U.S. patent application number 14/232794 was filed with the patent office on 2014-07-31 for foam mattress with progressive support characteristics and method for manufacturing the same.
This patent application is currently assigned to KINGSDOWN, INC.. The applicant listed for this patent is John Farnham. Invention is credited to John Farnham.
Application Number | 20140208521 14/232794 |
Document ID | / |
Family ID | 47558439 |
Filed Date | 2014-07-31 |
United States Patent
Application |
20140208521 |
Kind Code |
A1 |
Farnham; John |
July 31, 2014 |
FOAM MATTRESS WITH PROGRESSIVE SUPPORT CHARACTERISTICS AND METHOD
FOR MANUFACTURING THE SAME
Abstract
A mattress includes top and bottom foam layers. A bottom surface
of the top foam layer and a top surface of the bottom foam layer
include protrusions and recessions. The protrusions of the top
surface of the bottom foam layer protrude into the recessions of
the bottom surface of the top foam layer, and the protrusions of
the bottom surface of the top foam layer protrude into the
recessions of the top surface of the bottom foam layer. The most
protruded surfaces of the protrusions of the bottom surface of the
top foam layer are separated from corresponding surfaces of the
recessions of the top surface of the bottom foam layer by a
channel, but there is no channel between most protruded surfaces of
the protrusions of the top surface of the bottom foam layer and
corresponding surfaces of the recessions of the bottom surface of
the top foam layer.
Inventors: |
Farnham; John; (Mebane,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Farnham; John |
Mebane |
NC |
US |
|
|
Assignee: |
KINGSDOWN, INC.
Mebane
NC
|
Family ID: |
47558439 |
Appl. No.: |
14/232794 |
Filed: |
July 18, 2012 |
PCT Filed: |
July 18, 2012 |
PCT NO: |
PCT/US2012/047158 |
371 Date: |
March 26, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61509419 |
Jul 19, 2011 |
|
|
|
Current U.S.
Class: |
5/724 ; 29/91.1;
5/690 |
Current CPC
Class: |
A47C 27/15 20130101;
Y10T 29/481 20150115; A47C 27/146 20130101; A47C 21/042 20130101;
A47C 27/144 20130101 |
Class at
Publication: |
5/724 ; 29/91.1;
5/690 |
International
Class: |
A47C 27/15 20060101
A47C027/15; A47C 21/04 20060101 A47C021/04; A47C 27/14 20060101
A47C027/14 |
Claims
1. A mattress comprising: a top foam layer; and a bottom foam
layer, wherein a bottom surface of the top foam layer comprises a
series of protrusions and recessions, wherein a top surface of the
bottom foam layer comprises a series of protrusions and recessions,
wherein the protrusions of the top surface of the bottom foam layer
protrude into the recessions of the bottom surface of the top foam
layer, wherein the protrusions of the bottom surface of the top
foam layer protrude into the recessions of the top surface of the
bottom foam layer, wherein most protruded surfaces of the
protrusions of the bottom surface of the top foam layer are
separated from corresponding surfaces of the recessions of the top
surface of the bottom foam layer by a channel, and wherein there is
no channel between most protruded surfaces of the protrusions of
the top surface of the bottom foam layer and corresponding surfaces
of the recessions of the bottom surface of the top foam layer.
2. The mattress according to claim 1, wherein the most protruded
surfaces of the protrusions of the top surface of the bottom foam
layer are adhered to the corresponding surfaces of the recessions
of the bottom surface of the top foam layer by an adhesive, and
wherein no adhesive exists between the most protruded surfaces of
the protrusions of the bottom surface of the top foam layer and the
corresponding surfaces of the recessions of the top surface of the
bottom foam layer.
3. The mattress according to claim 1, further comprising first
ventilation channels formed in the top surface of the bottom foam
layer, wherein the first ventilation channels extend between
opposing side end surfaces of the bottom foam layer in a width
direction of the mattress, the width direction extending
perpendicular to a head-to-foot length direction of the
mattress.
4. The mattress according to claim 1, further comprising second
ventilation channels extending in a height direction of the
mattress from a top surface of the top foam layer to the bottom
surface of the top foam layer.
5. The mattress according to claim 1, wherein a height of the
channel in a direction perpendicular to the top surface of the
bottom foam layer is at least 0.25 inches.
6. The mattress according to claim 5, wherein the height of the
channel in the direction perpendicular to the top surface of the
bottom foam layer is less than 1.5 inches.
7. The mattress according to claim 1, wherein the mattress is
configured to provide progressively firmer support characteristics
as force applied to a top surface of the mattress increases.
8. A method for manufacturing a mattress, the method comprising:
cutting a first foam member in half to form first and second top
layers, a bottom surface of the first top layer comprising a series
of protrusions and recessions and a top surface of the second top
layer comprising a series of protrusions and recessions opposite to
the series of protrusions and recessions of the first top layer;
cutting a second foam member in half to form first and second
bottom layers, a bottom surface of the first bottom layer
comprising a series of protrusions and recessions and a top surface
of the second bottom layer comprising a series of protrusions and
recessions opposite to the series of protrusions and recessions of
the first bottom layer; and positioning the first top layer on top
of the second bottom layer such that the protrusions of the top
surface of the second bottom layer protrude into the recessions of
the bottom surface of the first top layer and the protrusions of
the bottom surface of the first top layer protrude into the
recessions of the top surface of the second bottom layer; wherein
the cutting the first foam member in half and the cutting the
second foam member in half are performed such that, when the first
top layer is positioned on top of the second bottom layer, most
protruded surfaces of the protrusions of the bottom surface of the
first top layer are separated from corresponding surfaces of the
recessions of the top surface of the second bottom layer by a
channel, and there is no channel between most protruded surfaces of
the protrusions of the top surface of the second bottom layer and
corresponding surfaces of the recessions of the bottom surface of
the first top layer.
9. The method according to claim 8, further comprising positioning
the second top layer on top of the first bottom layer such that the
protrusions of the bottom surface of the first bottom layer
protrude into the recessions of the top surface of the second top
layer, and the protrusions of the top surface of the second top
layer protrude into the recessions of the bottom surface of the
first bottom layer, wherein the cutting the first foam member in
half and the cutting the second foam member in half are performed
such that, when the second top layer is positioned on top of the
first bottom layer, most protruded surfaces of the protrusions of
the top surface of the second top layer are separated from
corresponding surfaces of the recessions of the bottom surface of
the first bottom layer by a channel, and there is no channel
between most protruded surfaces of the protrusions of the bottom
surface of the first bottom layer and corresponding surfaces of the
recessions of the top surface of the second top layer.
Description
TECHNICAL FIELD
[0001] Illustrative embodiments relate to mattresses, and in
particular, foam mattresses with progressive support
characteristics, improved airflow and cooling properties, and
methods for manufacturing the same.
BACKGROUND
[0002] Mattresses contain some type of support element, such as an
innerspring core or a foam core made of polyurethane form, for
example.
[0003] Some people prefer foam core mattresses to innerspring core
mattresses. However, foam core mattresses have several drawbacks as
compared to innerspring core mattresses.
[0004] For instance, unlike conventional foam core mattresses,
innerspring core mattresses can deliver support to a person through
the resistance provided by innersprings. Such innersprings may be
configured to hold the person in a proper postural alignment, while
evenly redistributing the person's body weight across a wide area
so as to relieve interface pressure.
[0005] Further, some innerspring core mattresses are configured to
provide progressive support to a person--meaning that the
innerspring core provides progressively increasing firmness as more
weight is applied to the innerspring core. Such progressive support
innerspring cores can provide increased comfort while maintaining
proper postural alignment. However, such progressive support
characteristics have not yet been reliably attained using
conventional foam core mattresses.
[0006] Foam core mattresses also have a drawback in that
polyurethane foams are good heat insulators. Thus, mattresses with
a polyurethane foam support core or a polyurethane foam topping can
retain too much heat and cause discomfort for some people as they
sleep on the mattress. Indeed, many people complain of becoming too
warm while sleeping on a foam mattress or foam mattress
topping.
[0007] Additionally, conventional methods of manufacturing foam
mattresses, such as die-cutting processes and contour-cutting
processes are time-consuming and wasteful. Thus, new manufacturing
methods are desired for manufacturing foam mattresses that reduce
and/or eliminate wasted material and which reduce manufacturing
time.
[0008] The above have been long felt, but unsolved problems in the
bedding industry.
SUMMARY
[0009] Illustrative embodiments overcome the above disadvantages
and other disadvantages not described above. Also, illustrative
embodiments are not required to overcome the disadvantages
described above, and an illustrative embodiment may not overcome
any of the problems described above.
[0010] According to one illustrative embodiment, a mattress
comprises: a top foam layer; and a bottom foam layer, wherein a
bottom surface of the top foam layer comprises a series of
protrusions and recessions, wherein a top surface of the bottom
foam layer comprises a series of protrusions and recessions,
wherein the protrusions of the top surface of the bottom foam layer
protrude into the recessions of the bottom surface of the top foam
layer, wherein the protrusions of the bottom surface of the top
foam layer protrude into the recessions of the top surface of the
bottom foam layer, wherein most protruded surfaces of the
protrusions of the bottom surface of the top foam layer are
separated from corresponding surfaces of the recessions of the top
surface of the bottom foam layer by a channel, and wherein there is
no channel between most protruded surfaces of the protrusions of
the top surface of the bottom foam layer and corresponding surfaces
of the recessions of the bottom surface of the top foam layer.
[0011] According to another illustrative embodiment, a method for
manufacturing a mattress is provided, the method comprising:
cutting a first foam member in half to form first and second top
layers, a bottom surface of the first top layer comprising a series
of protrusions and recessions and a top surface of the second top
layer comprising a series of protrusions and recessions opposite to
the series of protrusions and recessions of the first top layer;
cutting a second foam member in half to form first and second
bottom layers, a bottom surface of the first bottom layer
comprising a series of protrusions and recessions and a top surface
of the second bottom layer comprising a series of protrusions and
recessions opposite to the series of protrusions and recessions of
the first bottom layer; and positioning the first top layer on top
of the second bottom layer such that the protrusions of the top
surface of the second bottom layer protrude into the recessions of
the bottom surface of the first top layer and the protrusions of
the bottom surface of the first top layer protrude into the
recessions of the top surface of the second bottom layer; wherein
the cutting the first foam member in half and the cutting the
second foam member in half are performed such that, when the first
top layer is positioned on top of the second bottom layer, most
protruded surfaces of the protrusions of the bottom surface of the
first top layer are separated from corresponding surfaces of the
recessions of the top surface of the second bottom layer by a
channel, and there is no channel between most protruded surfaces of
the protrusions of the top surface of the second bottom layer and
corresponding surfaces of the recessions of the bottom surface of
the first top layer.
BRIEF DESCRIPTION OF THE FIGURES
[0012] Illustrative embodiments are described below by reference
with the following figures, in which like numerals indicate like
elements.
[0013] FIG. 1 illustrates a cross-sectional view of top layers for
progressive foam mattresses consistent with an illustrative
embodiment;
[0014] FIG. 2 illustrates a cross-sectional view of bottom layers
for progressive foam mattresses consistent with an illustrative
embodiment;
[0015] FIG. 3A illustrates a cross-sectional view of a progressive
foam core comprising a top layer and a bottom layer consistent with
an illustrative embodiment;
[0016] FIG. 3B illustrates an enlarged view of a portion of the
progressive foam core comprising a top layer and a bottom layer,
just before the top layer and the bottom layer are fitted together
consistent with an illustrative embodiment;
[0017] FIG. 4 illustrates a cross-sectional view of a typical
build-up configuration of a progressive foam mattress 400
consistent with an illustrative embodiment;
[0018] FIG. 5 illustrates a cross-sectional view of a firm build-up
configuration of a progressive foam mattress 500 consistent with an
illustrative embodiment;
[0019] FIG. 6 illustrates a top view of the bottom layers 21 and 22
consistent with the illustrative embodiment shown in FIG. 2, after
the bottom layers 21 and 22 have been separated and positioned with
the protrusions and recessions thereof facing upward; and
[0020] FIG. 7 illustrates a flow chart describing a method of
manufacturing a progressive foam mattress consistent with an
illustrative embodiment.
DETAILED DESCRIPTION
[0021] FIG. 1 illustrates a cross-sectional view of top layers 11
and 12 for a progressive foam mattress consistent with an
illustrative embodiment. As shown in FIG. 1, a first foam member
100 is cut in half to form two separate top layers (i.e., a first
top layer 11 and a second top layer 12) that may be used in two
different progressive foam mattresses, respectively. Such cutting
may be performed with any suitable means for cutting including, but
not limited to, a blade, laser, a convoluter machine, etc.
According to an illustrative embodiment, the foam may be
polyurethane foam, or the like.
[0022] As shown in FIG. 1, the foam member 100 is split in half so
that the first top layer 11 and the second top layer 12 are each
convoluted and comprise a series of protrusions and recessions.
Specifically, the foam member 100 is cut in such a way that the
series of protrusions 16 and recessions 14 of the first top layer
11 is formed simultaneously with the series of protrusions 13 and
recessions 15 of the second top layer 12.
[0023] That is, for example, as shown in FIG. 1, as the foam member
100 is split by a cutting action, such cutting simultaneously forms
a recession 14 in the first top layer 11 and a corresponding
opposite protrusion 13 in the second top layer 12. Such cutting
continues along the entire length of the foam member 100 until the
first top layer 11 is separated from the second top layer 12.
Conventional techniques for splitting a foam using a convoluter
machine, as are known in the art, can be used to split foam member
100.
[0024] Thus, consistent with an illustrative embodiment, two
separate top layers (i.e., a first top layer 11 and a second top
layer 12) that may be used in two different progressive foam
mattresses, respectively, are formed in a single spitting operation
which requires approximately 20-30 seconds of machine time. In
contrast, conventional die-cutting processes and contour-cutting
processes for manufacturing foam cores for mattresses typically
require 10-15 minutes of machine time to form comparable foam
layers.
[0025] In further contrast to conventional die-cutting processes
and contour-cutting processes for manufacturing foam cores for
mattresses, virtually no wasted foam material results in cutting
the foam member 100 in half consistent with an illustrative
embodiment.
[0026] According to an illustrative embodiment, the top layers 11
and 12 may have a plurality of holes or channels 17 that extend
from the top surface of the top layers 11 and 12 to the bottom
surface of the top layers 11 and 12, such as described in U.S.
Patent Application No. 61/425,303 filed Jan. 22, 2011, entitled
Mattress with Improved Cooling Properties, which is incorporated
herein by reference. The holes 17 facilitate airflow in a height
direction of the top layers 11 and 12. The dimensions and/or
configuration of the holes 17 can be adjusted to control and reduce
the heat insulating properties of the top layers 11 and 12 to
thereby provide increased comfort to a person resting thereon.
[0027] According to an illustrative embodiment, the holes 17 may
have a diameter of 1/4 inch, for example. In one embodiment, the
holes 17 in the top layers 11 and 12 can be formed in a grid
pattern and spaced apart a distance of 2 inches by 2 inches.
[0028] It will be understood that forming holes 17 in the top
layers 11 and 12 can reduce the structural support of the top
layers 11 and 12. Accordingly, only as many holes 17 as are needed
to provide the desired amount of airflow may be formed in the top
layers 11 and 12, so as to retain the structural support of the
foam. Although the holes 17 in one illustrative embodiment are 1/4
inch in diameter, other size holes may be used depending on the
desired airflow and support characteristics for the top layers 11
and 12.
[0029] Similar to the top layers 11 and 12 of FIG. 1, FIG. 2
illustrates a cross-sectional view of bottom layers 21 and 22 for a
progressive foam mattress consistent with an illustrative
embodiment. As shown in FIG. 2, a second foam member 200 is split
in half to form two separate bottom layers (i.e., a first bottom
layer 21 and a second bottom layer 22) that may be used in two
different progressive foam mattresses, respectively.
[0030] As shown in FIG. 2, the foam member 200 is split in half,
using a convoluter machine for example, so that the first bottom
layer 21 and the second bottom layer 22 are each convoluted and
comprise a series of protrusions and recessions. Specifically, the
foam member 200 is split in such a way that the series of
protrusions 26 and recessions 24 of the first bottom layer 21 is
formed simultaneously with the series of protrusions 23 and
recessions 25 of the second bottom layer 22.
[0031] That is, for example, as shown in FIG. 2, as the foam member
200 is split by a cutting action, such cutting simultaneously forms
a recession 24 in the first bottom layer 21 and a corresponding
opposite protrusion 23 in the second bottom layer 22. Such cutting
continues along the entire length of the foam member 200 until the
first bottom layer 21 is separated from the second bottom layer
22.
[0032] By way of illustration, FIG. 6 illustrates a top view of the
bottom layers 21 and 22 consistent with the illustrative embodiment
shown in FIG. 2, after the bottom layers 21 and 22 have been
separated and positioned with the protrusions and recessions
thereof facing upward.
[0033] After forming the top layers 11 and 12 and the bottom layers
21 and 22, the top layer 11 is positioned on top of the bottom
layer 22, as shown in FIG. 3A, to form a progressive foam core 300
for a progressive foam mattress consistent with an illustrative
embodiment. As shown in FIG. 3A, the protrusions 23 of the bottom
layer 22 protrude into the recessions 14 of the top layer 11,
fitting together like pieces in a jigsaw puzzle. Likewise, the
protrusions 16 of the top layer 11 protrude into the recessions 25
of the bottom layer 22.
[0034] FIG. 3B illustrates an enlarged view of a portion of the
progressive foam core 300 for a progressive foam mattress
comprising a top layer 11 and a bottom layer 22, just before the
top layer 11 and the bottom layer 22 are fitted together consistent
with an illustrative embodiment.
[0035] Significantly, the top layer 11 and the bottom layer 22 are
configured such that, after the top layer 11 is positioned on top
of the bottom layer 22, as shown in FIG. 3A, a void space remains
between the protrusions 16 of the top layer 11 and the recessions
25 of the bottom layer 22, thereby forming a channel 30 through
which air may flow. In particular, the most protruded surfaces of
the protrusions 16 of the top layer 11 are separated from the
corresponding surfaces of the recessions 25 of the bottom layer 22
by the channel 30.
[0036] Such a configuration (among other advantages) provides the
progressive foam core 300 with progressively firmer support
characteristics as force applied to a top surface of the mattress
(e.g., applied by a person resting on the mattress) increases. The
void space in channel 30 between the top layer 11 and bottom layer
22 provides a progressive support profile that can simulate a
support profile of mattresses using conventional progressive spring
coils. As a force is applied to the top surface of foam core 300,
the top layer 11 provides a certain degree of support due to the
support characteristics of the foam used in the top layer 11. As
the top layer 11 compresses and the protrusions 16 of the top layer
are pressed downward through the channels 30 and come into contact
with the recessions 25 of the bottom layer 22, a greater degree of
support is provided due to the support characteristics of the foam
of the bottom layer 22 foam combining with the support
characteristics of the form of the top layer 11. The effect is a
progressive support profile in which the support provided by the
foam core 300 increases as more force is applied from the top of
the foam core.
[0037] Various support characteristics can be achieved by selecting
the types and/or densities of foams used for the top and bottom
layers and by selecting the distance in the channel 30 between the
top layer 11 and the bottom layer 22.
[0038] Such a configuration also provides enhanced cooling
properties to the progressive foam core 300.
[0039] Alternatively, there is substantially no such void space or
channel between the most protruded surfaces of the protrusions 23
of the top surface of the bottom layer 22 and corresponding
surfaces of the recessions 14 of the bottom surface of the top foam
layer 11.
[0040] Consistent with an illustrative embodiment, surfaces of the
protrusions 23 of the top surface of the bottom layer 22 are
adhered to the corresponding surfaces of the recessions 14 of the
bottom surface of the top layer 11 by an adhesive. However, no
adhesive exists between the most protruded surfaces of the
protrusions 16 of the bottom surface of the top layer 11 and the
corresponding surfaces of the recessions 25 of the top surface of
the bottom layer 22. Using a roller, adhesive is applied only to
the top surfaces of the protrusions 23 of the bottom layer 22. The
top layer 21 is then positioned over and placed on top of the
bottom layer 22. The top surface of the protrusions 23 then adheres
to the corresponding surfaces of the recessions 25.
[0041] According to the illustrative embodiment shown in FIG. 3A,
the height at the protrusions 16 may be 2.0''-5.0'' and the height
at the recessions 14 may be 0.75''-3.5.'' Further, the height at
the protrusions 23 may be 2.0''-6.0'' and the height at the
recessions 25 may be 1.0''-3.0''. The total height of the
progressive foam core 300 may be 2.75''-9.5''. As shown in FIG. 3A,
the height of the channel 30 is at least 0.25'', but less than
1.5''. There is substantially no space between the protrusions 23
and the recessions 14. However, the present invention is not
limited to the above dimensions and one of ordinary skill in the
art would recognize that various modifications could be made to the
above dimensions consistent with the present invention.
[0042] According to the illustrative embodiment shown in FIG. 3A,
channels 30 are formed above the top surface of the bottom layer
22. The channels 30 extend at least partially across the width of
the bottom layer 22, the width direction extending perpendicular to
a head-to-foot length direction of the bottom layer 22. According
to an illustrative embodiment, the channels 30 may extend across
the entire width of the bottom layer 22.
[0043] The channels 30 facilitate airflow across the width of the
bottom layer 22. The dimensions and/or configuration of the
channels 30 can be adjusted to control and reduce the heat
insulating properties of the bottom layer 22 to thereby provide
increased comfort to a person resting thereon.
[0044] According to an illustrative embodiment, the channels 30 may
be wave-shaped. Alternatively, the channels 30 can extend
longitudinally, diagonally, or in other directions across the
bottom layer 22. As another alternative, the channels 30 may have a
shape other than a wave-shape, so long as the channels 30 allow air
to flow across the top of the bottom layer 22.
[0045] Attached to one or more sides of the mattress is a 3-D
fabric (not shown). The 3-D fabric 16 is disposed along the two
side edges of the foam core 300 where the ends of the channels 30
are located. As will be understood by those skilled in the art, the
3-D fabric can be a 3-D mesh or a spacer net type fabric. This 3-D
fabric has an open knit construction that provides a low pressure
environment that allows air to flow easily through the fabric,
requiring little force to draw air through the fabric. The 3-D
fabric is attached to the sides of the foam core 300.
[0046] According to an illustrative embodiment, cool air moves by
convection, across the top surface of the top layer 11. When a
person lies on a mattress comprising the top layer 11 and the
bottom layer 22, air warmed by that person's body rises causing
cooler air to be drawn through the holes 17 in the top layer 11 and
also through the channels 30. Although heat is typically retained
by polyurethane foam, the increased airflow across the top of the
mattress provides a cooling effect to the person lying on the
mattress. The rising body heat creates a convective air current
that draws the cooler air through the plurality of holes 17 in
through the channels 30 and the 3D fabric. This cooler air flowing
over the top of the top layer 11, operates to cool the body,
allowing the person to rest comfortably on top of the mattress
without overheating.
[0047] Further, according to an illustrative embodiment, the
channels 30 may extend so as to connect with vents (not shown)
placed on the top or bottom end surfaces, or the side surfaces of
the bottom layer 22, either in place of or in addition to the 3D
fabric. Such vents may penetrate to the exterior of a mattress. Any
number of vents may be used depending on the desired amount of
airflow to provide to the bottom layer 22. The vents are small
metal or plastic slotted ventilation members that allow air to
easily flow through the mattress cover and to the channels 30.
Alternatively, other types of vents may be used so long as air
passes through the vents with little resistance.
[0048] When a person lies on top of a mattress comprising the
bottom layer 22, heat from the person's body warms the surrounding
air causing it to rise. Through convection from the rising warm
air, cooler air is drawn through the holes 17 and through the vents
into the channels 30. This air drawn in from the holes and vents
travels along the wave-shaped channels cooling the body, resulting
in a more comfortable sleep surface for the person.
[0049] FIG. 4 illustrates a cross-sectional view of a typical
build-up configuration of a progressive foam mattress 400
consistent with an illustrative embodiment.
[0050] As shown in FIG. 4, a comfort (or topping) layer 40 may be
provided above the top layer 11A. A base layer 45 may also be
provided below the bottom layer 22A. Further, a rail 46 may be
provided around the perimeter of the progressive foam mattress
400.
[0051] According to the illustrative embodiment shown in FIG. 4,
the comfort layer 40 may be either flat or convoluted and may be
made of foam, for example. The comfort layer 40 may have a height
of 2.0'', but is not limited to these dimensions.
[0052] As shown in FIG. 4, the base layer 45 may have a height of
1.0'', but the base layer 45 is not limited to these
dimensions.
[0053] According to the illustrative embodiment shown in FIG. 4,
the top layer 11A has protrusions 16A and recessions 14A. The
bottom layer 22A has protrusions 23A and recessions 25A. The height
of the protrusions 16A may be 3.5'' and the height of the
recessions 14A may be 1.75''. The height of the protrusions 23A may
be 4.75'' and the height of the recessions 25A may be 2.375''. The
total height of the top layer 11A and bottom layer 22A may be
6.5''. The total height of the progressive foam mattress 400 may be
9.5''. However, the present invention is not limited to the
specific dimensions of the illustrative embodiment shown in FIG.
4.
[0054] FIG. 5 illustrates a cross-sectional view of a firm build-up
configuration of a progressive foam mattress 500 consistent with an
illustrative embodiment. The illustrative embodiment shown in FIG.
5 provides firmer support characteristics as compared to the
illustrative embodiment shown in FIG. 4.
[0055] As shown in FIG. 5, a comfort (or topping) layer 40 may be
provided above the top layer 11B. A base layer 45 may also be
provided below the bottom layer 22B. Further, a rail 46 may be
provided around the perimeter of the progressive foam mattress 500.
In contrast to the illustrative embodiment shown in FIG. 4, the
illustrative embodiment shown in FIG. 5 additionally comprises a
high support layer 59. The high support layer 59 may have a height
of 2.0'', but is not limited to these dimensions.
[0056] According to the illustrative embodiment shown in FIG. 5,
the comfort layer 40 may be either flat or convoluted and may be
made of foam, for example. The comfort layer 40 may have a height
of 2.0'', but is not limited to these dimensions.
[0057] As shown in FIG. 5, the base layer 45 may have a height of
1.0'', but the base layer 45 is not limited to these
dimensions.
[0058] According to the illustrative embodiment shown in FIG. 5,
the top layer 11B has protrusions 16B and recessions 14B. The
bottom layer 22B has protrusions 23B and recessions 25B. The height
of the protrusions 16B may be 2.5'' and the height of the
recessions 14B may be 1.0''. The height of the protrusions 23B may
be 3.5'' and the height of the recessions 25B may be 1.5''. The
total height of the top layer 11B and bottom layer 22B may be
4.5''. The total height of the progressive foam mattress 500 may be
9.5''. However, the present invention is not limited to the
specific dimensions of the illustrative embodiment shown in FIG.
5.
[0059] FIG. 7 illustrates a flow chart describing a method of
manufacturing a progressive foam mattress consistent with an
illustrative embodiment. As shown in FIG. 7, operation S100
comprises splitting a first foam member 100 in half to form a first
top layer 11 having a series of protrusions 16 and recessions 14
and a second top layer 12 having a series of protrusions 13 and
recessions 15.
[0060] Operation S200 comprises splitting a second foam member 200
in half to form a first bottom layer 21 having a series of
protrusions 26 and recessions 24 and a second bottom layer 22
having a series of protrusions 23 and recessions 25.
[0061] Finally, operation S300 comprises positioning the first top
layer 11 on top of the second bottom layer 22 so that the most
protruded surfaces of protrusions 16 are separated from
corresponding surfaces of recessions 25 by a channel 30, and there
is no channel between the most protruded surfaces of protrusions 23
and corresponding surfaces of recessions 14.
[0062] The foregoing illustrative embodiments and advantages are
merely illustrative and are not to be construed as limiting the
present invention. It will be understood by those of ordinary skill
in the art that the present teachings can be readily applied to
other types of apparatuses. Also, the description of the
illustrative embodiments is intended to be illustrative, and not to
limit the scope of the claims, and many alternatives,
modifications, and variations will be apparent to those skilled in
the art.
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