U.S. patent application number 15/220964 was filed with the patent office on 2017-02-09 for customizable mattress.
The applicant listed for this patent is Bedgear, LLC. Invention is credited to Eugene Alletto, JR..
Application Number | 20170035211 15/220964 |
Document ID | / |
Family ID | 57944054 |
Filed Date | 2017-02-09 |
United States Patent
Application |
20170035211 |
Kind Code |
A1 |
Alletto, JR.; Eugene |
February 9, 2017 |
CUSTOMIZABLE MATTRESS
Abstract
A customizable mattress includes a chassis defining a cavity. A
spring pack is removably positioned within the cavity. A top pad
removably covers at least a portion of the spring pack. In some
embodiments, kits and methods of use are provided.
Inventors: |
Alletto, JR.; Eugene; (Glen
Head, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bedgear, LLC |
Farmingdale |
NY |
US |
|
|
Family ID: |
57944054 |
Appl. No.: |
15/220964 |
Filed: |
July 27, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62200378 |
Aug 3, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/062 20130101;
A47C 23/002 20130101; A47C 27/07 20130101; A47C 27/064 20130101;
A47C 27/053 20130101; A47C 27/001 20130101 |
International
Class: |
A47C 27/00 20060101
A47C027/00; A47C 27/05 20060101 A47C027/05; A47C 27/07 20060101
A47C027/07; A47C 23/00 20060101 A47C023/00; A47C 27/06 20060101
A47C027/06 |
Claims
1. A customizable mattress, comprising: a chassis defining a
cavity; a spring pack removably positioned within the cavity; and a
top pad removably covering at least a portion of the spring
pack.
2. A customizable mattress as recited in claim 1, wherein the
spring pack is divided into a first side configured to support a
first sleeper and a second side configured to support a second
sleeper, the first side being removably coupled to the second
side.
3. A customizable mattress as recited in claim 1, wherein the
spring pack is divided into a first side configured to support a
first sleeper and a second side configured to support a second
sleeper, the first side interlocking with the second side such that
the first side is removably coupled to the second side.
4. A customizable mattress as recited in claim 1, wherein the
spring pack is divided into a first side configured to support a
first sleeper and a second side configured to support a second
sleeper, the first side comprising a series of recesses, the second
side comprising a series of projections disposed in the recesses to
interlock the first side with the second side such that the first
side is removably coupled to the second side.
5. A customizable mattress as recited in claim 1, wherein the
spring pack is divided into a first side configured to support a
first sleeper and a second side configured to support a second
sleeper, the first side being removably coupled to the second side,
the first side having a different firmness than the second
side.
6. A customizable mattress as recited in claim 1, wherein the
spring pack comprises a plurality of rows of springs, the springs
in each row being connected to one another by a piece of material
or similar support structure such as nested cradle base egg carton
support structure.
7. A customizable mattress as recited in claim 6, wherein the
material comprises at least one slit positioned between adjacent
springs to prevent or limit movement of one of the adjacent springs
when another one of the adjacent springs moves.
8. A customizable mattress as recited in claim 6, wherein the
material comprises welds positioned between adjacent springs to
prevent or limit movement of one of the adjacent springs when
another one of the adjacent springs moves.
9. A customizable mattress as recited in claim 1, wherein the
chassis comprises a foam material.
10. A customizable mattress as recited in claim 1, wherein the
chassis comprises a top portion, a bottom portion opposite the top
portion and opposite side portions that extend between the top and
bottom portions, the top and bottom portions each being removably
coupled to the side portions.
11. A customizable mattress as recited in claim 1, wherein the
chassis comprises a top portion, a bottom portion opposite the top
portion and opposite side portions that extend between the top and
bottom portions, the side portions each including opposite first
and second mortises, the top portion comprising tenons that fit
into the first mortises to connect the top portion with the side
portions, the bottom portion comprising tenons that fit into the
second mortises to connect the top portion with the side
portions.
12. A customizable mattress as recited in claim 1, wherein the
chassis comprises a top portion, a bottom portion opposite the top
portion and opposite first and second side portions that extend
between the top and bottom portions, the first side portion
including opposite first and second mortises, the second side
portion including opposite third and fourth mortises, the top
portion including opposite fifth and sixth mortises, the bottom
portion including opposite seventh and eighth mortises, the
mattress further comprising a first corner piece comprising tenons
that fit into the first and fifth mortises, a second corner pieces
comprising tenons that fit into the second and seventh mortises, a
third corner piece that fits into the third and sixth mortises and
a fourth corner piece comprising tenons that fit into the fourth
and eighth mortises to join the first and second side portions with
the top and bottom portions.
13. A customizable mattress as recited in claim 1, further
comprising an outer lower covering that surrounds at least a
portion of the chassis.
14. A customizable mattress as recited in claim 1, further
comprising retention fabric that covers at least a portion of the
top pad.
15. A kit comprising: the customizable mattress of claim 1, wherein
the spring pack comprises a plurality of spring packs each having a
different firmness and the top pad comprises a plurality of top
pads each having a different firmness.
16. A kit as recited in claim 15, further comprising instructions
for selecting one of the spring packs and one of the top pads based
upon a sleeper's body type and/or sleep preference.
17. A method comprising: providing the kit recited in claim 16;
selecting one of the spring packs based upon a sleeper's first body
type and/or sleep preference; selecting one of the top pads based
upon the sleeper's first body type and/or sleep preference;
positioning the selected spring pack in the cavity; and covering
the selected spring pack with the selected top pad.
18. A method as recited in claim 17, further comprising: removing
the selected top pad from the selected spring pack; removing the
selected spring pack from the cavity; selecting a second spring pad
based upon an updated second body type and/or sleep preference;
positioning the selected second spring pad within the cavity;
selecting a second top pad based upon the updated second body type
and/or sleep preference; and covering the selected second spring
pack with the selected second top pad.
19. A method as recited in claim 18, wherein the selected second
spring pack has a firmness that is different than that of the
selected spring pack and the selected second top pad has a firmness
that is different than that of the selected top pad.
20. A method as recited in claim 17, further comprising: removing
the selected top pad from the selected spring pack after the
selected top pad becomes worn; removing the selected spring pack
from the cavity after the selected spring pad becomes worn;
selecting a second spring pad; positioning the selected second
spring pad within the cavity; selecting a second top pad; and
covering the selected second spring pack with the selected second
top pad.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to bedding, and
more particularly to customizable mattresses that include variable
components that allow a sleeper to create a mattress that has
performance characteristics specifically tailored to the sleeper's
body type and/or sleep preferences while also allowing the sleeper
to replace the variable components with other variable components
should the variable components become worn and/or the sleeper's
body type or sleep preferences change over time.
BACKGROUND
[0002] Sleep is critical for people to feel and perform their best,
in every aspect of their lives. Sleep is an essential path to
better health and reaching personal goals. Indeed, sleep affects
everything from the ability to commit new information to memory to
weight gain. It is therefore essential for people to use bedding
that suit both their personal sleep preference and body type in
order to achieve comfortable, restful sleep.
[0003] Certain components of a mattress, such as, for example,
springs and/or a mattress topper may become worn before other
components of the mattress. It would thus be beneficial to provide
a mattress that allows some components to be replaced without
replacing the entire mattress. Indeed, replacing the springs of a
mattress, for example, without replacing other components of the
mattress would significantly reduce the cost to the user who would
otherwise have to buy a new mattress if the springs become worn or
otherwise in need of replacement.
[0004] Furthermore, sleeper's body type may change over time. For
example, a sleeper may lose or gain weight. The change in weight
may be slight or significant. When the change in weight is
significant, it may affect the type of bedding the sleeper requires
to achieve restful sleep. For example, a significant gain in weight
may require that a sleeper use a firmer mattress, to provide
support for the added weight. The sleeper's sleep preference may
also change over time. For example, a sleeper who typically likes
to sleep on their back may, over time, prefer to sleep on his or
her side. The change in sleep preference may affect the type of
bedding the sleeper requires to achieve restful sleep. For example,
a sleeper changing from a back sleeper to a side sleeper may
require that the sleeper use a firmer mattress.
[0005] Accordingly, this disclosure is directed to customizable
mattresses that include variable components that allow a sleeper to
create a mattress that has performance characteristics specifically
tailored to the sleeper's body type and/or sleep preferences while
also allowing the sleeper to replace the variable components with
other variable components over time should the variable components
become worn and/or the sleeper's body type or sleep preferences
change over time.
SUMMARY
[0006] A customizable mattress is provided, in accordance with the
principles of the present disclosure. The customizable mattress
includes a chassis that defines a cavity. A spring pack is
removably positioned within the cavity. A top pad removably covers
at least a portion of the spring pack. In some embodiments, the
customizable mattress includes an outer lower covering that
surrounds at least a portion of the chassis. In some embodiments,
the customizable mattress includes retention fabric that covers at
least a portion of the top pad.
[0007] In some embodiments, the spring pack is divided into a first
side configured to support a first sleeper and a second side
configured to support a second sleeper, the first side being
removably coupled to the second side. In some embodiments, the
spring pack is divided into a first side configured to support a
first sleeper and a second side configured to support a second
sleeper, the first side interlocking with the second side such that
the first side is removably coupled to the second side. In some
embodiments, the spring pack is divided into a first side
configured to support a first sleeper and a second side configured
to support a second sleeper, the first side comprising a series of
recesses, the second side comprising a series of projections
disposed in the recesses to interlock the first side with the
second side such that the first side is removably coupled to the
second side. In some embodiments, the spring pack is divided into a
first side configured to support a first sleeper and a second side
configured to support a second sleeper, the first side being
removably coupled to the second side, the first side having a
different firmness than the second side. In some embodiments, the
spring pack comprises a plurality of rows of springs, the springs
in each row being connected to one another by a piece of material.
In some embodiments, the material comprises at least one slit
positioned between adjacent springs to prevent or limit movement of
one of the adjacent springs when another one of the adjacent
springs moves. In some embodiments, the material comprises welds
positioned between adjacent springs to prevent or limit movement of
one of the adjacent springs when another one of the adjacent
springs moves.
[0008] In some embodiments, the chassis comprises a foam or formed
plastic or similar material. In some embodiments, the chassis
comprises a top portion, a bottom portion opposite the top portion
and opposite side portions that extend between the top and bottom
portions, the top and bottom portions each being removably coupled
to the side portions. In some embodiments, the chassis comprises a
top portion, a bottom portion opposite the top portion and opposite
side portions that extend between the top and bottom portions, the
side portions each including opposite first and second mortises,
the top portion comprising tenons that fit into the first mortises
to connect the top portion with the side portions, the bottom
portion comprising tenons that fit into the second mortises to
connect the top portion with the side portions. In some
embodiments, the chassis comprises a top portion, a bottom portion
opposite the top portion and opposite first and second side
portions that extend between the top and bottom portions, the first
side portion including opposite first and second mortises, the
second side portion including opposite third and fourth mortises,
the top portion including opposite fifth and sixth mortises, the
bottom portion including opposite seventh and eighth mortises, the
mattress further comprising a first corner piece comprising tenons
that fit into the first and fifth mortises, a second corner pieces
comprising tenons that fit into the second and seventh mortises, a
third corner piece that fits into the third and sixth mortises and
a fourth corner piece comprising tenons that fit into the fourth
and eighth mortises to join the first and second side portions with
the top and bottom portions.
[0009] In one embodiment, in accordance with the principles of the
present disclosure, a kit is provided. The kit includes a
customizable mattress having a chassis that defines a cavity. A
spring pack is removably positioned within the cavity. A top pad
removably covers at least a portion of the spring pack. In some
embodiments, the customizable mattress includes an outer lower
covering that surrounds at least a portion of the chassis. In some
embodiments, the customizable mattress includes retention fabric
that covers at least a portion of the top pad. In some embodiments,
the spring pack comprises a plurality of spring packs each having a
different firmness and the top pad comprises a plurality of top
pads each having a different firmness. In some embodiments, the kit
includes instructions for selecting one of the spring packs and one
of the top pads based upon a sleeper's body type and/or sleep
preference.
[0010] In one embodiment, in accordance with the principles of the
present disclosure, a method is provided. The method includes the
steps of: providing a kit that includes a customizable mattress
having a chassis that defines a cavity, spring pack removably
positioned within the cavity, a top pad removably covering at least
a portion of the spring pack, an outer lower covering that
surrounds at least a portion of the chassis and retention fabric
that covers at least a portion of the top pad, wherein the spring
pack comprises a plurality of spring packs each having a different
firmness and the top pad comprises a plurality of top pads each
having a different firmness; selecting one of the spring packs
based upon a sleeper's first body type and/or sleep preference;
selecting one of the top pads based upon the sleeper's first body
type and/or sleep preference; positioning the selected spring pack
in the cavity; and covering the selected spring pack with the
selected top pad. In some embodiments, the method includes the
steps of: removing the selected top pad from the selected spring
pack; removing the selected spring pack from the cavity; selecting
a second spring pad based upon an updated second body type and/or
sleep preference; positioning the selected second spring pad within
the cavity; selecting a second top pad based upon the updated
second body type and/or sleep preference; and covering the selected
second spring pack with the selected second top pad. In some
embodiments, the selected second spring pack has a firmness that is
different than that of the selected spring pack and the selected
second top pad has a firmness that is different than that of the
selected top pad. In some embodiments, the method includes the
steps of: removing the selected top pad from the selected spring
pack after the selected top pad becomes worn; removing the selected
spring pack from the cavity after the selected spring pad becomes
worn; selecting a second spring pad; positioning the selected
second spring pad within the cavity; selecting a second top pad;
and covering the selected second spring pack with the selected
second top pad.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present disclosure will become more readily apparent
from the specific description accompanied by the following
drawings, in which:
[0012] FIG. 1 is a perspective view of a bedding system in
accordance with the present disclosure;
[0013] FIG. 2A shows the assembly of a component of the bedding
system shown in FIG. 1;
[0014] FIG. 2B shows the assembly of a component of the bedding
system shown in FIG. 1;
[0015] FIG. 2C shows the assembly of a component of the bedding
system shown in FIG. 1;
[0016] FIG. 2D shows the assembly of a component of the bedding
system shown in FIG. 1;
[0017] FIG. 2E shows the assembly of a component of the bedding
system shown in FIG. 1;
[0018] FIG. 2F shows the assembly of a component of the bedding
system shown in FIG. 1;
[0019] FIG. 3 is a top view of components of the bedding system
shown in FIG. 1;
[0020] FIG. 3A is a perspective view of one embodiment of a
component of the bedding system shown in FIG. 1;
[0021] FIG. 3B is a perspective, breakaway view of one embodiment
of a component of the bedding system shown in FIG. 1;
[0022] FIG. 4A is a top view of a component of the bedding system
shown in FIG. 1;
[0023] FIG. 4B is atop view of a component of the bedding system
shown in FIG. 1;
[0024] FIG. 4C is a top view of a component of the bedding system
shown in FIG. 1;
[0025] FIG. 5A is a top view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0026] FIG. 5B is a top view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0027] FIG. 5C is a top view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0028] FIG. 6A is a top view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0029] FIG. 6B is a top view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0030] FIG. 6C is a top view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0031] FIG. 7 is a perspective, breakaway view of a component of
the bedding system shown in FIG. 1;
[0032] FIG. 8A is a side view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0033] FIG. 8B is a side view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0034] FIG. 8C is a side view of one embodiment of a component of
the bedding system shown in FIG. 1;
[0035] FIG. 9 shows a comparison between a component of the bedding
system shown in FIG. 1 and prior art components;
[0036] FIG. 10 is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1, with parts
separated;
[0037] FIG. 10A is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0038] FIG. 11A is a side view of a component of the bedding system
shown in FIG. 1;
[0039] FIG. 11B is a perspective view of a component of the bedding
system shown in FIG. 1;
[0040] FIG. 11C is a top view of a component of the bedding system
shown in FIG. 1;
[0041] FIG. 11D is a perspective view of a component of the bedding
system shown in FIG. 1;
[0042] FIG. 12 is a perspective view of components of the bedding
system shown in FIG. 1;
[0043] FIG. 12A is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0044] FIG. 12B is a side view of one embodiment of components of
the bedding system shown in FIG. 1;
[0045] FIG. 12C is a perspective view of one embodiment of a
component of the bedding system shown in FIG. 1;
[0046] FIG. 12D is a perspective view of a component of the bedding
system shown in FIG. 1;
[0047] FIG. 13A is a perspective view of one embodiment of a
component of the bedding system shown in FIG. 1;
[0048] FIG. 13B is a perspective view of one embodiment of a
component of the bedding system shown in FIG. 1;
[0049] FIG. 13C is a perspective view of one embodiment of a
component of the bedding system shown in FIG. 1;
[0050] FIG. 13D is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0051] FIG. 13E is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0052] FIG. 13F is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0053] FIG. 14 is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0054] FIG. 15 is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0055] FIG. 15A is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0056] FIG. 15B is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0057] FIG. 15C is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0058] FIG. 15D is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0059] FIG. 15E is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0060] FIG. 15F is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0061] FIG. 16 is a schematic showing elements of assembly of the
bedding system shown in FIG. 1;
[0062] FIG. 17 shows instructions for customizing the bedding
system shown in FIG. 1;
[0063] FIG. 17A shows details concerning zoning choices for the
bedding system shown in FIG. 1;
[0064] FIG. 17B shows details concerning zoning choices for the
bedding system shown in FIG. 1;
[0065] FIG. 17C shows details concerning zoning choices for the
bedding system shown in FIG. 1;
[0066] FIG. 17D shows details concerning zoning choices for the
bedding system shown in FIG. 1;
[0067] FIG. 17E-1 shows details concerning zoning choices for the
bedding system shown in FIG. 1;
[0068] FIG. 17E-2 shows details concerning zoning choices for the
bedding system shown in FIG. 1;
[0069] FIG. 17F shows perspective views of embodiments of the
bedding system shown in FIG. 1;
[0070] FIG. 18 shows a chart used to customize the bedding system
shown in FIG. 1;
[0071] FIG. 18A is a perspective view of the bedding system shown
in FIG. 1 in a retail setting;
[0072] FIG. 19 is a perspective view of a bedding system in
accordance with the present disclosure, with parts separated;
[0073] FIG. 20A is a perspective view of the bedding system shown
in FIG. 19;
[0074] FIG. 20B is a perspective view of the bedding system shown
in FIG. 19;
[0075] FIG. 21 is a side, breakaway view, in part phantom of
components of the bedding system shown in FIG. 19;
[0076] FIG. 22 is a side, cross sectional view of components of the
bedding system shown in FIG. 19;
[0077] FIG. 23 is a top view of one embodiment of components of the
bedding system shown in FIG. 1;
[0078] FIG. 24 is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0079] FIG. 25 is a perspective view of one embodiment of
components of the bedding system shown in FIG. 1;
[0080] FIG. 26 shows details of a method used in connection with
the bedding system shown in FIG. 1;
[0081] FIG. 27 shows details of a method used in connection with
the bedding system shown in FIG. 1;
[0082] FIG. 28 shows details of a method used in connection with
the bedding system shown in FIG. 1; and
[0083] FIG. 29 shows details of a method used in connection with
the bedding system shown in FIG. 1.
[0084] Like reference numerals indicate similar parts throughout
the figures.
DETAILED DESCRIPTION
[0085] The present disclosure may be understood more readily by
reference to the following detailed description of the disclosure
taken in connection with the accompanying drawing figures, which
form a part of this disclosure. It is to be understood that this
disclosure is not limited to the specific devices, conditions or
parameters described and/or shown herein, and that the terminology
used herein is for the purpose of describing particular embodiments
by way of example only and is not intended to be limiting of the
claimed disclosure.
[0086] The present disclosure is directed to customizable
mattresses. In some embodiments, a mattress fitting method is
provided for selecting components of a customizable mattress based
upon body type and sleep position. In some embodiments, the
mattress fitting method includes selecting a mattress category
based on quality, price and/or value. In some embodiments, the
mattress category is based upon the number of zones in the
mattress. For example, one of the categories may include mattresses
that have one zone such that the mattress is universal from head to
foot; one of the categories may include mattresses that have three
zones from head to foot; and one of the categories may include
mattresses that have five or more zones or have additional zoning
custom molded to a sleeper's body. In some embodiments, the
additional zoning is determined by sinking the sleeper into a
waterbed-like structure and using 3D mapping so that every location
on the mattress is zoned to the sleeper's specific body contours,
similar to racing car seats and dental molding. In some
embodiments, the mattress categories are assigned numerical values
for different ascending degrees of performance materials,
personalized fit, and durability based on body type. In some
embodiments, the numerical values of the mattress categories are 3,
5 and 7. In some embodiments, the mattress fitting method includes
selecting the mattress category and selecting a level based upon
body type and/or sleep position. In some embodiments, the levels
are assigned numerical values for different body types and/or sleep
positions. In some embodiments, the numerical values of the levels
are 0, 1, 2 and 3. In some embodiments, the body types include
small, medium and large body frames. In some embodiments, the body
types include narrow, medium and broad body frames. In some
embodiments, the sleep positions include stomach, back, side and
multiple positions. In some embodiments, the multiple positions
include any combination of stomach, back and side.
[0087] In some embodiments, the customizable mattress includes
"driver vs. passenger" independent suspension choices that
interlink and can be interchanged, to either side of the bed, as
well as replaced over time. In some embodiments, the independent
suspension is provided by springs or spring-like inner core support
structures that stand and operate separately from each other via
various methods of construction so the sleeper gets balanced
support and flexibility with reduced motion transfer to other body
areas and/or another sleeper. In some embodiments, the independent
suspension includes a plurality of springs that each are positioned
within spring pockets, the spring pockets being connected to one
another by fabric. In some embodiments, the fabric is a flexible
fabric that allows full individual movement that avoids dragging
down adjoining springs. In some embodiments, the fabric includes
sonic welds that define the spring pockets. A slit may be cut into
the fabric between two rows of sonic welds to allow full individual
movement that avoids dragging down adjoining springs. In some
embodiments, the independent suspension includes a plurality of
cradles each having a spring positioned therein to allow full
individual movement that avoids dragging down other springs. In
some embodiments, the springs snap into a cap and a base and
include a cord between the cap and the base to give the spring a
constant height. In some embodiments, the caps include a logo, such
as, for example, a logo of the mattress manufacturer.
[0088] In some embodiments, an easy to ship and/or easy to carry
packaging method is provided for transporting a customizable
mattress. In some embodiments, the easy to ship and/or easy to
carry packaging method includes packaging a modular customizable
mattress in three or more boxes. In some embodiments, one box
includes a first inner spring inner core of the customizable
mattress. In some embodiments, one box includes a second inner
spring inner core of the customizable mattress. In some
embodiments, one box includes a frame or chassis of the
customizable mattress. In some embodiments, one box includes a
zippered topper or upper cover of the customizable mattress. In
some embodiments, the chassis is made from a foam material, such
as, for example, dual durometer foam or injection molded latex. In
some embodiments, the easy to ship and/or easy to carry packaging
method allows the modular pieces of the customizable mattress to be
assembled at the moment of delivery by a retail store driver. In
some embodiments, the easy to ship and/or easy to carry packaging
method requires only a single driver, such as, for example, a
delivery person, drone or UPS delivery to transport the modular
pieces of the customizable mattress from a factory or warehouse to
an end user.
[0089] In some embodiments, an easy to fit shopper and/or easy to
return method is provided for purchasing and/or returning a
customizable mattress. In some embodiments, the easy to fit shopper
and/or easy to return method includes providing an SKU optimized
for a retailer. In some embodiments, the easy to fit shopper and/or
easy to return method includes providing the least amount of SKUs,
while providing the most options. In some embodiments, the easy to
fit shopper and/or easy to return method includes swapping
independent suspension cores or power plants to alternate sides
such that the independent suspension cores still interlink. In some
embodiments, the easy to fit shopper and/or easy to return method
includes reselecting a support level.
[0090] In some embodiments, a subscription sales method is provided
for purchasing replacement components for a customizable mattress.
In some embodiments, the subscription sales method includes
collecting customer information. In some embodiments, the
subscription sales method includes reaching out to customers
periodically, such as, for example, annually. In some embodiments,
the subscription sales method includes reaching out to customers
based upon the date the customizable mattress was purchased
(mattress birthday). In some embodiments, the subscription sales
method includes renewing the subscription.
[0091] In some embodiments, the customizable mattress includes an
adjustable chassis that allows for articulation of one portion of
the chassis relative to other portions of the chassis. In some
embodiments, the adjustable chassis is manual or electric. In some
embodiments, the adjustable chassis includes motion devices
embedded within the chassis. In some embodiments, the customizable
mattress includes a self-enclosed powered adjustable chassis.
[0092] In some embodiments, the chassis includes "X" technology
that provides features of an ambient to allow the chassis to
circulate and generate airflow within one or more zones. In some
embodiments, the "X" technology allows the chassis to circulate and
generate airflow without having air blow on the sleeper. That is,
the airflow is similar to that of a radiant floor to provide
creature comfort. In some embodiments, the "X" technology allows
the chassis to be as efficient in heating and/or cooling the
environment surrounding the customizable mattress for the sleeper's
comfort as well as the system itself. In some embodiments, topper
pads have a material surface texture for comfort and pressure
sensitivity. In some embodiments, the customizable mattress
includes various topper attachment concepts that allow for easy
replacement and/or reselection of the comfort layer. In some
embodiments, the topper attachment concepts include carabineer
style connections. In some embodiments, the topper attachment
concepts include stretched straps that connect the topper pad to a
lower mattress. In some embodiments, the lower mattress is made
from woven tent material. In some embodiments, the topper
attachment concepts include hot rod strap style connections. In
some embodiments, the topper attachment concepts include leather
straps that connect the topper pad to a lower mattress.
[0093] In some embodiments, the customizable mattress includes a
chassis that defines a cavity, two spring packs removably
positioned within the cavity and a top pad that removably covers at
least a portion of the spring pack. The spring packs and the top
pad may have variable components. That is, different versions of
the spring packs and the top pad are available to allow a sleeper
to customize the mattress to suit his or her preferred sleep
position and/or body type. In some embodiments, three versions of
the spring packs are available and include a soft spring pack, a
medium spring pack and a firm spring pack. In that each mattress
includes two spring packs, this allows for six combinations:
soft/soft, medium/medium, firm/firm, soft/medium, soft/firm and
medium/firm. Furthermore, left/right reversals of the spring packs
double the number of combinations. In some embodiments, the two
spring packs of a given mattress interlock to allow a blend of
firmness at the center. In some embodiments, the spring packs
interlock using a one row, one spring blend. In some embodiments,
the spring packs interlock using a two row, one spring blend. In
some embodiments, the spring packs interlock using a one row, two
spring blend. In some embodiments, three versions of the top pads
are available and include a soft top pad, a medium top pad and a
firm top pad. In some embodiments, the top pads include stitching
that forms a pattern in the top pads. For example, in one
embodiment, the top pads include a pattern that resembles a
flame.
[0094] In some embodiments, the chassis is made from molded foam,
carbon fiber or fiberglass or other thermo-molded plastic-like
material foundation that shapes the interior or the exterior. In
some embodiments, sculpting the exterior gives the mattress a
unique appearance. In some embodiments, the chassis is made up of a
plurality of separate pieces and the customizable mattress includes
an outer lower cover that surrounds at least a portion of the
chassis to hold the separate pieces together. The chassis may be
rolled for delivery, with the outer lower cover coupled to the
chassis. After delivery, the chassis is unrolled, with the outer
lower cover coupled to the chassis. Any of the separate pieces that
are not connected to the chassis are then connected to the chassis.
Selected spring packs are positioned within a cavity of the
chassis. A top pad is then positioned over the spring packs.
[0095] Also, as used in the specification and including the
appended claims, the singular forms "a," "an," and "the" include
the plural, and reference to a particular numerical value includes
at least that particular value, unless the context clearly dictates
otherwise. Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment. It is also understood that all spatial references, such
as, for example, horizontal, vertical, top, upper, lower, bottom,
left and right, are for illustrative purposes only and can be
varied within the scope of the disclosure. For example, the
references "upper" and "lower" are relative and used only in the
context to the other, and are not necessarily "superior" and
"inferior".
[0096] The following discussion includes a description of a
customizable mattress in accordance with the principles of the
present disclosure. Alternate embodiments are also disclosed.
Reference will now be made in detail to the exemplary embodiments
of the present disclosure, which are illustrated in the
accompanying figures. Turning to FIGS. 1-29, there are illustrated
components of a bedding system 10.
[0097] System 10 includes a mattress 12. Mattress 12 is configured
to be customizable to create a mattress that has performance
characteristics specifically tailored to the sleeper's body type
and/or sleep preferences while also allowing the sleeper to replace
components with other components should the components become worn
and/or the sleeper's body type or sleep preferences change over
time. Mattress 12 includes a chassis 14 having an inner surface
that defines a cavity 16, as shown in FIG. 2B. A pair of spring
packs 18 are removably positioned within cavity 16, as shown in
FIGS. 2E and 2F. A top pad 20 removably covers at least a portion
of spring pack 18.
[0098] In some embodiments, shown in FIGS. 2A-2F and 3, chassis 14
includes a base 22, opposite first and second side portions 22a,
22b that extend upwardly from base 22, a top portion 22c and a
bottom portion 22d opposite top portion 20c, top and bottom
portions 20c, 20d each extending between first and second side
portions 22a, 22b. In some embodiments, first and second side
portions 22a, 22b are fixed to base 22 and top and bottom portions
20c, 20d are removably connected to first and second side portions
22a, 22b and base 22. First side portion 22a includes opposite
first and second mortises 24, second side portion 22b includes
opposite third and fourth mortises 24, top portion includes
opposite fifth and sixth mortises 24 and bottom portion 22d
includes opposite seventh and eighth mortises 24. Chassis 14
includes a first corner piece 26 comprising tenons 28 that fit into
first and fifth mortises 24, a second corner piece 26 comprising
tenons 28 that fit into second and seventh mortises 24, a third
corner piece 26 that fits into third and sixth mortises 24 and a
fourth corner piece 26 comprising tenons 28 that fit into the
fourth and eighth mortises 24 to join first and second side
portions 22a, 22b with top and bottom portions 22c, 22d. A planar
surface of base 22 and inner surfaces of first and second side
portions 22a, 22b, top portion 22c and bottom portion 22d define
the inner surface of chassis 14 that defines cavity 16. One
particular embodiment of chassis 14 is shown in FIG. 3A.
[0099] In one embodiment, shown in FIG. 3B, chassis 14 includes at
least one opening that defines a vent 25 extending through opposite
inner and outer surfaces of chassis 14. Vents 25 are configured to
allow air flow in and out of cavity 16. That is, vents 25 allow air
to circulate and exchange from an inner core of mattress 12 to a
room environment. In one embodiment, vent 25 is molded into sides
of chassis 14, such as, for example, at least one of side portions
22a, 22b. Each vent 25 includes a mesh material 35 positioned
therein. Mesh material 35 acts as a filter to trap particulate
matter as air flows in and out of cavity 16. In some embodiments,
at least one of base 22, first and second side portions 22a, 22b
and top portion 22c includes one or more vents 25. In some
embodiments, at least one of vents 25 is positioned within a
recessed cavity of chassis 14.
[0100] In some embodiments, mattress 12 comprises an outer lower
covering 30 that surrounds or encloses at least a portion of
chassis 14, as shown in FIGS. 2A-2F and 3. In some embodiments,
outer lower covering 30 covers an entire bottom surface of base 22,
entire outer surfaces of first and second side portions 22a, 22b,
entire outer surfaces of top and bottom portions 22c, 22d, at least
a portion of top surfaces of first and second side portions 22a,
22b and at least a portion of top surfaces of top and bottom
portions 22c, 22d. In some embodiments, outer lower cover 30 may be
configured to entirely cover the top surfaces of first and second
side portions 22a, 22b and/or the top surfaces of top and bottom
portions 22c, 22d. In some embodiments, outer lower cover 30 may be
configured to entirely cover corner pieces 26. In some embodiments,
outer lower cover 30 includes curved corners that each cover at
least a portion of one of corner pieces 26. In some embodiments,
outer lower covering 30 includes a mesh material.
[0101] In some embodiments, chassis 14 may be rolled for delivery,
with outer lower cover 30 coupled to chassis 14. In some
embodiments, top and bottom portions 22c, 22d have been removed
from chassis 14 prior to rolling chassis 14. After delivery,
chassis 14 is unrolled; with outer lower cover 30 coupled to
chassis 14. Tenons 28 of corner pieces 26 are positioned in
mortises 24 of first and second side portions 22a, 22b and top and
bottom portions 22c, 22d in the manner discussed above. Either
before or after spring packs 18 are positioned within cavity 16,
outer lower cover 30 may be moved relative to top and bottom
portions 22c, 22d such that outer lower cover 30 covers at least a
portion of top and bottom portions 22c, 22d.
[0102] In some embodiments, spring packs 18 include a first spring
pack 18a, a second spring pack 18b and a third spring pack 18c, as
shown in FIGS. 4A-4C. Spring packs 18a, 18b, 18c are identical in
terms of size and shape, but differ with regard to firmness. For
example, spring pack 18b may be firmer than spring pack 18a and
spring pack 18c may be firmer than spring pack 18b. In some
embodiments, system 10 may include one or a plurality of additional
spring packs each having a firmness that is different than that of
spring packs 18a, 18b, and 18c. In that mattress 12 includes two
spring packs 18, providing spring packs 18a, 18b, and 18c with
different firmnesses that allows for six combinations: soft/soft,
medium/medium, firm/firm, soft/medium, soft/firm and medium/firm.
In some embodiments, spring packs 18a, 18b, 18c are formed from the
same material. In some embodiments, spring packs 18a, 18b, 18c are
formed from different materials.
[0103] In some embodiments, spring packs 18 each include
projections 32 that are configured to be positioned within recesses
34 of another one of spring packs 18, such as, for example, one of
spring packs 18a, 18b, 18c. Spring packs 18 each include a
plurality of springs 36, as shown in FIGS. 5A-5C. In one
embodiment, shown in FIG. 5A and 6A, projections 32 of spring packs
18 are each made up of one spring 36 and recesses 34 span the cross
sectional distance or width of one spring 36 such that spring packs
18 have a one row one spring blend, as shown in FIGS. 5A and
6A.
[0104] In one embodiment, shown in FIG. 5B and 6B, projections 32
of spring packs 18 are each made up of four springs 36 that are
arranged to have a pyramidal or triangular configuration. That is,
a tip of each projection 32 spans the cross sectional distance or
width of one spring 36 and a base of each projection 32 that the
tip extends from spans the cross sectional distance or width of
three springs 36. Recesses 34 each have a narrowed first end
portion that receives the tip of one of projections 32. The first
end portion of recess 34 spans the cross sectional distance or
width of one spring 36. Recesses 34 also include an enlarged second
end portion that spans the cross sectional distance or width of
three springs 36. The enlarged second end portion of recess 34
receives the base of one of projections 34 such that spring packs
18 have a two row one spring blend, as shown in FIGS. 5B and
6B.
[0105] In one embodiment, shown in FIGS. 5C and 6C, projections 32
of spring packs 18 are each made up of two springs 36 and recesses
34 span the cross sectional distance or width of two springs 36
such that spring packs 18 have a one row two spring blend, as shown
in FIGS. 5C and 6C.
[0106] In some embodiments, shown in FIGS. 7-9, springs 36 are
positioned in spring pockets 38. Spring pockets 38 comprise a
fabric that each enclose one of springs 36. Adjacent spring pockets
38 are joined to one another by a material 40. In some embodiments,
material 40 is the same material as the fabric that makes up spring
pockets 38. In some embodiments, material 40 is a different
material than the fabric that makes up spring pockets 38. In some
embodiments, spring pockets 38 include welds, such as, for example,
sonic welds 42 that provide strength to spring pockets 38. In some
embodiments, welds 42 are double weld rows, as shown in FIG. 9.
[0107] In one embodiment, shown in FIG. 8A, material 40 is free of
any slits or vertical cuts. In some embodiments, shown in FIGS. 7
and 8B-9, material 40 includes a slit 44 between adjacent welds 42.
In some embodiments, slits 44 are positioned between double welds
42, as shown in FIG. 9. Slits 44 allow a spring 36 in a spring
pocket 38 to be compressed without compressing springs 36 in
adjacent spring pockets 38, as shown in FIG. 9. That is, without
slits 44, compressing a spring 36 in a spring pocket 38 will also
compress springs 36 in adjacent spring pockets 38, as also shown in
FIG. 9. FIG. 9 also shows a comparison between components of the
bedding system 10 and prior art components 31. In one embodiment,
shown in FIG. 8B, slits 44 are made by making a short cut into
material 40. In this embodiment, slits 44 are between 0-1/3 the
height of material 40, wherein the height of material 40 is defined
by the height of springs 36 when springs are not compressed. In one
embodiment, shown in FIG. 8C, slits 44 are made by making a longer
cut into material 40. In this embodiment, slits 44 are between
1/3-1/2 the height of material 40, wherein the height of material
40 is defined by the height of springs 36 when springs 36 are not
compressed. In some embodiments, slits 44 are between 1/2-3/4 the
height of material 40, wherein the height of material 40 is defined
by the height of springs 36 when springs 36 are not compressed.
[0108] In one embodiment, shown in FIG. 10, chassis 14 includes a
plurality of cradles 46 that each house one of springs 36. Cradles
46 are fixed to chassis 14. Cradles 46 each have a cylindrical
configuration with an open top that allows springs 36 to be
positioned therein. In some embodiments, cradles 46 each have a
height that is less than that of springs 36 when springs 36 are not
compressed such that top portions of springs 36 will extend out of
cradles 46 when springs 36 are not compressed. In some embodiments,
cradles 46 each have a height that is equal to that of springs 36
when springs 36 are compressed such that top portions of springs 36
will be flush with top portions of cradles 46 when springs 36 are
compressed. That is, cradles 46 will fully surround springs 36 when
springs 36 are compressed. In some embodiments, cradles 46 each
have a height that is less than that of springs 36 when springs 36
are compressed such that top portions of springs 36 will extend out
of cradles when springs 36 are compressed. Cradles 46 are spaced
apart from one another such that when one spring 36 is compressed,
cradles 46 prevent adjacent springs 36 from compressing. That is,
cradles 46 allow springs 36 to stand and operate separately from
other springs 36.
[0109] In one embodiment, shown in FIG. 10A, chassis 14 includes a
plurality of cradles 47 that each house a lower portion of one of
springs 36. Cradles 47 are fixed relative to chassis 14. In some
embodiments, cradles 47 are formed from a silicon membrane. Cradles
47 each have a cylindrical configuration with an open top that
allows the lower portions of springs 36 to be positioned therein.
In some embodiments, cradles 47 each have a height that is less
than that of springs 36 when springs 36 are not compressed such
that top portions of springs 36 will extend out of cradles 46 when
springs 36 are not compressed. Top pad 20 includes a plurality of
spring cups 49 each configured to receive a top portion of one of
springs 36. Spring cups 49 are fixed relative to top pad 20. Each
of spring cups 49 is coaxial with one of cradles 47 such that when
springs 36 are positioned within cradles 47 and spring cups 49, an
interlocking upper and lower mattress is created that does not need
the support of side foam. This allows for the use of a mesh and/or
breathable material to be used in place of side foam. As such, in
this embodiment, chassis 14 may include a perforate side mesh to
allow mattress 12 to breath, unlike traditional side foam.
[0110] In one embodiment, shown in FIGS. 11A-11D, springs 36 each
include a cap 48a, a base 48b, a coiled element 48c and a cord 48d.
Cord 48 extends between cap 48a and base 48b such that cap 48a and
base 48b each extend perpendicular to cord 48d. In some
embodiments, cord 48d includes at least one bend, as shown in FIG.
11B. Cord 48d is configured to provide spring 36 with a constant
height. That is, cord 48d ensures that spring 36 cannot be
compressed to have a height that is less than that of cord 48d. A
first end of coiled element 48c is fixed to cap 48a and an opposite
second end of coiled element 48c is fixed to base 48b. In some
embodiments, cap 48a and base 48b each include an arcuate cavity
48e configured to receive one of the first and second ends of
coiled element 48c, as shown in FIGS. 11A and 11B. In some
embodiments, the first and second ends of coiled element 48c are
configured to snap into cavities 48e. In some embodiments, cap 48a
includes a logo, such as, for example, the logo of the manufacturer
of mattress 12 that faces away from base 48b.
[0111] In one embodiment, shown in FIG. 12, spring packs 18 have an
egg carton-like configuration that includes a plurality of spaced
apart cavities 50 each having a bottom portion of one of springs 36
positioned therein. Spacing cavities 50 apart from one another also
spaces springs 36 apart from one another. In this embodiment,
spring packs 18 do not include any sleeves or spring pockets, such
as, for example, spring pockets 38. This allows better airflow
between adjacent springs 36. In the embodiment shown in FIG. 12A,
base 48b includes a dowel 49 and cap 48a includes a sleeve 51
having a passageway configured to receive dowel 49 therein. Dowel
49 is movable within sleeve 51 such that cap 48a moves toward base
48b as coiled element 48e compresses and cap 48a moves away from
base 48b as coiled element 48e decompresses or expands. In this
embodiment, spring 36 comprises a plastic or rubberized material to
hold spring 36 in tension to control firmness.
[0112] In one embodiment, shown in FIGS. 12B-12D, top pad 20 may
include cavities 50a configured to receive top portions of springs
36. Positioning springs 36 within cavities 50, 50a secures springs
36 between chassis 14 and top pad 20. As shown in FIG. 12D, spring
36 may be formed from a plurality of layers each having an
undulating configuration. In particular, concave portions of a
first undulating layer are in direct contact with convex portions
of a second undulating layer and convex portions of the first
undulating layer are in direct contact with concave portions of a
third undulating layer, the first undulating layer being positioned
between the second and third undulating layers. In some
embodiments, spring 36 is formed from a single strip of material
that is coiled to form the undulating layers.
[0113] In some embodiments, top pads 20 include a first top pad
20a, a second top pad 20b and a third top pad 20c, as shown in
FIGS. 13A-13C. In some embodiments, top pads 20a, 20b, 20c are
identical in terms of size and shape, but differ with regard to
firmness. For example, top pad 20b may be firmer than top pad 20a
and top pad 20c may be firmer than top pad 20b. In some
embodiments, system 10 may include one or a plurality of additional
top pads each having a firmness that is different than that of
spring packs 18a, 18b, and 18c. In some embodiments, top pads 20a,
20b, 20c are formed from the same material. In some embodiments,
top pads 20a, 20b, 20c are formed from different materials. In some
embodiments, top pads 20a, 20b, 20c each have a different
thickness, as shown in FIG. 17F.
[0114] In some embodiments, top pad 20 includes a first side 21 and
a second side 23 that is removably attached to first side 21, as
shown in FIGS. 13D and 13E. In some embodiments, first and second
sides 21, 23 may have different characteristics, such as, for
example, different firmnesses, different thicknesses, different
materials, materials with different textures, etc. In some
embodiments, first and second sides 21, 23 are connected to one
another via a zipper, hook and loop fasteners, Velcro.RTM., magnets
connectors, buttons, etc. In some embodiments, top pad 20 includes
a band 27 that extends between upper and lower surfaces of top pad
20. Band 27 extends annularly or circumferentially about the
perimeter of top pad 20, as shown in FIG. 13E. That is, band 27
perimetrically bounds the upper and lower surfaces of top pad 20.
Band 27 is configured to show levels of breathability and firmness
of top band 27. In some embodiments, the upper surface of top pad
20 has a honeycomb design.
[0115] In one embodiment, shown in FIG. 13F, first side 21 includes
zones 21a, 21b, 21c and side 23 includes zones 23a, 23b, 23c. At
least one of zones 21a, 21b, 21c are different from another one of
zones 21a, 21b, 21c as to firmness and at least one of zones 23a,
23b, 23c are different from another one of zones 23a, 23b, 23c as
to firmness. Zones 21a, 21b, 21c may be the same or different than
zones 23a, 23b, 23c.
[0116] In one embodiment, shown in FIG. 14, top pad 20 is coupled
to chassis 14 by carabineer style connections. In particular, top
pad 20 includes a plurality of stretchable straps 52 each
configured to connect to a buckle 54 on chassis 14. Straps 52 are
fixed to top pad 20 and buckles 54 are fixed to chassis 14 such
that connecting straps 52 with buckles 54 secures top pad 20 to
chassis 14. In this embodiment, straps 52 have a loop-like
configuration that is captured by a portion of buckle 54. Top pad
20 has a textured upper surface for comfort and pressure
sensitivity and chassis 14 is made from a woven tent material. In
some embodiments, top pad 20 is at least partially covered with a
retention fabric to further secure top pad 20 to chassis 14. In
some embodiments, the retention fabric entirely covers top pad 20.
In some embodiments, the retention fabric entirely covers top pad
20 and at least a portion of chassis 14.
[0117] In one embodiment, shown in FIG. 15, top pads 20 are coupled
to chassis 14 by hot rod strap style connections. In particular,
top pad 20 includes a plurality of leather straps 56 each
configured to connect to a buckle 58 on chassis 14. Straps 56 are
fixed to top pad 20 and buckles 58 are fixed to chassis 14 such
that connecting straps 56 with buckles 58 secures top pad 20 to
chassis 14. In this embodiment, straps 56 each include at least one
opening configured to receive a prong of buckle 58 similar to how a
prong of a belt buckle is received within a hole of a belt.
[0118] In one embodiment, shown in FIG. 15A, top pad 20 has a
material surface texture for comfort and pressure sensitivity.
Chassis 14 includes a woven dimensional material with a silver or
white stitch. Chassis 14 includes a panel 62 toward the foot of
mattress 12. In some embodiments, panel 62 includes indicia 64.
Indicia 64 may be stitched onto panel 62 or may be otherwise
coupled to panel 62 by adhesive or some other material. In some
embodiments, indicia 64 includes letters that spell a model or
other words describing characteristics of mattress 12. In one
embodiment, indicia 64 includes letters that spell one or more
words that describe top pad 20, such as, for example,
characteristics of top pad 20. In one embodiment, indicia 64
includes letters that spell one or more words that describe the
theme of mattress 12, such as, for example, words relating to
racing, cars, camping, outdoors, etc. In one embodiment, shown in
FIG. 15B, mattress 12 is stiffer than mattress 12 shown in FIG.
15A. Topper pad 20 in FIG. 15B is made from Patagonia style
material for feel and durability. In one embodiment, shown in FIG.
15C, mattress 12 is stiffer than mattress 12 shown in FIG. 15B. Top
pad 20 in FIG. 15C is made of a material surface to depict firm
comfort.
[0119] In one embodiment, shown in FIG. 15D, sides 21, 23 of top
pad 20 each include color coded zones for comfort designation.
Sides 21, 23 are joined together by a center zipper 66. Zippered
corners 68 help to keep mattress 12 together. That is, zippered
corners 68 secure top pad 20 to chassis 14, while maintaining
spring packs 18 between chassis 14 and top pad 20. Chassis 14
includes one or a plurality of vents 70 that extend through inner
and outer surfaces of chassis 14. Vents 70 may each have an arcuate
configuration, as shown in FIG. 15D. Although vent 70 is shown in
this configuration, other configurations such as, circular,
elliptical, polygonal or the like are also possible. In some
embodiments, at least one of base 22, first and second side
portions 22a, 22b and top portion 22c includes one or more vents
70. Vents 70 are configured to allow air flow in and out of cavity
16. That is, vents 70 allow air to circulate and exchange from an
inner core of mattress 12 to a room environment.
[0120] In one embodiment, shown in FIG. 15E, sides 21,23 of top pad
20 are stitched together. Sides 21, 23 may be stitched together
using a baseball style stitch. Band 27 (shown in FIG. 15C) is
joined to the upper surface of top pad 20 using stitching.
Likewise, band 27 is joined to the lower surface of top pad 20
using stitching. In some embodiments, the stitching that joins band
27 with the upper and lower surfaces of top pad 20 is a baseball
style stitch. In one embodiment, shown in FIG. 15F, chassis 14
includes a first piece of material 72 and a second piece of
material 74 that is joined with first piece of material 72 along
seams 76. Second piece of material 74 is not joined to first piece
of material 72 along seam 78 such that first and second pieces of
material 72, 74 form a pocket. In some embodiments, the pocket is
configured for holding sheets in place and/or storage. It is
envisioned that one or more of base 22, first and second side
portions 22a, 22b and top portion 22c may include a pocket. As
shown in FIG. 15F, seam 78 extends at an acute angle relative to
top pad 20 such that the depth of the pocket is greater at one end
of the pocket than an opposite end of the pocket. However, in some
embodiments, seam 78 extends parallel to top pad 20 such that the
depth of the pocket is the same at one end of the pocket as the
opposite end of the pocket.
[0121] As discussed above, mattress 12 is customizable according to
the sleep position and/or body type of one or more sleepers. To
achieve this, a plurality of spring packs 18 and top pads 20 having
different firmnesses are available to be included in a given
mattress 12, as shown in FIG. 16. This allows sleepers to choose
spring packs 18 and top pads 20 having a firmness that correlates
to their body type and/or sleep position. In some embodiments, only
one type of chassis 14, only one type of outer lower covering 30
and only one type of retention fabric are available, as shown in
FIG. 16. As such, mattress 12 may be customized by choosing spring
packs 18 and top pads 20 having a firmness that correlates to their
body type and/or sleep position and combining the same with chassis
14, outer lower covering 30 and/or the retention fabric.
[0122] In some embodiments, a plurality of different chassis 14 are
available to build a mattress 12. For example, at least three types
of chassis 14 may be provided, wherein each chassis 14 includes
different zoning and/or materials, as shown in FIG. 17. In some
embodiments, the different types of chassis 14 are assigned a
numerical value for different ascending degrees of performance,
materials, personal fit and durability, based upon body type. Three
different chassis are shown in FIG. 17F. In some embodiments,
chassis 14 is chosen from among the different types of chassis 14
based on the sleepers' body types and sleep positions. In some
embodiments, the mattress category is based upon the number of
zones in the mattress. For example, one of the categories may
include mattresses that have one zone such that the mattress is
universal from head to foot; one of the categories may include
mattresses that have three zones from head to foot; and one of the
categories may include mattresses that have five or more zones or
have additional zoning custom molded to a sleeper's body, as shown
in FIG. 17A. In some embodiments, the additional zoning is
determined by sinking the sleeper into a waterbed-like structure
and using 3D mapping so that every location on the mattress is
zoned to the sleeper's specific body contours, similar to racing
car seats and dental molding. Examples of the types of zones that
may be included in chassis 14 are shown in FIGS. 17B and 17C. As
shown in FIGS. 17B and 17C, the zones may be specifically
positioned to provide a selected amount of support for a particular
body part. As shown in FIG. 17D, chassis 14 may include a plurality
of heated zones that may be variously positioned about chassis 14.
In some embodiments, the heated zones are arranged similar to that
of a sneaker tread pattern. As shown in FIGS. 17E1-E2, one side of
mattress 12 may include a first zone or zones, such as, for
example, a "his zone," and another side of mattress 12 may include
a second zone or zones, such as, for example, a "her zone" that
is/are different from the first zone or zones.
[0123] Once the proper chassis 14 is selected, the sleeper then
chooses spring packs 18 and a top pad 20 based on the sleepers'
body types and sleep positions. In one embodiment, the sleeper may
consult a chart similar to that shown in FIG. 18 that assigns a
number based upon the sleepers' body types and sleep positions. For
example, a sleeper with a small frame (dress size 0-2 or jacket
size 34-36) who sleeps on their stomach may have a number 0.0,
while a sleeper with a large frame (dress size 12+ or jacket size
44+) who sleeps on their stomach may have a number 3.0. This
indicates that the sleeper with the large frame will require a
firmer spring pack 18 and/or top pad 20 than the sleeper with the
small frame. As such, the sleeper with the large frame would likely
select spring pack 18c and the sleeper with the small frame would
likely select spring pack 18a. Likewise, the sleeper with the large
frame would likely select top pad 20c and the sleeper with the
small frame would likely top pad 20a. As discussed above, spring
packs 18a, 18b, 18c can be combined with any of spring packs 18a,
18b, 18c such that two spring packs 18 having the proper firmness
can be selected for one mattress 12 so as to provide proper support
for each of the two sleepers that sleeps on mattress 12. Although
mattress 12 has been discussed in terms of chassis 14, spring packs
18a, 18b, 18c and top pads 20a, 20b, 20c, it should be understood
that mattress 12 can include any of the chassis discussed in this
disclosure, any of the spring packs discussed in this disclosure
and any of the top pads discussed in this disclosure, in any
combination. Indeed, the features or components of one embodiment
discussed herein may be incorporated into any of the other
embodiments discussed herein, thus providing a variety of options
in forming a mattress that is specifically suited for a sleeper or
sleepers. This is facilitated by, among other things, the modular
nature of mattress 12. FIG. 18A shows an assembled mattress 12 in a
retail setting, such as, for example, a showroom that has been
adapted to appear like a typical bedroom, with a rug, furniture and
decorations typically found in a bedroom.
[0124] In one embodiment, shown in FIGS. 19-21, chassis 14 is
powered for adjustability and/or articulation. Chassis 14 may be
manual or electric. Motion devices may be embedded within chassis
14. In particular, chassis 14 may include at least four portions
14a, 14b, 14c, 14d that are movable relative to one another, as
shown in FIGS. 20A and 20B. Portions 14a, 14b, 14c, 14d are
connected to one another by rotatable gears (FIG. 21) that are
configured to rotate portions 14a, 14b, 14c, 14d relative to one
another such that portions 14a, 14b, 14c, 14d can move from a first
position, shown in FIG. 20A, in which portions 14a, 14b, 14c, 14d
extend parallel to one another to a second position, shown in FIG.
20B, in which portions 14a, 14b, 14c, 14d extend at acute angles
relative to one another. In some embodiments, the rotatable gears
are configured to lock to fix portions 14a, 14b, 14c, and 14d in
the first position and/or the second position.
[0125] In one embodiment, shown in FIG. 23, mattress 12 has a six
zone system. In one embodiment, shown in FIG. 24, chassis 14
includes at least three portions 14a, 14b, 14c that are joined to
one another by hinges 15 such that portions 14a, 14b, 14c are
movable relative to one another. Mattress 12 includes a cushion 60
positioned within cavity 16. Cushion 60 includes portions 1-6, as
shown in FIG. 24. Portions 1-6 are joined to one another by hinges
17. This configuration allows mattress 12 to recline, while still
providing multiple zones. In one embodiment, shown in FIG. 25,
chassis 14 is a tray that does not articulate. In some embodiments,
at least two of zones 1-6 have different characteristics, such as,
for example, different firmnesses.
[0126] In some embodiments, system 10 includes an easy to ship/easy
to carry packaging method, as shown in FIGS. 26 and 27, for
transporting mattress 12. The method includes packaging mattress 12
in four boxes. In some embodiments, one box includes one spring
pack 18, another box includes another spring pack 18, another box
includes chassis 14 and another box includes top pad 20. In some
embodiments, the easy to ship and/or easy to carry packaging method
allows the modular pieces of the customizable mattress to be
assembled at the moment of delivery by a retail store driver. In
some embodiments, the easy to ship and/or easy to carry packaging
method requires only a single driver, such as, for example, a
delivery person, drone or UPS delivery to transport the modular
pieces of the customizable mattress from a factory or warehouse to
an end user. As shown in FIG. 27, the easy to ship/easy to carry
packaging method includes assembling mattress 12. In particular,
chassis 14, spring packs 18 and top pad 20 are unpacked from their
respective boxes. Spring packs 18 are positioned within cavity 16
of chassis 14. Top pad 20 is positioned to cover spring packs 18
and portions of chassis 14.
[0127] In some embodiments, system 10 includes an easy to fit to
shopper/easy to return method, as shown in FIG. 28. The method
includes providing an SKU optimized for a retailer. In some
embodiments, the easy to fit shopper and/or easy to return method
includes providing the least amount of SKUs, while providing the
most options. In one embodiment, chassis 14 includes one SKU, each
spring pack 18 includes one SKU and top pad 20 includes one SKU.
Outer lower cover 30 and the retention fabric may each include one
SKU, if used. The SKUs will help identify the components that are
going to be used in a given mattress 12. For example, each of the
different versions or embodiments of chassis 14 will have its own
unique SKU, each of the different versions or embodiments of spring
packs 18 will have its own Stock Keeping Unit (SKU) and each of the
different versions or embodiments of top pad 20 will have its own
SKU. This allows a worker to select the proper components by
reading the SKUs. For example, this ensures the worker will choose
the chassis 14, the spring packs 18 and the top pad 20 that each
has the desired firmness or other characteristics selected by the
consumer. In some embodiments, the easy to fit shopper and/or easy
to return method includes swapping independent suspension cores or
power plants to alternate sides such that the independent
suspension cores still interlink. In some embodiments, the easy to
fit shopper and/or easy to return method includes reselecting a
support level.
[0128] In some embodiments, system 10 includes a subscription sales
method that includes reaching out to customers based upon the date
the customizable mattress was purchased (mattress birthday), as
shown in FIG. 29. In some embodiments, the subscription sales
method includes renewing the subscription. In some embodiments, the
subscription sales method includes collecting customer information.
In some embodiments, chassis 14 has a five year warranty, in which
case, the subscription sales method will begin contacting a
customer who purchased a mattress 12 regarding replacing or
upgrading chassis 14 five years or more after mattress 12 was
purchased. In some embodiments, top pad 20 has a one year warranty,
in which case, the subscription sales method will begin contacting
a customer who purchased a mattress 12 regarding replacing or
upgrading top pad 20 one year or more after mattress 12 was
purchased.
[0129] It will be understood that various modifications may be made
to the embodiments disclosed herein. For example, features of any
one embodiment can be combined with features of any other
embodiment. Therefore, the above description should not be
construed as limiting, but merely as exemplification of the various
embodiments. Those skilled in the art will envision other
modifications within the scope and spirit of the claims appended
hereto.
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