(2) through
the bottom openings 100 (FIG. 9D) of the side support and the top
interface openings 102 (FIG. 8G). The secondary channels 104 are
also offset horizontally from the inter-level channel 96C. In this
manner, the foam side support members 40F(1)-40F(4) are made
further stronger because passageways and channels are spread more
uniformly within an interior of the foam side support members
40F(1)-40F(4).
[0070] Other embodiments are possible to reduce stagnant air and
humidity in the interior space 36. FIGS. 10A-10D are a top
perspective, front side, and two right sectional views of a
mattress assembly 30(7) which is another embodiment of the mattress
assembly 30(6) of FIG. 9A. The mattress assembly 30(7) comprises
the foam side support members 40F(1)-40F(4) of the mattress
assembly 30(6), but uses a foam base 42(3) instead. The foam base
42(3) comprises a foam deck 106 and a plurality of protrusions
108(1)-108(p). The protrusions 108(1)-108(p) comprise distal end
surfaces 110(1)-110(p), respectively, which each are configured to
support the second support end 48 (FIG. 2D) of the mattress core 44
and the second surface 60(1)-60(n) of the foam side support members
40F(1)-40F(4). The foam deck 106 is a connecting structure for the
protrusions 108(1)-108(p) to establish spacing channels
112(1)-112(p-1) between adjacent ones of the protrusions
108(1)-108(p). The spacing channels 112(1)-112(p-1) are configured
to serve as unobstructed passageways for airflow to and from the
interior space 36. In this manner, stagnant air and humidity may be
eliminated or reduced from the interior space 36 which may
otherwise cause unhealthy conditions or unpleasant odors for
users.
[0071] Moreover, the bottom openings 100 of the foam side support
members 40F(1)-40F(4) are disposed above the spacing channels
112(1)-112(p-1). In this manner, stagnant air or humidity disposed
within the foam side support members 40F(1)-40F(4) may be in
communication with the air in the spacing channels 112(1)-112(p).
Changes in either the foam side support members 40F(1)-40F(4)
and/or the protrusions 108(1)-108(p) may cause airflow to increase
to thereby reduce stagnant air or humidity within the interior
space 36 of the mattress assembly 30(7).
[0072] Other embodiments are possible to reduce stagnant air and
humidity in the interior space 36. FIGS. 11A-11D are a top
perspective, front side, and two right sectional views of a
mattress assembly 30(8) which is another embodiment of the mattress
assembly 30(7) of FIG. 10A. The mattress assembly 30(8) comprises
foam side support members 40G(1)-40G(4) and a foam base 42(4). The
foam base 42(4) comprises the foam deck 106 and the protrusions
108(1)-108(p) having the distal end surfaces 110(1)-110(p).
However, the protrusions 108(1)-108(p) of the foam base 42(4) may
comprise the inner base surfaces 94 forming inner base passageways
92. The inner base passageways 92 may extend parallel to the foam
deck 106. The inner base passageways 92 may facilitate the collapse
of the distal end surfaces 110(1)-110(p) and thereby increase an
amount of cushioning provided by the protrusions 108(1)-108(p). In
the mattress assembly 30(8) the inner base passageways 92 exchange
airflow with the foam side support members 40G(1)-40G(4) via top
interface openings 102 of the foam base 42(4) and bottom openings
100 of the foam side support members 40G(1)-40G(4). The foam side
support members 40G(1)-40G(4) comprise the longitudinal passageways
88(1)-88(3) connected by an inter-level channel 96D which further
extends from the opening 98 at the first surface 58 of the foam
side support members 40G(1)-40G(4) to the bottom openings 100 at
the second surface 60. In this manner, the longitudinal passageways
88(1)-88(3) of the foam side support members 40G(1)-40G(4) may be
in airflow communication with the inner base passageways 92. In
this manner, any changes in the airflow of the inner base
passageways 92 protrusions 108(1)-108(p) will be communicated to
the longitudinal passageways 88(1)-88(3) which are in close
proximity to the passageways 32. The passageways 32 are in airflow
communication with the interior space 36. In this manner, airflow
changes in inner base passageways 92 of the protrusions
108(1)-108(p) may cause airflow to increase to thereby reduce
stagnant air or humidity within the interior space 36 of the
mattress assembly 30(8).
[0073] The mattress assembly 30(8) comprises at least one
inter-level channel 96D connecting the longitudinal passageways
88(1)-88(3) of the foam side support members 40E(1)-40E(4), and
extend from the first surface 58 to bottom openings 100 (FIG. 11E)
at the second surface 60(1)-60(4) of the foam side support members
40E(1)-40E(4). The bottom openings 100 of the foam side support
members 40E(1)-40E(4) connect with the inner base passageways 92 of
the foam base 42(2) via top interface openings 102 on the inner
base surface 68 of the foam base 42(2) (FIG. 11F). In this manner,
the stagnant air and humidity may be more efficiently eliminated or
reduced from the interior space 36 by exiting out the inter-level
channels 96D to the foam base 42(2).
[0074] FIG. 11F depicts a top view of the foam base 42(4). The foam
deck 106 of the foam base 42(4) includes passageways 114
therethrough at the spacing channels 112(1)-112(p-1). The
passageways 114 provide more opportunities for airflow exchange
between the interior space 36 and the exterior environment 34
particularly when the foam base 42(4) may be supported by
components allowing airflow communication between the passageways
114 and the exterior environment 34.
[0075] With continued reference to FIGS. 11A-11F and also to FIG.
11G, the foam base 42(4) also may comprise passageways 116 in
opposing sidewalls 118A(1)-118A(p), 118B(1)-118B(p) of the
protrusions 108(1)-108(p) to allow airflow to be exchanged between
the spacing channels 112(1)-112(p-1) and the inner base passageways
92(1)-92(p). The opposing sidewalls 118A(1)-118A(p),
118B(1)-118B(p) may attach the distal end surface 110(1)-110(p) to
the foam deck 106. In this manner, the passageways 116 permit
airflow to be exchanged between the spacing channels
112(1)-112(p-1) and the inner base passageways 92(1)-92(p) and
thereby may improve the opportunity for airflow to be exchanged
between the interior space 36 and the exterior environment 34.
[0076] Embodiments disclosed herein are exemplary, and may be
provided together in any combination desired. Based on this
disclosure, mattress assemblies may be assembled using the foam
side support members disclosed herein around any of a variety of
mattress cores, including for example, air bladder mattress cores,
innerspring coil mattress cores, pocketed coil spring mattress
cores (e.g. Marshall coil mattress cores), and mattress cores
formed from a cellular material (e.g. foam). Because each elongated
edge-support member disclosed herein is adaptable to be disposed
around a variety of types and dimensions of mattress cores, the
embodiments disclosed herein enable mattress core manufacturers to
more easily store and transport the elongated edge-support
members.
[0077] Those skilled in the art will recognize improvements and
modifications to the embodiments disclosed herein. Many
modifications and other embodiments of the invention set forth
herein will come to mind to one skilled in the art to which the
invention pertains having benefit of the teachings presented in the
foregoing descriptions and the associated drawings. The materials
or compositions of the aforementioned components can be varied as
well, including but not limited to whether foam may be exclusively
thermoset or thermoplastic materials, or a composite of both. All
such improvements and modifications are considered within the scope
of the concepts disclosed herein.
[0078] It is also noted that the operational steps described in any
of the exemplary embodiments herein are described to provide
examples and discussion. The operations described may be performed
in numerous different sequences other than the illustrated
sequences. Furthermore, operations described in a single
operational step may actually be performed in a number of different
steps. Additionally, one or more operational steps discussed in the
exemplary embodiments may be combined. It is to be understood that
the operational steps illustrated in the flow chart diagrams may be
subject to numerous different modifications as will be readily
apparent to one of skill in the art.
[0079] Further, it is to be understood that the embodiments are not
limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. It is intended that the
embodiments cover the modifications and variations of this
invention provided they come within the scope of the appended
claims and their equivalents. Although specific terms are employed
herein, they are used in a generic and descriptive sense only and
not for purposes of limitation.
[0080] The previous description of the disclosure is provided to
enable any person skilled in the art to make or use the disclosure.
Various modifications to the disclosure will be readily apparent to
those skilled in the art, and the generic principles defined herein
may be applied to other variations without departing from the
spirit or scope of the disclosure. Thus, the disclosure is not
intended to be limited to the examples and designs described
herein, but is to be accorded the widest scope consistent with the
principles and novel features disclosed herein.
* * * * *