U.S. patent application number 15/369201 was filed with the patent office on 2017-06-08 for simulated zero "g" mattress and cover.
The applicant listed for this patent is Polar Generation LLC. Invention is credited to Eric CHAN, Evan L. RYAN, Nicholas SEGAL.
Application Number | 20170156508 15/369201 |
Document ID | / |
Family ID | 58798048 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170156508 |
Kind Code |
A1 |
SEGAL; Nicholas ; et
al. |
June 8, 2017 |
SIMULATED ZERO "G" MATTRESS AND COVER
Abstract
A mattress is provided having three layers of differing
properties stacked on top of each other which together have the
effect of letting the user sleep in a simulated Zero G position
without the aid of an articulating base. Two layers are contoured
within the mattress let specific areas of the user's body sink
further into the mattress than others. A cover with removable
inserts is also provided for the mattress.
Inventors: |
SEGAL; Nicholas; (Old
Greenwich, CT) ; CHAN; Eric; (New York, NY) ;
RYAN; Evan L.; (Brooklyn, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Polar Generation LLC |
White Plains |
NY |
US |
|
|
Family ID: |
58798048 |
Appl. No.: |
15/369201 |
Filed: |
December 5, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62262579 |
Dec 3, 2015 |
|
|
|
62410584 |
Oct 20, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/001 20130101;
A47C 27/15 20130101; A47C 27/22 20130101; A47C 27/148 20130101;
A47C 27/005 20130101; A47C 31/105 20130101 |
International
Class: |
A47C 27/15 20060101
A47C027/15; A47C 27/00 20060101 A47C027/00; A47C 27/14 20060101
A47C027/14 |
Claims
1. A mattress having a length greater than a width, the mattress
comprising: a first layer formed from a breathable and spring-like
material; a second layer formed from a visco-elastic polyurethane
(memory foam); a third layer formed from a high density
polyurethane foam (HD foam); wherein the mattress is divided into
five zones along the length of the mattress; wherein a thickness of
the third layer in a first zone and a fifth zone is greater than a
thickness of the second layer; wherein a thickness of the second
layer in a third zone is greater than a thickness of the third
layer; and wherein a thickness of the first layer is the same in
each of the five zones.
2. The mattress according to claim 1, wherein a density of the
second layer is 3-8 lb/ft 3 and a density of the third layer is 1-3
lb/ft 3.
3. The mattress according to claim 1, wherein a thickness of the
second layer in a second zone increases in thickness from 1-4'' at
a beginning of the second zone to 2-10'' at an end of the second
zone.
4. The mattress according to claim 3, wherein a thickness of the
third layer in the second zone decreases in thickness from 3-16''
at the beginning of the second zone to 1-10'' at the end of the
second zone.
5. The mattress according to claim 3, wherein the thickness of the
second layer in the second zone increases at a constant rate.
6. The mattress according to claim 1, wherein the fifth zone is a
mirror image of the first zone and a fourth zone is a mirror image
of a second zone.
7. The mattress according to claim 1, further comprising a cover
for the mattress, wherein the cover comprises: a bottom portion
fully surrounding a bottom of the mattress and an outer periphery
of the mattress, wherein, along the length of the mattress, a top
of the bottom portion extends downward in a consistent convex arc
from 3'' to 10'', and wherein, along the width of the mattress, the
top of the bottom portion is parallel to a top surface of the a
mattress.
8. The mattress according to claim 7, further comprising: an inner
cover connected to the bottom portion along the top of the bottom
portion, wherein the top portion and the bottom portion fully
surround the second layer and the third layer.
9. The mattress according to claim 8, further comprising: a top
cover, wherein the top cover is releasably connected to the top of
the bottom portion, wherein the first layer is located between the
inner cover and the top cover.
10. The mattress according to claim 8, wherein the inner cover is
formed from a waterproof material.
11. The mattress according to claim 8, wherein a top surface of the
inner cover comprises at least two zippers, with a first zipper
along a top portion of the top surface and a second zipper along a
bottom portion of the top surface, and wherein a rectangular insert
containing at least a portion of first layer is attached to the top
portion using the first zipper and the second zipper.
12. The mattress according to claim 11, wherein the rectangular
insert comprises: a fabric layer folded over an edge of the first
layer, wherein the edges of the fabric layer are joined on three
sides to fully surround first layer, and a pair of zippers on
opposing ends of the fabric layer for mating with the first zipper
and the second zipper on the top surface of the inner cover.
13. The mattress according to claim 11, further comprising: a third
zipper aligned adjacent the first zipper; a fourth zipper aligned
adjacent the second zipper adjacent the first zipper; and a second
rectangular insert containing a remainder of the first layer not
contained within the rectangular insert, wherein the second
rectangular insert is attached to the top portion using the third
zipper and the fourth zipper.
14. The mattress according to claim 11, wherein the first
rectangular insert and the second rectangular insert substantially
cover the top surface of the mattress.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional
Application Ser. No. 62/262,579, filed Dec. 3, 2015 and U.S.
Provisional Application Ser. No. 62/410,584, filed Oct. 20, 2016,
both of which are incorporated by reference herein in their
entirety.
FIELD OF THE INVENTION
[0002] The present invention provides a mattress capable of letting
a user sleep in a simulated zero G position.
BACKGROUND
[0003] In recent years, many new mattress types have come to market
to address various deficiencies in the industry. For example,
memory foam mattresses have become very popular. However, these
mattresses can often be uncomfortable because the memory foam is
not very breathable and can create hot spots. Further, memory foam
mattresses do not provide any capability for a user to adjust the
softness or firmness of the mattress, leading to further user
discomfort. The mattress of the present invention has been designed
to address these and other various deficiencies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 depicts a view a side cutaway view of a first view of
the mattress.
[0005] FIG. 2 depicts a perspective view of the mattress without a
cover.
[0006] FIG. 3 depicts a user on their back laying on the
mattress.
[0007] FIG. 4 depicts a user on their side laying on the
mattress.
[0008] FIG. 5 depicts a view of the mattress with a cover.
[0009] FIG. 6 depicts a view of the mattress with the cover
partially removed.
[0010] FIG. 7 depicts a view of the mattress with inserts
added.
[0011] FIG. 8 depicts a top view of the mattress with two inserts
attached.
[0012] FIG. 9 depicts a cutaway view of the inserts showing the
inner construction.
[0013] FIG. 10 depicts a full cutaway view of the mattress.
[0014] FIGS. 11-13 show a view of the mattress being packaged for
transport with the inserts attached.
SUMMARY
[0015] Disclosed herein is a mattress comprised of different layers
of material stacked on top of each other which together have the
effect of letting the user sleep in a "simulated Zero G" position
without the aid of an articulating base. Contoured layers within
the mattress let specific areas of the user's body sink further
into the mattress than others which create the Zero G effect when
sleeping on the back (FIG. 3), and contour to the user's body when
sleeping on the side (FIG. 4). Specifically, when sleeping on the
back, the user's head, upper back and feet are supported at
mattress level, while the torso and hips sink into the mattress on
an even slope. This position is more natural to the human body than
laying on flat surface with a consistent amount of give &
support throughout. Additionally, there is a top layer of material
specifically designed to retain minimum heat and to dissipate body
heat over time, keeping the user cooler while sleeping and to
retain the feeling of "bounce" or "springiness" in the
mattress.
DETAILED DESCRIPTION
[0016] FIG. 1 shows a side view of mattress 100 with internal
layers A-C visible. Layer A is a breathable, springy and bouncy
structural mesh layer (polymer material or other materials) between
one inch and three inches thick which does not retain heat and
serves to add spring and comfort for the user. For example, Layer A
may be a material such as Airstring offered by Spec Tex.RTM. or any
other similar material. Layer B is formed from a visco-elastic
polyurethane foam (memory foam) which has a horizontal top surface
and has a contoured bottom surface so that it is not a uniform
thickness. The purposes of the "zones" formed by the various
contours of the bottom surface of layer B will be explained later.
In a preferred embodiment, the visco-elastic polyurethane foam of
Layer B has a density in the range of 3-8 lb/ft 3, preferably 4
lb/ft 3.
[0017] Layer C is a High Density polyurethane foam (HD foam) which
has a horizontal bottom surface and is cut on a contour on its top
surface so that it perfectly matches and fits together with the
bottom contour of layer B. Preferably, the high density
polyurethane foam has a density range of 1-3 lb/ft 3, but
preferably 2.8 lb/ft 3. When fully assembled, the mattress 100 is
flat on both top and bottom, appearing similar in shape and size to
a traditional mattress.
[0018] Preferably, layers B-C are permanently bonded to each other
while layer A is removable as will be described later. However, it
should be apparent that layers A-C can all be permanently bonded or
attached to each other using known methods in the art.
[0019] The mattress is divided laterally by five "zones" which are
defined by the contour line (FIG. 1) (or contact area between the
bottom of layer B and the top of layer C). Zone 1 is a fully
horizontal section starting at the head of the bed and extending
from one inch in length to 18 inches along a length of mattress
100. Zone 2 is a transition area between Zone 1 and Zone 3, and
extends from the end of Zone 1 from 1 inch to 20 inches along a
length of mattress 100. As previously explained, the top surface of
layer 2 is flat while the bottom surface of layer 2 extends
downward toward a bottom of mattress 100 at an angle which can vary
from 5 degrees to 85 degrees from horizontal. The transition of
layer B in zone 2 from flat to sloped can either be a sharp
transition, as shown in FIG. 1, or a smooth transition with a
convex surface into zone 1 and a concave surface into zone 3.
[0020] Zone 3 is a horizontal section symmetrical about the
centerline of the bed connecting zone 2 and zone 4 in which layers
A-C have a constant thickness. In zone 3, layer B is the thickest
layer. Zone 4 is a mirror image of zone 2 and zone 5 is a mirror
image of zone 1 about the centerline of the mattress 100. Because
mattress 100 is symmetrical, a user can lie lengthwise in either
direction. Table 1 below summarizes the thicknesses of the various
layers in the various zones:
TABLE-US-00001 TABLE 1 Zones 1 & 5 Zones 2 & 4 Zone 3 Layer
A 1-4'' 1-4'' 1-4'' Layer B 1-4'' Start--1-4'' 2-10'' End--2-10''
Layer C 3-16'' Start--3-16'' 1-10'' End--1-10''
[0021] Layers B and C work together to create a support system for
the body that allow for the "simulated Zero G positon." The HD foam
of layer C provides support which will give less under the user's
weight, thus defining the user's sleeping position. The memory foam
of layer B provides comfort and "give", letting the user sink into
the mattress 100. Areas where the memory foam is thicker in layer
B, such as zone 3, provide a deeper sink and a more customized
contour for the user's body. Areas with thicker HD foam in layer C,
such as zones 1, 2, 4, and 5, provide more support and
definition.
[0022] Layer A has a number of distinct roles. Its first function
is to be breathable, retain as little heat as possible and
dissipate body heat over time, keeping the user cool while sleeping
and separating the user from the memory foam of layer B which
otherwise would retain much of the user's body heat. Secondly,
layer A functions to distribute the weight of the user onto layer
B. Memory foam deflects at highly local levels which can create a
"sunk in" feeling, which prevents the user from easily
moving/changing-position during sleep and also does not provide the
ideal amount of support for all areas of the body. Layer A deflects
in a very broad way, conforming to the body contour while
distributing the weight of the user evenly over the memory foam's
surface. In this way the memory foam will still offer the benefit
of its "give" or vertical deflection, but layer A will prevent the
"sunk in" feeling. Layer A also offers a desirable level of spring
or bounce, common to an innerspring mattress, which foam alone
cannot provide.
Zone Roles for Back Sleeping (FIG. 3)
[0023] As shown in FIG. 3, when a user lays on their back on
mattress 100, zone 1 supports the user's head, keeping it raised
above the mattress. Zone 2 supports the user's shoulders and upper
back and defines the angle from horizontal that the user will sleep
at. Zone 3 has a deeper area of memory foam in layer B that lets
the user's hips and lower back sink into the mattress. Zones 4 and
5 support the user's legs but the contour underneath does not
affect leg resting position as the legs are not heavy enough to
sink into the mattress. Zone's 4 and 5 exist in order to keep the
mattress 100 symmetrical, in this way the user can not set up the
mattress in an incorrect orientation.
[0024] If the user sets up the mattress 100 in reverse (head
resting on Zone 5), zones 5 and 4 will function identically to
zones 1 and 2 respectively. Together, these zones create the
"simulated Zero G" position where the back/spine is in alignment in
a downward slope (head rests higher than the hips) and the legs are
elevated in a semi bent position.
Zone Roles for Side Sleeping (FIG. 4)
[0025] As shown in FIG. 4, when a user lays on their side on
mattress 100, zone 1 supports the user's head, keeping it raised
above the mattress. Zone 2 offers a thicker section of memory foam
to allow the user's shoulders to sink in further by following the
neck, shoulder and arm and body profile. Zone 3 offers the thickest
section of memory foam to allow the heaviest areas of the body, the
hips and torso, to sink in. Sections 4 and 5 offer less memory foam
which still provide adequate support for the legs. This setup for
side sleeping keeps the head supported and keeps the spine relaxed
and naturally straight and in a parallel alignment with the
floor.
Cover Construction (FIG. 5)
[0026] In some embodiments, mattress 100 is further provided with a
cover 500 which comprises top cover 502, inner cover, 504, and
lower portion 506. Top cover 502 is joined to lower portion 506
through exterior zipper 508 which can be used to completely
separate top cover 502 from lower portion 506. Piping 510 can be
used to conceal the path of zipper 508 so the user never feels the
metal or plastic zipper around the edge of the mattress cover 500
(FIG. 5, FIG. 6). The zipper 508 and piping 510 follow the same
path around the perimeter of the mattress 100. On the short ends of
the mattress 100, the zipper 508 and piping 510 are on a straight
line near the top of mattress 100. On the long sides of mattress
100, the zipper 508 and piping 510 dip downward in a consistent
convex arc ranging anywhere from 3'' to 10'' deep (FIG. 5). The
other side of mattress 100 not shown in FIG. 5 is a mirror image of
that shown in FIGS. 5-6.
[0027] The cover 500 is constructed so that the user can unzip the
top layer 502 as shown in FIG. 6 (FIG. 6). This is primarily so the
user can access inner cover 504 located beneath top layer 502 (FIG.
7). The top layer 502 can be removed for spot washing, washing in a
washing machine, dry cleaning, or replacement.
[0028] Top layer 502 generally comprises two distinct materials.
The first material, ticking 512, is a soft fabric which is quilted
to an internal spacer fabric 1002 (FIG. 10) in consistent width
increments (FIG. 5). As an example, ticking 512 may be 500 gram
100% polyester. A fire retardant fabric, such as Palidn FR fiber,
may also be used.
[0029] The internal spacer fabric enhances the breathability of the
entire mattress and adds a plush-like topper to mattress 100.
Spacer fabrics are generally made up of two breathable pieces of
fabric that have fine plastic threads oriented vertically between
the two fabrics to create a defined space between the two pieces of
fabric. The thickness of the spacer fabric located internal to
ticking 512 can vary from 2 mm to 75 mm in thickness.
Inner Cover Construction (FIG. 7)
[0030] In some embodiments, inner layer A of the mattress 100 shown
in FIGS. 1-4 may be inside one or more removable inserts 700 as
depicted in FIG. 7. For full, queen, king and California king
mattresses, layer A is made up of 2 inserts 700. However, in some
embodiments, layer A may be made up on a single insert 700 that is
the full length and width of mattress 100. Each insert 700 is
preferably zippered to inner cover 504 using insert zippers 706.
However, other connection means, such as hook and loop fasteners,
may also be used to attach inserts 700 to inner cover 504.
[0031] Inner cover 504 and lower portion 506 fully encase layers B
and C so that the user is never exposed to those layers (FIG. 7).
In some embodiment, inner cover 504 is formed from a waterproof
fabric to prevent any spills from traveling to parts of the
mattress that are not washable. Inner cover 504 extends around the
border of the mattress 100 and is attached to lower portion 506
along the same convex arc as top layer 502. Preferably, inner cover
504 is sewn to lower portion 506 so it is not removable for holding
the piping 510 and zipper 508 in place on mattress 100. Inner cover
504 also prevents the user from smelling layers B and C of mattress
100 off-gassing, a natural property in foam. When the user removes
top layer 502 to adjust inserts 700, they only see a finished case.
The user is never subjected to raw materials as in other foam
mattresses (FIG. 7).
[0032] The bottom of lower portion 506 comprises a hidden zipper
1004 (FIG. 10) which is used to attach lower portion 506 and inner
cover 504 to mattress 100 during production. The construction of
cover 500 allows the user to remove top layer to adjust the
firmness using inserts 700 having varying densities while still
maintaining the look and feel of a finished product (FIG. 6).
Insert Construction (FIG. 9)
[0033] In a preferred embodiment, layer A is contained within
inserts 700 which are removable from mattress 100 as has been
described. This allows users to select different densities of layer
A to suit two users' unique sleeping preferences. This can be due
to heat, softness/firmness preferences, change in sleeping
behavior, medical reasons, pregnancy, etc.
[0034] As depicted in FIG. 9, Layer A is encased in fabric 902
using a folded fabric construction in which fabric 902 underneath
layer A and is folded over the top of layer A. In the preferred
embodiment, the fabric 902 is lightweight and breathable to
optimize the breathability of layer A. The open edges of fabric 902
are then sewn shut. In the preferred embodiment, the open edges are
sewn shut with bias tape 904. Layer A is completely encased in the
fabric 902 so the user never sees or touches the raw material. As
shown in FIG. 8, the folded fabric construction allows for the two
inserts 700 to sit side by side with no gap or crease between the
two inserts 700 when users are laying on mattress 100.
[0035] At each end of insert 700 is a zipper 706 used to attach
insert 700 to inner cover. In the preferred embodiment, zippers 706
are used to prevent the inserts from shifting while moving the
mattress 100. Other methods of securing the mattress include Velcro
strips, strips of fabric, or strips of elastic on the corners of
the mattress case which are pulled over layer A to keep inserts 700
in place. The zippers 706 on each end are designed so an insert can
be zipped to either side of the mattress 100 by simply rotating the
insert 180 degrees.
Roll Pack Packaging
[0036] The mattress 100 is packaged for shipment with inserts 700
attached using a roll packing method in which the mattress 100 is
first compressed and sealed in plastic. As shown in FIG. 11, the
compressed mattress 100 is then folded in half along the centerline
(FIG. 1) so that both inserts 700 face outward. Mattress 100 is
then rolled up as depicted in FIGS. 12-13 and sealed with a plastic
sheet. In the preferred embodiment, the mattress 100 is folded in
the reverse along the center line. This prevents any permanent
creasing or folding lines to layer A or the mattress case 500
during shipping.
* * * * *