U.S. patent application number 15/419386 was filed with the patent office on 2017-07-20 for ventilating sleep system.
The applicant listed for this patent is Neven Sleep, LLC. Invention is credited to Randy A. Reynolds.
Application Number | 20170202362 15/419386 |
Document ID | / |
Family ID | 59314052 |
Filed Date | 2017-07-20 |
United States Patent
Application |
20170202362 |
Kind Code |
A1 |
Reynolds; Randy A. |
July 20, 2017 |
VENTILATING SLEEP SYSTEM
Abstract
Embodiments of a ventilated sleep system are disclosed, and
typically may be configured to provide ventilation to a mattress,
for example through an upper surface of a foundation allowing
airflow therethrough. Typically, sleep system embodiments may
include mattresses with foam layers with pinholes and a bottom
cover allowing airflow therethrough, and some embodiments also
include foam pillars. Such sleep system embodiments typically may
have such a ventilation mattress atop such a ventilation
foundation, with airflow therebetween.
Inventors: |
Reynolds; Randy A.; (High
Point, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Neven Sleep, LLC |
Dallas |
TX |
US |
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|
Family ID: |
59314052 |
Appl. No.: |
15/419386 |
Filed: |
January 30, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15183348 |
Jun 15, 2016 |
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15419386 |
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14681278 |
Apr 8, 2015 |
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15183348 |
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62289773 |
Feb 1, 2016 |
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62175767 |
Jun 15, 2015 |
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61977989 |
Apr 10, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 19/025 20130101;
A47C 27/15 20130101; A47C 31/007 20130101; A47C 21/044 20130101;
A47C 21/048 20130101; A47C 27/001 20130101; A47C 27/142 20130101;
A47C 27/148 20130101 |
International
Class: |
A47C 21/04 20060101
A47C021/04; A47C 27/00 20060101 A47C027/00; A47C 27/15 20060101
A47C027/15; A47C 27/14 20060101 A47C027/14; A47C 19/02 20060101
A47C019/02; A47C 31/00 20060101 A47C031/00 |
Claims
1. A sleep system comprising: a mattress, which comprises: a
mattress cover; and one or more foam layers within the mattress
cover; wherein the mattress cover comprises a bottom surface;
wherein the bottom surface of the mattress cover comprises a
mattress air permeable element; wherein the mattress is
spring-free; wherein the one or more foam layers each comprise a
plurality of substantially vertical air passageways which pass
through the entire thickness of the corresponding foam layer;
wherein the one or more foam layers comprise: a base layer of foam
comprising a sculpted upper surface with a plurality of foam
pillars projecting upward; a transition layer of foam with uniform
thickness located atop and in contact with the upper surface of the
base foam layer; a middle sculpted layer of foam having a sculpted
lower surface with a plurality of foam pillars projecting downward,
wherein the middle sculpted layer of foam is located atop and in
contact with the transition layer of foam; and a top layer of foam
with uniform thickness, which is located above the middle sculpted
layer; and a mattress foundation, which comprises: a support
structure; an air flow unit; and a foundation cover comprising an
upper surface; wherein the upper surface of the foundation cover
comprises a foundation air permeable element; and wherein the
mattress is located atop the foundation, and wherein the mattress
and foundation are in fluid communication with each other.
2. The sleep system of claim 1 wherein the middle sculpted layer of
foam further comprises a sculpted upper surface with a plurality of
foam pillars projecting upward.
3. A sleep system comprising a mattress, which comprises: a cover;
wherein the cover comprises a bottom surface, and wherein the
bottom surface comprises an air permeable element.
4. The sleep system of claim 3 wherein the entire bottom surface of
the mattress cover is formed of high airflow mesh fabric.
5. The sleep system of claim 3 wherein the mattress cover further
comprises an upper surface, and wherein the upper surface comprises
a second air permeable element.
6. The sleep system of claim 3 wherein the mattress further
comprises one or more foam layers within the mattress cover.
7. The sleep system of claim 6 wherein the mattress is
spring-free.
8. The sleep system of claim 6 wherein the one or more foam layers
each comprise a plurality of substantially vertical air
passageways.
9. The sleep system of claim 8 wherein the one or more foam layers
comprise: a base layer of foam comprising a sculpted upper surface
with a plurality of foam pillars projecting upward; a transition
layer of foam with uniform thickness located atop and in contact
with the upper surface of the base foam layer; a middle sculpted
layer of foam having a sculpted lower surface with a plurality of
foam pillars projecting downward, wherein the middle sculpted layer
of foam is located atop and in contact with the transition layer of
foam; and a top layer of foam with uniform thickness, which is
located above the middle sculpted layer.
10. The sleep system of claim 9 wherein the middle sculpted layer
of foam further comprises a sculpted upper surface with a plurality
of foam pillars projecting upward.
11. The sleep system of claim 10 wherein the sculpted upper surface
of the middle sculpted layer of foam comprises pillars of a
different size than the sculpted lower surface of the middle
sculpted layer of foam.
12. The sleep system of claim 9 wherein the one or more foam layers
further comprises a penultimate foam layer with uniform thickness
located atop and in contact with the middle sculpted layer and
beneath and in contact with the top layer of foam.
13. The sleep system of claim 9 wherein at least some of the
substantially vertical air passageways in the foam layers align to
provide continuous airflow paths from the bottom surface of the
mattress to an upper surface of the mattress.
14. The sleep system of claim 3 further comprising a mattress
foundation, which comprises: a support structure; an air flow unit;
and a cover comprising an upper surface, and wherein the upper
surface of the foundation cover comprises a foundation air
permeable element; wherein the mattress is located atop the
foundation and wherein the mattress and foundation are in fluid
communication with each other.
15. The sleep system of claim 14 wherein the foundation cover
further comprises a port for fluid communication of the foundation
with the outside environment; and wherein the remainder of the
cover other than the upper surface and the port is substantially
air impermeable.
16. The sleep system of claim 15 wherein the air flow unit is
located within the support structure and cover of the
foundation.
17. The sleep system of claim 14 wherein the air flow unit
comprises filtration.
18. The sleep system of claim 14 wherein the air flow unit
comprises a climate control unit operable to cool or heat air.
19. The sleep system of claim 8 wherein the one or more foam layers
comprise two sculpted foam layers, each comprising a sculpted
surface with a plurality of foam pillars.
20. The sleep system of claim 19 wherein the two sculpted foam
layers comprise a lower sculpted foam layer with sculpted surface
facing upward; and an upper sculpted foam layer with sculpted
surface facing downward.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional of and claims priority
to related U.S. provisional patent application Ser. No. 62/289,773
filed Feb. 1, 2016 and entitled "Mattress Ventilating Foundation
and Sleep System". This application also claims priority to U.S.
patent Ser. No. 15/183,348 (entitled "Mattress Ventilating
Foundation and Sleep System" and filed Jun. 15, 2016) and to
related U.S. provisional patent application Ser. No. 62/175,767
(filed Jun. 15, 2015 and entitled "Mattress Ventilating Foundation
and Sleep System"); and to U.S. patent application Ser. No.
14/681,278 (entitled "Independent Foam Spring Mattress" and filed
Apr. 8, 2015), and to related provisional patent application Ser.
No. 61/977,989 (entitled "Independent Foam Spring Mattress" and
filed Apr. 10, 2014). Thus, this application claims priority to all
five applications set forth above. All of the above-cited priority
documents are hereby incorporated by reference for all purposes as
if reproduced in their entirety to the extent that they are
compatible (e.g. not inconsistent) with and/or do not directly
contradict disclosure herein (e.g. the explicit disclosure herein
would always govern/trump in instances of contradiction,
inconsistency, or incompatibility).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more complete understanding of the present disclosure,
reference is now made to the following brief description, taken in
connection with the accompanying drawings and detailed description,
wherein like reference numerals represent like parts.
[0005] FIG. 1A is a schematic diagram illustrating an exemplary
sleep/bedding system, in which a mattress may be used atop one of
two possible ventilating foundation exemplary variants;
[0006] FIG. 1B is a schematic diagram illustrating an alternate
exemplary sleep/bedding system, in which a mattress may be used
atop one of two possible ventilating foundation exemplary
variants;
[0007] FIGS. 1Ca-1Cc illustrates a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
internal air input unit with optional HEPA filter and an access
panel, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view (from the foot of the bed), and FIG. 1Cc showing a top
view;
[0008] FIGS. 1Da-1Dc illustrates a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
external air input unit with optional HEPA filter and an access
panel, with FIG. 1Da showing a side view, FIG. 1Db showing an end
view (from the foot of the bed), and FIG. 1Dc showing a top
view;
[0009] FIG. 1E illustrates a perspective view of an exemplary
sleep/bedding system similar to FIGS. 1Ca-1Cc;
[0010] FIGS. 2A1 and 2A2 illustrate an exemplary mattress
embodiment (without the cover being shown, to allow viewing of
internal components) which is an all-foam (e.g. spring-free)
mattress configured for ventilation, with FIG. 2A1 showing an
exploded perspective view of an exemplary mattress and FIG. 2A2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2A1;
[0011] FIGS. 2B1 and 2B2 illustrate an exemplary mattress
embodiment (similar to that of FIG. 2A1 in configuration, but
comprising different foam materials for at least some of the
layers) configured for ventilation, with FIG. 2B1 showing an
exploded perspective view of an exemplary mattress and FIG. 2B2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2B1;
[0012] FIG. 3 illustrates a top/plan view of an exemplary base
(sculpted) layer of foam (of the sort that might be used in FIG.
2A1, for example);
[0013] FIG. 4 illustrates a bottom/plan view of an exemplary middle
sculpted foam layer (of the sort that might be used in FIG. 2A1,
for example);
[0014] FIGS. 5A and 5B illustrate exemplary mattress embodiments
configured for ventilation;
[0015] FIGS. 6A and 6B illustrate detailed views of the middle
sculpted foam layers;
[0016] FIGS. 7A and 7B illustrate alternative detailed views of the
middle sculpted foam layers; and
[0017] FIG. 8 illustrates an exemplary base foam layer similar to
that shown and described in FIG. 3.
DETAILED DESCRIPTION
[0018] It should be understood at the outset that although
illustrative implementations of one or more embodiments are
illustrated below, the disclosed systems and methods may be
implemented using any number of techniques, whether currently known
or not yet in existence. The disclosure should in no way be limited
to the illustrative implementations, drawings, and techniques
illustrated below, but may be modified within the scope of the
appended claims along with their full scope of equivalents.
[0019] The following brief definition of terms shall apply
throughout the application:
[0020] The term "comprising" means including but not limited to,
and should be interpreted in the manner it is typically used in the
patent context.
[0021] The term "foam" means a material in a lightweight cellular
form, for example resulting from introduction of gas bubbles during
manufacture to produce a consistent cell structure, and/or any of
various light, porous, semirigid or spongy materials or cellular
solids, usually the solidified form of a liquid full of gas
bubbles, which may be used as a building material or for shock
absorption, and includes open cell foams such as polyurethane foam,
latex, memory foam, specialty memory foam, gel memory foam, gel
latex foam or other gel foams, etc.;
[0022] The term "IFD" means indentation force deflection, and
describes a well-known measurement system for foam firmness;
[0023] Directions, such as up (e.g. upward) and/or down (e.g.
downward), typically are intended to be based on the mattress (or
sleep system or foundation) in its normal sleeping position as
understood by persons of skill; for example, the upper surface of
the mattress might face the ceiling and/or serve as the sleep
surface upon which the user might lie, while the bottom surface of
the mattress might face the floor or ground and/or be placed atop a
foundation;
[0024] The phrases "in one embodiment," "according to one
embodiment," and the like generally mean that the particular
feature, structure or characteristic following the phrase may be
included in at least one embodiment of the present invention, and
may be included in more than one embodiment of the present
invention (importantly, such phrases do not necessarily refer to
the same embodiment);
[0025] If the specification describes something as "exemplary" or
as an "example," it should be understood that refers to a
non-exclusive example:
[0026] The terms "about" or "approximately" or the like, when used
with a number may mean that specific number, or alternatively, a
range in proximity to the specific number, as understood by persons
of skill in the art field (for example, +/-10%); and
[0027] If the specification states a component or feature "may,"
"can," "could," "should," "would," "preferably," "possibly,"
"typically," "optionally," "for example," "often," or "might" (or
other such language) be included or have a characteristic, that
particular component or feature is not required to be included or
have the characteristic. Such component or feature may be
optionally included in some embodiments, or it may be excluded.
[0028] Typical sleep or bedding systems may have a conventional
(typically inner-spring) mattress located atop a conventional box
spring foundation unit. In such conventional sleep systems, there
is typically no interaction between the mattress and the box spring
foundation, other than the fact that the box spring foundation
supports (e.g. underlies) the mattress. While conventional sleep
systems may be sufficient for some sleepers/users, many users might
desire and are looking for an improved sleep experience.
[0029] For example, many users might find conventional sleep
systems rather hot (especially when the mattress includes foam, and
most especially when the mattress includes memory foam), resulting
in a rather sweaty, uncomfortable night's sleep of the sort that
may result in restlessness and lack of deep slumber. Other users
may have allergy problems, and a conventional mattress may, over
time, collect dust and other allergens that might trouble the user
during sleep. Additionally, conventional inner-spring mattresses
may not support the user's body as effectively as desired, perhaps
resulting in discomfort.
[0030] The presently disclosed embodiments may address one or more
of these issues. For example, disclosed embodiments may provide
ventilation (e.g. airflow), such that the mattress may better
breathe and/or disperse heat (e.g. improving sleep comfort while a
user is atop the mattress); disclosed embodiments may refresh the
mattress, for example sucking out stale air with potential
allergens (which could happen either when the user is atop the
mattress or, alternatively, when the user is not on the mattress
(for example, based on a timer)); and/or disclosed embodiments may
provide superior comfort/support. Typically, disclosed embodiment
sleep systems might have the mattress and foundation interact with
each other (for example, being in fluid communication), to provide
one or more such sleep benefits, as persons of skill will
understand based on the disclosure below. Typical foundation
embodiments might comprise an upper surface (of a cover) allowing
airflow therethrough (and typically having an air flow unit (such
as a fan or air pump) operable to direct air through the upper
surface), while typical mattress embodiments might comprise a
bottom surface (of a cover) (and in some embodiments a top surface
of the cover) allowing airflow therethrough (and often also
including air pathways (such as pinholes) vertically throughout the
mattress). So, most disclosed sleep system embodiments typically
might have a ventilation mattress atop a ventilation foundation,
with airflow therebetween.
[0031] Disclosed embodiments relate generally to mattress
ventilation sleep systems (and/or related foundations and/or
mattresses), which typically would include a mattress ventilation
foundation in conjunction with a mattress (for example, typically
located atop the foundation). Typically, the mattress ventilation
foundation might comprise a support structure (such as support
struts and structural frame, for example, which might be similar to
a conventional box spring foundation), operable to support a
mattress in a manner similar to a conventional mattress foundation
(and which typically might be hollow); an air flow unit (such as a
forced air supply unit (e.g. fan) operable to either blow air into
the supported mattress atop the foundation or suck air from the
supported mattress); and a cover (including an upper, support
surface upon which the mattress would lay), which would typically
include a means for airflow between the foundation (e.g. the air
flow unit) and the supported mattress (e.g. an air permeable
element/panel, such as one or more panels of high air flow mesh
fabric located in the upper surface of the foundation cover, for
example). In some embodiments, the air flow unit might include
filtration (such as a HEPA filter), which might for example be
located at the intake and/or outtake for the air flow unit. The air
flow unit might be housed within the support structure of the
foundation in some embodiments, while in other embodiments the air
flow unit might be external to (for example, mounted onto) the
support structure (for example, mounted onto the bottom surface of
the cover/support structure and in fluid communication with the
hollow cavity within the cover/support structure by an
opening).
[0032] Typically, the foundation cover would
surround/enclose/encompass the support structure on all sides, and
the foundation cover would be airtight/air impermeable (e.g. formed
of an airtight material such as fabric overtop a polyvinyl
substrate, for example) except for the attachment/fluid
communication port (e.g. inlet/outlet/opening) for the air flow
unit (which allows fluid communication between the external
environment and the hollow cavity within the foundation, for
example) and the means for airflow between the foundation and the
supported mattress (e.g. air permeable element/panel, such as high
airflow mesh panel(s)). For example, the bottom and side surfaces
of the foundation cover would typically be airtight (except for the
inlet/outlet/opening for the air flow unit), while the upper
surface of the foundation cover (which would typically support
and/or contact the bottom surface of the mattress) would include
the means for airflow between the foundation (e.g. the air flow
unit) and the supported mattress (e.g. at least one air permeable
element/panel, such as one or more panels of high air flow mesh
fabric located in the upper surface of the foundation cover, for
example). In some embodiments, the entire upper surface of the
foundation cover might be formed of high airflow mesh fabric, while
in other embodiments, the upper surface might include a plurality
of panels of such high airflow mesh fabric and/or other means for
allowing airflow between the foundation and the supported mattress
(such as air passageways).
[0033] Typically, air might flow through the hollow cavity of the
foundation to the upper surface of the foundation cover (as
directed by the air flow unit, for example), but alternatively,
there could be tubing or ducts leading from the air flow unit to
the upper surface of the foundation cover (e.g. to specific
locations on the upper surface of the foundation cover
corresponding to the pinholes in the supported mattress thereupon).
In such embodiments, it might not be necessary for the bottom and
sides of the foundation cover to be airtight.
[0034] Additionally, some embodiments of the air flow unit might
optionally comprise a climate control unit, which might cool and/or
heat air flowing through the air flow unit (for example, before the
air flows into the supported mattress atop the foundation). In some
embodiments, the climate control unit would be located within the
housing for the air flow unit, while in other embodiments, the
climate control unit might be located external to such housing
(e.g. it may be either separate or combined with the blower portion
of the air flow unit). Similarly, embodiments of the air flow unit
might optionally comprise an air ionizer (for electric
sterilization of air prior to entering the foundation) and/or an
ultraviolet germicidal irradiation light (for irradiating light
sufficiently to substantially destroy harmful microbes, such as
bacteria, prior to entering the foundation). As with the optional
climate control unit, the air ionizer and/or UV germicidal
irradiation light units could be located within the housing for the
air flow unit or (in other embodiments) located external to such
housing (e.g. each may be either separate or combined with the
blower portion of the air flow unit). Typically, the air flow unit
might be controlled/operated by a controller, which might be a
separate device and which might allow for remote control of the air
flow device (e.g. the blower and/or climate control unit). In some
embodiments, the controller and/or air flow unit may include a
timer, for example allowing the user to set the air flow unit for a
regular (for example daily or weekly) refresh cycle. And typically,
the air flow unit would be electrically powered (for example with a
plug allowing power to be drawn from a standard electrical wall
socket).
[0035] So typically in operation, air might be drawn into the
foundation (for example by the air flow unit, through the intake
opening/fluid communication port), and then forced out the upper
surface (for example through a high airflow mesh fabric upper
surface or panel(s)) and into the supported mattress. This may
allow for a supported mattress to be refreshed with clean air
and/or may enhance sleep comfort for a user lying atop the
mattress. Alternatively, air might be sucked out of the supported
mattress (for example by operating the air flow unit in reverse to
create suction), into the foundation (for example through the upper
surface of the cover of the foundation, perhaps through one or more
high air flow mesh panels), and out the air flow unit's outtake
opening/fluid communication port (which might be the same intake
opening if the air flow device is operated for blowing instead of
suction in some embodiments). In some embodiments, the air flow
unit might be operable to run in forward (e.g. blowing mode) and/or
reverse (e.g. suction mode). So in some embodiments, the air flow
unit might be run in reverse (for example, suction mode to suck air
from the supported mattress) to refresh the mattress (e.g. a
refresh cycle, which in some embodiments might be periodically
run), while the air flow unit might be run in forward (for example,
blowing mode to blow fresh (e.g. filtered) and/or climate
controlled (e.g. cooled or heated) and/or ionized and/or UV
sanitized air into the supported mattress) to enhance sleep comfort
atop the supported mattress (for example, improving allergy
conditions and/or temperature and/or airflow for the user atop the
supported mattress, perhaps while the user is actually lying
atop/sleeping on the mattress).
[0036] While it is possible that any sort of mattress might be used
to some advantage atop such a ventilation foundation, more
typically specialized air flow (e.g. ventilation) mattress
embodiments might be used in conjunction with the disclosed
foundation embodiments. For example, the mattress might comprise a
mattress cover having a bottom surface which includes a means for
airflow between the foundation and the supported mattress (e.g.
into and/or out of the mattress, for example at least one air
permeable element/panel). For example, in some embodiments the
bottom surface of the mattress cover might be formed of or include
one or more panels of high airflow mesh fabric (or alternatively,
the bottom surface of the mattress cover might include air
passageways, which might correspond to those of the upper surface
of the foundation cover). In some embodiments, the top surface of
the mattress cover might also comprise air permeable element/panel
or other means of airflow into/out of the mattress (e.g. high
airflow mesh or loosely woven fabric panel(s)). And in some
embodiments, the remainder of the mattress cover might be
(substantially) air impermeable. Furthermore, the mattress might
comprise one or more (and typically a plurality of) primarily
vertical air pathways (e.g. pin holes), operable to allow air flow
vertically throughout the mattress (for example from the bottom of
the mattress to the top of the mattress). In some embodiments, the
mattress might be an all-foam and/or spring-free mattress. For
example, the mattress might be formed entirely of layers of foam,
and each layer of foam might include vertical pin holes, at least
some of which align to provide continuous airflow
passages/pathways/pinholes vertically throughout the mattress.
[0037] Some such mattress embodiments might include one or more
foam layers having a sculpted surface with a plurality of foam
pillars. For example, some embodiments might have a base layer of
foam (e.g. the bottom layer of foam) with an upward facing sculpted
surface (e.g. the pillars of foam facing/projecting upward), and
another layer of foam (typically a middle foam layer, located
somewhere between the base foam layer and the uppermost (sleep
surface) layer of foam) with a downward facing sculpted surface
(e.g. the pillars of foam facing/projecting downward). Typically,
the sculpted foam layers would each have scoring (e.g. a series of
grooves/gaps) forming a grid on one surface (termed the sculpted
surface), with the grid pattern resulting in a plurality of foam
pillars projecting outward from a common, unified slab/base of foam
(e.g. the surface opposite the sculpted surface typically would be
flat, such that the foam pillars would all be joined together into
an integral whole layer at their bases/bottoms). The sculpted foam
layer(s) might effectively replace the support functionality of the
springs while also often providing added benefits. For example, a
sculpted foam surface (e.g. foam pillars) may provide more
flexibility in adjusting to various body contours than metal
springs, and therefore may be more effective in reducing pressure
points against the human body than traditional metal springs in
conventional mattresses. More specifically, the layer(s) of foam
with a sculpted surface would typically include a plurality of foam
pillars (or blocks), each of which is freestanding (e.g.
independent) with respect to the other pillars, but all of which
are joined together into a single integral base (which typically
has a flat exterior surface). So, the base portion of the pillars
are all joined together (e.g. a common base), while the remaining
freestanding portion of the layer of foam comprises a plurality of
independent pillars separated from one another by a gap or groove
on all sides. Stated another way, the sculpted layer(s) of foam may
comprise each a base portion (which typically is a uniform flat
sheet of foam) and a pillar portion (which typically comprises a
plurality of independent pillars or blocks of foam, each of which
is completely separate from the other pillars), with the pillar
portion being securely attached to a surface of the base portion
(so in effect the pillars project out from the flat base portion).
Thus, the sculpted surface of the sculpted layer of foam would
typically be the distal surface of the pillars (or pillar portion).
Typically, the sculpted layer of foam may be formed by cutting a
pattern of grooves in one surface (which would then become the
sculpted surface) of an initially uniform (e.g. flat sheet with
constant thickness) sheet of foam, thereby forming a plurality of
foam pillars which extend out from the base portion (with the
pillar portion and the base portion integrally forming a single
layer of foam having different shapes/characteristics on opposing
sides). Thus, the sculpted layer of foam might also be termed a
contour cut layer of foam in some embodiments (since in many
embodiments the layer of foam is sculpted via cutting, for example
contour cutting). In other embodiments, it may be possible to form
the sculpted layer of foam by molding (with the mold forming the
pillar portion projecting outward from the base portion).
Typically, the substantially one entire surface of the sculpted
foam layer (e.g. the entire sculpted surface) would be entirely
comprised of such pillars (e.g. substantially the entire sculpted
surface of the sculpted foam layer would be formed of pillars),
although in other embodiments the sculpted surface might have
pillars only on a portion of the sculpted surface.
[0038] Typical mattress embodiments might have vertical pin holes
passing through (at least) the base portion of the sculpted foam
layers, and such pin holes might typically be positioned to align
with the grooves/gaps between the foam pillars (so that air could
flow continuously through the vertical pin holes and the grooves to
pass from one surface of the sculpted foam layer all the way
through to the other surface of the sculpted foam layer). In some
embodiments, the base layer of foam would comprise a foam component
having a sculpted surface (typically with pillars facing upward)
surrounded by foam edge support perimeter rails (which typically
would be solid blocks of foam encompassing the sides of the base
foam component with sculpted surface, and typically having an
uncompressed height approximately equal to the uncompressed height
of the base foam component (e.g. the upper surface of the edge
support perimeter rails would typically be approximately the same
as the uncompressed height of (e.g. flush with) the upper surface
of the foam pillars of the base foam component with sculpted
surface).
[0039] Typically, mattress embodiments would have at least one
(foam) layer located between the base sculpted foam layer (which
typically would have the sculpted surface (e.g. foam pillars)
facing upward) and the middle sculpted foam layer (which typically
would have the sculpted surface (e.g. foam pillars) facing
downward), and would have at least one (foam) layer located above
the middle sculpted foam layer (e.g. a sleep surface layer
(typically of foam) would be located atop the middle sculpted foam
layer). In some embodiments, the foam pillars of the base sculpted
foam layer would be larger (e.g. the cross-section/footprint/outer
surface of the pillars would be larger) than the foam pillars of
the middle sculpted foam layer. And as mentioned above, typically
the various (foam) layers of the mattress would each have vertical
pin holes, at least some of which would align to provide continuous
airflow from the bottom to the top of the mattress. For example, in
some embodiments all (foam) layers located above the base layer of
foam might have vertical pinholes which entirely align, even though
the base foam layer might have less vertical pinholes spaced
further apart such that only some of the pinholes in the remaining
layers align with pinholes in the base layer. Although the base
layer in some embodiments may have fewer pinholes spaced further
apart than the other layers of foam, air may be operable in some
such embodiments to move through the grooves in the base portion
(e.g. since the pinholes in the base portion may be in fluid
communication with the grooves in the base portion) to the pinholes
in the upper layers of foam which are not aligned with the pinholes
in the base layer of foam.
[0040] Typically, the sculpted layer of foam would have a plurality
of foam pillars forming the sculpted surface, and the pillars would
be configured within the sculpted foam layer and the mattress as a
whole to essentially be limited to movement only (or in some
embodiments, primarily) in the vertical direction (e.g. without any
horizontal/sideways movement of the pillars during use of the
mattress). In other words, the configuration of the foam layers of
the mattress (for example, with the layers placed in contact in
such a way as to minimize shear or torsion in the pillars during
construction (e.g. essentially placing the pillars only in
compression) and with the layers perhaps laminated together) would
typically ensure that compression on the top (e.g. sleep surface)
of the mattress would be transmitted to the foam pillars entirely
as a vertical (e.g. compression) force (without, for example,
introducing any (e.g. substantial) horizontal, shear, or torsion
forces to the foam pillars) for each affected foam pillar.
Additionally, each pillar of foam in the sculpted layer would
typically be configured for essentially independent movement (e.g.
each pillar moves independent of the other surrounding/proximate
pillars). This independence might arise due to the contour cuts
(e.g. grooves/gaps) separating the foam pillars and/or the fact
that the base of the foam pillars would be linked by conformable
foam (e.g. in the form of an integrated base of foam linking all
pillars together). So, embodiments might have pillars of the
sculpted foam layer configured for essentially independent movement
and/or essentially only vertical movement during usage of the
mattress (e.g. by a user lying atop the mattress). Typical
embodiments might have the pillars configured for independent
movement essentially only in the vertical direction. For example,
each foam pillar might be operable to move vertically without
substantially imparting any vertical movement to
surrounding/proximate foam pillars in the sculpted foam layer.
Thus, movement by one foam pillar typically might not impart any
movement to other foam pillars in proximity within the sculpted
foam layer (such that each pillar movement would independently
relate to its own loading from the sleep surface above). So, each
foam pillar of an exemplary sculpted foam layer in a disclosed
mattress embodiment may be operable to only (or in some embodiments
primarily) carry/support compression forces from directly above the
foam pillar. Of course, Applicant does not intend to be bound by
theory, but rather simply notes that the presently disclosed
embodiments may perform/operate differently and/or better. Such
configuration of the sculpted foam layer (with regard to movement)
may be quite different from the typical movement allowed/provided
by conventional metal springs (e.g. coil springs in a mattress).
Conventional coil spring mattresses have a series of springs which
typically are linked by wire across their top surfaces. Thus, the
coil springs do not move independently (e.g. movement by one coil
spring necessarily affects the surrounding coil springs due to the
rigid nature of the linking wire frame) and the linking wire frame
at the top of the coil springs may typically introduce non-vertical
(e.g. non-compression) forces into the springs (such that the coil
springs may flex and move horizontally and/or torsionally, for
example, in response to a user atop the mattress sleep surface).
Thus, the disclosed embodiments (with foam pillars in a spring-less
mattress) may perform quite differently in operation than a
conventional spring mattress. Applicant notes that disclosed
mattress embodiments typically do not include traditional springs,
but for example might be termed all-foam mattresses (e.g. all the
cushion/support elements are foam) and/or (metal/coil) spring-free
mattresses (e.g. no springs, even if the mattress embodiment may
include some other cushion/support element(s) in addition to or
instead of one or more foam elements).
[0041] While typical sleep system embodiments would comprise a
mattress embodiment atop a foundation embodiment, other embodiments
might be focused on only the mattress or only the foundation. In
other words, disclosed mattress embodiments could alternatively be
used with conventional foundation elements (or even
separately/alone), and disclosed foundation embodiments could
alternatively be used with conventional mattress elements (although
doing so might reduce potential benefits available through the
joint use of disclosed mattress embodiment(s) with disclosed
foundation embodiment(s), since the joint use of ventilation
mattress atop ventilation foundation may provide for improved fluid
communication therebetween). A preferred embodiment, however, would
typically place a mattress configured to allow airflow/air transfer
(e.g. airflow) through its bottom surface (and perhaps also
typically having some means of air distribution throughout the
mattress (e.g. pinholes) for air passing through the bottom surface
of the mattress) atop a foundation configured to provide
airflow/air transfer (for example, forced airflow, which might be
suction and/or blowing) through its upper surface.
[0042] Turning now to the figures for specific exemplary
embodiments, FIG. 1A illustrates exemplary embodiment(s) of a
ventilated sleep system 100 (typically comprising a mattress and a
foundation), with a ventilated mattress 140 used in conjunction
with (typically directly atop) a ventilation foundation (such as
either 120a or 120b, which basically differ regarding the location
of the air flow unit 130a). The mattress 140 has a bottom surface
142 which allows airflow into and/or out of the mattress 140. For
example, the bottom surface 142 of the mattress 140 cover might be
formed of or comprise high airflow mesh fabric (for example 150 gsm
100% polyester spacer mesh fabric restricting airflow CFM less than
about 35% at 3 PSI). In some embodiments, the upper surface of the
mattress 140 might also allow airflow into/out of the mattress 140
(for example, with the upper surface of the mattress 140 cover
being formed of or comprising high airflow mesh fabric, similar to
that used for the bottom surface 142 of the mattress cover as
described above).
[0043] Either foundation 120a (with an air flow unit 130a external
to the support structure of the foundation and/or cover of the
foundation, for example externally mounted on the foundation,
perhaps underneath the foundation at or near the foot end of the
bed, for example centered from side to side, and in fluid
communication with the foundation hollow cavity via
inlet/intake/opening 132a) or 120b (with air flow unit 130b located
within the foundation support structure and/or cover, for example
mounted internally on the bottom/base panel of the foundation,
perhaps within the foundation at or near the foot end of the bed,
for example on the left side when looking at the foundation from
the foot, and in fluid communication with the external environment
via inlet/intake/opening 132b) might optionally be used with the
mattress 140, with the mattress 140 being located atop either
foundation 120a or 120b to form the ventilated sleep system 100. In
both foundation embodiments 120a and 120b, the upper surface 122a
or 122b, respectively, of the foundation 120a/b would be configured
to allow airflow out of the foundation (for example, into a
mattress 140 directly atop (and in contact with) the foundation. So
for example, the upper surface 122a or 122b of the foundation cover
might be formed of or comprise high airflow mesh fabric (similar to
that described above with respect to the bottom surface 142 of the
mattress cover, for example, to allow airflow communication between
the foundation and the mattress 140, for example). And typically,
the foundation might be held above the floor by a frame or legs
111a,b (which might be similar to conventional bed frames used for
conventional box springs, for example, and which might provide
sufficient clearance from the floor to allow the required airflow
for operation of the ventilation mattress system). Typically, the
frame would not interfere with or block the inlet/intake/opening
132a/b for the air flow unit 130a,b.
[0044] So in FIG. 1A, air might pass into the foundation 120a,b,
for example through a filter such as a HEPA filter and/or through a
climate control unit (which might, for example, be operable to cool
and/or heat the air) via an air flow unit 130a,b, passing through
the foundation 120a/b (e.g. hollow cavity) to exit through the
upper surface 122a,b of the foundation 120a/b and enter the bottom
surface 142 of the mattress 140 in order to pass (vertically)
through at least a portion of the mattress 140. In such a system,
the air flow unit 130a,b might pump air into the mattress 140
through the foundation 120a/b. Alternatively, air might flow
through the system in reverse, with the air flow unit 130a,b
sucking air out of the mattress 140 and into the foundation 120a/b
(and then out to the external environment). The air flow unit
130a,b typically might displace about 100-300 CFM, and typically
might operate at less than about 6 dB. In some embodiments, the
upper surface of the mattress 140 might also allow for airflow (for
example, being formed of or comprising high airflow mesh or loosely
woven fabric panels, similar to those previously described). In
some embodiments, the high airflow fabric panels throughout the
sleep system (or at least for the upper foundation cover surface
and lower mattress cover surface) might all be similar and/or
formed of the same material. In some embodiments, the air flow unit
130a,b might be configured to allow for forward and reverse
operation (e.g. operable to allow air to be blown into or sucked
out of the mattress 140 by the foundation 120a/b). The arrows in
FIG. 1A illustrate potential airflow in the system, as persons of
skill would understand.
[0045] Typically, the foundation(s) 120a,b of FIG. 1A would
comprise a hollow structure (formed for example by support struts
and a structural frame), and air would be pumped into/out of the
hollow structure cavity (for example by the air flow unit 130a,b).
In other words, in such embodiments, air would simply flow through
the hollow cavity of the foundation 120a/b as it interacts with the
mattress 140 and the outside environment. So for example, external
air might be drawn into the hollow cavity of the foundation 120a/b
through the inlet/intake/opening 132a,b, flow through the hollow
cavity to the upper surface of the foundation 120a,b, flow out of
the foundation 120a/b through the upper surface 122a,b and into the
mattress 140 through the mattress bottom 142, and then pass through
at least a portion of the mattress 140 (and in some embodiments,
air might flow all the way through the mattress 140 and optionally
might flow out the upper surface of the mattress 140).
Alternatively, air might flow into the hollow cavity of the
foundation 120a,b through the upper surface 122a,b (for example,
sucking air from the mattress 140 through the bottom surface 142 of
the mattress 140), through the hollow cavity of the foundation 120,
and out of the foundation 120 via inlet/intake (which in the case
would actually serve as an outtake)/opening 132a,b to the external
environment.
[0046] FIG. 1B illustrates an alternative embodiment sleep/bedding
system, similar to that of FIG. 1A. One version of the foundation
120b of FIG. 1B may have an access panel, which for example might
allow for easy access to change the HEPA filter and/or to provide
maintenance or repair to the air flow unit 130b. FIGS. 1Ca-1Cc
illustrates in more detail an exemplary sleep/bedding system
embodiment similar to FIG. 1B, having an internal (e.g.
mounted/located within the foundation frame/cover) air flow unit
130b, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view of the foot of the bed, and FIG. 1Cc showing a top view.
Typically, in the embodiment of FIGS. 1Ca-1Cc the air flow unit
130b might be located at (e.g. in proximity to) the foot of the bed
within the foundation. For example, the optional HEPA filter might
be located over the air intake, with air then flowing through the
blower to be expelled into the hollow cavity of the foundation
120b. In some embodiments, there may be an access panel, for
example located on the upper surface of the foundation 120b above
the HEPA filter or air intake or air flow unit 130b. The access
panel might be a hinged section (for example, operable to open by
pivoting upward) of the upper foundation surface (although in some
embodiments, the access panel portion of the upper foundation 120b
cover might not be air permeable, for example to help direct air
through the blower and into the foundation).
[0047] FIGS. 1Da-1Dc illustrates in more detail an exemplary
sleep/bedding system embodiment similar to FIG. 1B, having an
external (e.g. mounted/located outside the foundation 120b
frame/cover, for example mounted beneath the foundation 120b) air
flow unit 130a (shown in FIG. 1B), with FIG. 1Da showing a side
view, FIG. 1Db showing an end view of the foot of the bed, and FIG.
1Dc showing a top view. Typically, the air flow unit 130a of FIGS.
1Da-1Dc might be mounted to the bottom surface of the foundation at
or in proximity to the foot of the bed (perhaps located towards the
center between the sides). And again, there may be an access panel,
which for example might typically be located on the housing of the
air flow unit to allow access to the HEPA filter and/or blower.
FIG. 1E illustrates an exemplary sleep/bedding system in 3D
perspective view, showing that externally the sleep/bedding system
would resemble a conventional mattress atop a conventional
box-spring foundation unit (e.g. a typical conventional bed).
[0048] FIGS. 2A1 and 2A2 illustrate an exemplary ventilation
mattress 240A, which is an all-foam (or spring-free) mattress
formed of a plurality of foam layers (with the base layer being a
sculpted foam layer having the sculpted surface (with foam pillars)
facing upward, a middle sculpted foam layer having the sculpted
surface (with foam pillars) facing downward, a sleep surface layer,
at least one foam layer (e.g. transition layer) between the middle
sculpted foam layer and the base sculpted foam layer, and/or a foam
layer located between the sleep surface layer and the middle
sculpted foam layer). While FIG. 2A1 shows the foam components of
the mattress (e.g. with the cover removed) in perspective view,
FIG. 2A2 shows a side cross-section view of the same mattress.
FIGS. 2B1 and 2B2 illustrate a similar all foam mattress (e.g. with
the foam components removed from the cover), and differs primarily
in the particular foam material selected (with the embodiment of
FIG. 2A1 being formed of conventional high density foam (e.g. all
component foam layers are formed of conventional high density
foam), and the embodiment of FIG. 2B1 having the top two layers
formed of memory foam, for example gel memory foam, while the
remaining layers are formed of conventional high density foam). And
in some embodiments, all such foam layers would be adhered into an
integrated whole (e.g. laminated) and/or enclosed/encased in a
cover, thereby forming an integrated mattress.
[0049] So in FIG. 2A1, the mattress 240A comprises a base layer of
foam 242 (which comprises a sculpted foam element 243 with the
sculpted surface (e.g. the foam pillars) facing/extending upward)
located as the bottom layer of foam in the mattress 240A, a middle
sculpted foam layer 250 with the sculpted surface (e.g. foam
pillars) facing/projecting downward and located above the base
layer (although typically not directly above or in contact with the
base layer), a transition foam layer 260 located between (and
typically in contact with) the base layer of sculpted foam 242 and
the middle layer of sculpted foam 250, a top/sleep surface layer of
foam 270 (typically located as the uppermost foam layer 250 in the
mattress 240), and (optionally) a second (e.g. penultimate) layer
of foam 280 located between the sleep surface layer 270 and the
middle sculpted foam layer 250. FIG. 2A1 shows the layers foam of
the mattress 240A without the cover (not shown), illustrating the
order and orientation of the foam layers in this mattress
embodiment. Typically, the foam layers are arranged one atop
another in the order described above, with proximate layers
contacting one another (e.g. the base layer 242 is the bottom
layer, the transition layer 260 is located atop and in contact with
the base layer 242, the middle sculpted foam layer 250 is located
atop and in contact with the transition layer, the second
(penultimate) layer 280 is located atop and in contact with the
middle sculpted foam layer 250, and the top (sleep surface) layer
270 is located atop and in contact with the second (penultimate)
layer 280 and forms the upper foam layer of the mattress 240A).
Typically, the layers would all be encased within a cover (not
shown here), and typically the cover would have a bottom surface
with means for airflow (for example, one or more panels of high
airflow mesh fabric). Also, in some embodiments, the upper surface
of the cover might include means for airflow (for example, an air
permeable element, such as one or more panels of high airflow mesh
fabric).
[0050] In FIG. 2A1, the base layer 242 comprises a sculpted foam
element/layer 243 with upward facing sculpted surface (e.g. foam
pillars 248 projecting upward and separated by a series (e.g. grid)
of gaps or grooves or cuts 247), and edge perimeter rails of foam
244 which surround/encase the sculpted foam element 243 on all
sides (e.g. about/around the perimeter of the sculpted foam element
243). Typically, the edge support perimeter rails 244 might be
formed of the same foam as the base layer sculpted foam element 243
and/or might have the same uncompressed height as the sculpted foam
element 243 (e.g. the upper surface of the edge support perimeter
rails 244 might be approximately level with the upper surface of
the foam pillars 248 of the sculpted foam element 243 when both are
uncompressed). In the embodiment of FIG. 2A1, the foam pillars 248
would typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars 248 might
typically have a width of about 0.75 inches and a depth of about 3
inches. So for example, the gaps/grooves 247 in the base layer
sculpted foam element 243 might typically have a depth ranging from
about 1/2 to 2/3 the total height for the base layer 242, for
example about 60% in some exemplary embodiments. In addition, the
joined bases of the foam pillars 248 of the sculpted foam element
243 typically would have a plurality of pinholes (e.g. essentially
vertical air passageways), as will be described in greater detail
below. In alternate embodiments, the pinholes might pass through
both the base portion and the pillar portion of one or more of the
sculpted foam layers.
[0051] In FIG. 2A1, the transition layer of foam 260 would
typically be a flat sheet of foam with a plurality of pinholes 265
(e.g. essentially vertical air passageways). In the embodiment of
FIG. 2A1, the transition layer 260 would typically have the same
width and length dimensions (e.g. depending on whether the mattress
240A is a twin, full/double, queen, king, etc.) as the base layer
242 (e.g. including both the sculpted foam element 243 and the
surrounding edge support perimeter rails 244), although in other
embodiments (in which the foam pillars 248 are lower than the
surrounding edge support perimeter rails 244, for example by a
height approximately equal to the thickness of the transition
layer, the transition layer 260 might be sized to fit over just the
sculpted foam element 243 of the base layer 242 (e.g. so that it
would be located within the edge support perimeter rails 244 as
well).
[0052] The middle sculpted foam layer 250 of FIG. 2A1 would
typically be sized (e.g. width and length) approximately the same
as the base layer 242 and/or the transition layer 260 (and
typically the same as the layers atop it as well), and would be
oriented with the sculpted surface (e.g. foam pillars 258)
facing/projecting downward. In the embodiment of FIG. 2A1, the foam
pillars 258 would typically have a square rectangular outer surface
(and/or cross-section) of about 2 inches by 2 inches, and the
gaps/grooves 257 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. So for example, the gaps/grooves 257 in the
middle sculpted layer 250 might typically have a depth ranging from
about 1/2 to 2/3 the total height for the middle sculpted layer,
for example about 55-60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars 258 of the middle
sculpted layer 250 typically would have a plurality of pinholes 255
(e.g. essentially vertical air passageways), as will be described
in greater detail below. Typically, the pinholes 255 of the middle
sculpted foam layer 250 would be spaced and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer
260 (and typically also the same as the layers located above it),
with the pinholes 255 aligning vertically with the pinholes 265.
And typically, at least some of the pinholes 255/265 would also
align with the pinholes 245 in the base layer 242 (e.g. the
sculpted foam element 243 of the base layer 242). For example,
every other pinhole 255/265 might align with a pinhole 245 (and
groove/gap 247) in the sculpted foam element of the base layer.
[0053] The second (penultimate) foam layer 280 and the upper (sleep
surface) foam layer 270 would typically each be a flat sheet of
foam with a plurality of pinholes 285, 275 respectively (e.g.
essentially vertical air passageways). In the embodiment of FIG.
2A1, both the second (penultimate) foam layer 280 and the upper
(sleep surface) foam layer 270 would typically have the same width
and length dimensions (e.g. depending on whether the mattress 240A
is a twin, full/double, queen, king, etc.) as the base layer 242,
the transition layer 260, and/or the middle sculpted layer 250.
And, the pinholes 285, 275 of the second (penultimate) foam layer
280 and the top (sleep surface) layer 270 respectively would
typically be spaced and/or oriented/located the same (identically)
as the pinholes 265 in the transition foam layer 260 and the
pinholes 255 in the middle sculpted foam layer 250, with the
pinholes 285, 275 aligning vertically with the pinholes 265, 255.
Thus, the pinholes 265, 255, 285, and 275 of FIG. 2A1 would
typically align to form continuous airflow pathways from the upper
surface of the base layer 242 upward to the upper surface of the
mattress 240A (although in other embodiments, only some of the
pinholes might align). And typically, at least some of the pinholes
285/275 would also align with the pinholes 245 in the base layer
242 (e.g. the sculpted foam element 243 of the base layer 242). For
example, every other pinhole 285/275 might align with a pinhole 245
(and groove/gap 247) in the sculpted foam element 243 of the base
layer 242. In other embodiments, the pinholes 265, 255, 285, and
275 might all align with the pinholes 245 in the base layer 242
(e.g. the pinholes in all the layers could be spaced equally so
they all align to form continuous air flow pathways from the bottom
surface of the mattress to the upper surface of the mattress
240A).
[0054] Similarly, FIG. 2A2 shows a cross-section view of the foam
elements of the mattress 240A shown in FIG. 2A1. In this
embodiment, the base layer 242 typically would have an uncompressed
height of about 5 inches, the transition layer 260 typically would
have an uncompressed height of about 1.25 inches, the middle
sculpted foam layer 250 typically would have an uncompressed height
of about 3 inches, the second (penultimate) foam layer 280
typically would have an uncompressed height of about 1.75 inches,
and the top (sleep surface) layer 270 typically would have an
uncompressed height of about 1.25 inches. In FIG. 2A2, the foam
layers 250 would typically vary in firmness, from softest at the
top to hardest/firmest at the bottom. For example, the top (sleep
surface) layer 270 would typically be the softest layer of foam
(for example, IFD of about 14), the second (penultimate) layer 280
would typically be somewhat firmer that the top layer (for example,
IFD of about 20), the middle sculpted foam layer 250 would
typically be somewhat firmer than the second (penultimate) layer
280 (for example, IFD of about 35), the transition layer 260
typically would be somewhat firmer than the middle sculpted layer
(for example, IFD of about 45), while the base layer 242 might
typically have the same firmness as the transition layer 260 (for
example, IFD of about 45). In other embodiments, the base layer 242
might be somewhat firmer than the transition layer 260. Typically,
the edge support perimeter rails 244 would have the same firmness
(e.g. IFD) and/or be formed of the same foam as the sculpted foam
element 243 of the base layer. In other embodiments, the firmness
of the various layers may differ and/or may vary differently from
the descriptions above. And in FIG. 2A2, the thickness (e.g.
lateral width) of the edge support perimeter rails typically would
be about 4 inches (or in other embodiments, about the same size as
one of the foam pillar's 248 square rectangular outer surface
(and/or cross-section) sides).
[0055] FIG. 2A2 also shows the alignment of the pinholes 265, 255
(and gap 257), 285, and 275, and the fact that every other pinhole
265, 255, 285, 275 aligns with a pinhole 245 (and gap 247) of the
base layer 242 in this embodiment. The alignment of pinholes may
allow continuous airflow upward from the bottom surface of the
mattress 240A to the upper surface of the mattress 240A and/or
downward from the upper surface of the mattress 240A to the bottom
surface of the mattress 240A, as illustrated by the exemplary
airflow arrows (except along the perimeter edges where the edge
support perimeter rails 244 may not have pinholes, in some
embodiments). In some embodiments, the pinholes may be hole punched
into the foam sheets/layers, while in other embodiments the
pinholes might be formed for example by molding of the foam
sheets/layers). And in some embodiments, the gaps/grooves 247, 257
might be cut/scored into the foam to form the sculpted surface(s),
while in other embodiments the gaps/grooves 247, 257 might be
formed for example by molding (e.g. due to the shape of the foam
mold forming the layer(s)). The upper surface of the top layer of
foam 270 forms the sleep surface 272 (although typically there
would be a cover, not shown here, lying atop/encasing the
foam).
[0056] So in some embodiments, the mattress might comprise at least
two sculpted foam layers (with each having a sculpted surface with
a plurality of pillars) with a transition foam layer (and typically
only one such transition foam layer) therebetween. The upper
sculpted foam layer would typically be oriented with its sculpted
surface facing downward (although in other embodiments, it could
face upward and/or there might not be a foam (transition) layer
between the two sculpted foam layers), while the lower/bottom
sculpted foam layer (e.g. the base layer) would typically be
oriented with its sculpted surface facing upward. And typically
(although optionally), there would be one or more foam layers
located above the uppermost sculpted foam layer (e.g. the middle
sculpted foam layer), with these top foam layers having a softer
IFD than that of the middle sculpted foam layer. A series of
pinholes in the foam layers (perhaps in conjunction with the
gaps/grooves forming the sculpted surface of the sculpted foam
layers) would allow for airflow vertically throughout the mattress
(or at least through a plurality of foam layers of the mattress).
And typically, the foam layers would be enclosed/encased within a
cover, which typically would have a bottom/lower surface which is
air permeable (for example, formed of or comprising high airflow
mesh fabric, typically allowing airflow comparable to the upper/top
surface of the ventilation foundation upon which such a mattress
would typically operate). So as discussed above, the mattress
embodiment would typically have a bottom cover surface allowing
airflow therethrough (e.g. one or more panels restricting airflow
cubic feet per minute less than about 35% at 3 PSI), and the
ventilation foundation (upon/atop which the mattress embodiment
would typically be used) typically would also have an upper/top
cover surface allowing airflow therethrough (for example, similar
to the airflow allowed by the bottom surface of the cover of the
mattress), such that the joint mattress-foundation sleep/bedding
system embodiment typically would effectively allow airflow between
the foundation and the mattress (for example, based on an airflow
unit in or on the foundation).
[0057] FIGS. 2B1 and 2B2 show a similar foam mattress 240B formed
of multiple layers of foam (typically within a cover (not shown)).
The embodiment of FIGS. 2B1 and 2B2 is substantially the same in
structure as the embodiment of FIGS. 2A1 and 2A2, primarily
differing in the foam material used. For example, in FIG. 2B1, the
top two layers might be memory foam (for example, gel memory foam).
Persons of skill will understand that the foam materials and/or
characteristics of the layers of foam for such exemplary mattresses
may differ, for example being selected based on the specific needs
of the particular mattress.
[0058] FIG. 3 illustrates an exemplary base foam layer 242 (similar
to that of FIG. 2A1, for example), showing the sculpted surface
(e.g. upper surface) of the sculpted foam element 243 (with foam
pillars 248 separated by gaps/grooves 247 in a grid) and the edge
support perimeter rails 244 in plan view (of the upper, sculpted
surface). As noted above, the foam edge support perimeter rails 244
surround and abut all four sides of the sculpted foam element 243,
and they each may typically have a width (e.g. lateral dimension)
approximately equal to one of the sides of the square rectangular
outer surface (and/or cross-section) of the foam pillars 248.
Typically (as shown in FIG. 3), all of the foam pillars 248 would
be equally sized (for example, they might all be equally sized with
square cross-section, as for example formed by a grid of
grooves/gaps 247 in which the longitudinal grooves/gaps 247 are
equally spaced, and the lateral gaps/grooves 247 are also equally
spaced apart by the same amount as the longitudinal gaps, for
example forming a grid that resembles a checkerboard). So for
example in the embodiment of FIG. 3, the foam pillars 248 would
typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars 248 might
typically have a width of about 0.75 inches and a depth of about 3
inches.
[0059] FIG. 3 also shows the pinholes 245 in the base layer 242,
which are typically located in the joined base portion of the foam
pillars 248 of the base layer 242 so that they exit into the
gaps/grooves 247 separating the foam pillars 248. In other words,
the pinholes 245 typically do not pass through the projecting foam
pillar 248 portion of the base layer 242 sculpted foam element 243,
but rather pass only though the integral base portion of the
sculpted foam element 243 (e.g. the bottom portion where the foam
pillars are joined together into an integral whole) such that the
pinholes 245 extend upward from the bottom of the base layer 242 to
exit within the gaps/grooves 247 between the foam pillars 248. The
pinholes 245 of FIG. 3 typically might have a diameter of about 0.5
inches (and typically would all be about the same size), and
typically would be spaced apart approximately 3.937 inches. So for
example, the pinholes 245 typically might be located within the
gaps/grooves 247 at locations in proximity to the corners of each
foam pillar 248 of the base layer 242 (e.g. at the grid groove
intersections).
[0060] Similarly, FIG. 4 illustrates an exemplary middle sculpted
surface layer 250 (similar to that of FIG. 2A1, for example),
showing the sculpted surface (e.g. the bottom surface) (with foam
pillars 258 separated by gaps/grooves 257 in a grid) in plan view
(of the sculpted surface). Typically (as shown in FIG. 4), all of
the foam pillars 258 would be equally sized (for example, they
might all be equally sized with a square cross-section, as for
example formed by a grid of grooves/gaps 257 in which the
longitudinal grooves/gaps 257 are equally spaced, and the lateral
gaps/grooves are also equally spaced apart by the same amount as
the longitudinal gaps, for example forming a grid that resembles a
checkerboard). So for example in the embodiment of FIG. 4, the foam
pillars 258 would typically have a square rectangular outer surface
(and/or cross-section) of about 2 inches by 2 inches, and the
gaps/grooves 257 forming the grid resulting in the foam pillars 258
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. While the embodiment of FIG. 2A1, for example,
has the foam pillars 258 of the middle sculpted foam layer sized to
be about 1/4 the size of the foam pillars 248 of the base layer
(e.g. 2 inches by 2 inches versus 4 inches by 4 inches, such that
each 4.times.4 pillar in the base layer of FIG. 2A1, for example,
might have four 2.times.2 pillars in the middle sculpted layer
located above it); in other embodiments, the ratio of the foam
pillar sizing may vary (for example, the foam pillars 258 could be
the same size as the foam pillars 248 in some embodiments, or the
foam pillars 258 might be 1/2, 1/3, 1/8, or 1/16 the size of the
foam pillars 248 in other embodiments). Typically, the sizing ratio
would be such that at least some of the gaps/grooves 257 in the
middle sculpted foam layer would align with at least some of the
gaps/grooves 247 of the base layer (since that may be important to
aid in alignment of pinholes in some embodiments, as well as
perhaps providing consistent support and/or comfort
characteristics).
[0061] FIG. 4 also shows the pinholes 255 in the middle sculpted
layer 250, which are typically located in the joined base portion
of the foam pillars 258 of the middle sculpted layer 250 so that
they exit into the gaps/grooves 257 separating the foam pillars
258. In other words, the pinholes 255 typically do not pass through
the projecting foam pillar 258 portion of the middle sculpted foam
layer 250, but rather pass only though the integral base portion of
the middle sculpted layer 250 (e.g. the bottom portion where the
foam pillars 258 are joined together into an integral whole) such
that the pinholes 255 extend downward from the top of the middle
sculpted layer 250 to exit within the gaps/grooves 257 between the
foam pillars 258. The pinholes 255 of FIG. 4 typically might have a
diameter of about 0.25 inches (and typically would all be about the
same size), and typically would be spaced apart approximately
1.9685 inches. So for example, the pinholes 255 typically might be
located within the gaps/grooves 257 at locations in proximity to
the corners of each foam pillar 258 in the middle sculpted layer
250 (e.g. at the grid groove intersections). As discussed above,
the pinholes in the foam layers (of an exemplary mattress) above
the middle sculpted layer 250 (as well as perhaps an underlying
transition layer) typically would be sized and spaced (e.g.
located) identical to those in the middle sculpted layer 250, in
order to form continuous airflow pathways upward.
[0062] FIG. 5A illustrates an exemplary ventilation mattress 540,
which is an all-foam (or spring-free) mattress formed of a
plurality of foam layers (with the base layer being a sculpted foam
layer having the sculpted surface (with foam pillars) facing
upward, a middle sculpted foam layer having the sculpted surface
(with foam pillars) facing downward, a sleep surface layer, at
least one foam layer (e.g. transition layer) between the middle
sculpted foam layer and the base sculpted foam layer, and/or a foam
layer located between the sleep surface layer and the middle
sculpted foam layer). FIG. 5B illustrates a similar all foam
mattress (e.g. with the foam components removed from the cover),
and differs primarily in the middle layer construction. In some
embodiments, all such foam layers would be adhered into an
integrated whole (e.g. laminated) and/or enclosed/encased in a
cover, thereby forming an integrated mattress.
[0063] So in FIG. 5A, the mattress 540 comprises a base layer of
foam 242 (which comprises a sculpted foam element with the sculpted
surface (e.g. the foam pillars) facing/extending upward) located as
the bottom layer of foam in the mattress 540 (wherein the base
layer 242 may be similar to the base layer 242 described above), a
middle sculpted foam layer 550 with the sculpted surface (e.g. foam
pillars) facing/projecting downward and located above the base
layer 242 (although typically not directly above or in contact with
the base layer 242), a transition foam layer 260 located between
(and typically in contact with) the base layer of sculpted foam 242
and the middle layer of sculpted foam 550 (wherein the transition
foam layer 260 may be similar to the transition foam layer 260
described above), a top/sleep surface layer of foam 270 (typically
located as the uppermost foam layer in the mattress, wherein the
top surface layer 270 may be similar to the top surface layer 270
described above), and (optionally) a second (e.g. penultimate)
layer of foam 280 located between the sleep surface layer 270 and
the middle sculpted foam layer 550 (wherein the second layer of
foam 280 may be similar to the second layer of foam 280 described
above).
[0064] FIG. 5A shows the layers foam of the mattress 540 without
the cover (not shown), illustrating the order and orientation of
the foam layers in this mattress embodiment. Typically, the foam
layers are arranged one atop another in the order described above,
with proximate layers contacting one another (e.g. the base layer
242 is the bottom layer, the transition layer 260 is located atop
and in contact with the base layer, the middle sculpted foam layer
550 is located atop and in contact with the transition layer 260,
the second (penultimate) layer 280 is located atop and in contact
with the middle sculpted foam layer 550, and the top (sleep
surface) layer 270 is located atop and in contact with the second
(penultimate) layer 280 and forms the upper foam layer of the
mattress 540). Typically, the layers would all be encased within a
cover (not shown here), and typically the cover would have a bottom
surface with means for airflow (for example, one or more panels of
high airflow mesh fabric). Also, in some embodiments, the upper
surface of the cover might include means for airflow (for example,
an air permeable element, such as one or more panels of high
airflow mesh fabric).
[0065] In FIG. 5A, the base layer 242 comprises a sculpted foam
element/layer 243 with upward facing sculpted surface (e.g. foam
pillars 248 projecting upward and separated by a series (e.g. grid)
of gaps or grooves or cuts 247), and edge perimeter rails of foam
244 which surround/encase the sculpted foam element 243 on all
sides (e.g. about/around the perimeter of the sculpted foam element
243). Typically, the edge support perimeter rails 244 might be
formed of the same foam as the base layer sculpted foam element 243
and/or might have the same uncompressed height as the sculpted foam
element 243 (e.g. the upper surface of the edge support perimeter
rails 244 might be approximately level with the upper surface of
the foam pillars 248 of the sculpted foam element 243 when both are
uncompressed).
[0066] In the embodiment of FIG. 5A, the foam pillars 248 would
typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars might typically
have a width of about 0.75 inches and a depth of about 3 inches. So
for example, the gaps/grooves 247 in the base layer might typically
have a depth ranging from about 1/2 to 2/3 the total height for the
base layer, for example about 60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the sculpted foam
element 243 typically would have a plurality of pinholes 265 (e.g.
essentially vertical air passageways), as will be described in
greater detail below. In alternate embodiments, the pinholes might
pass through both the base portion and the pillar portion of one or
more of the sculpted foam layers.
[0067] In FIG. 5A, the transition layer of foam 260 would typically
be a flat sheet of foam with a plurality of pinholes 265 (e.g.
essentially vertical air passageways). In the embodiment of FIG.
5A, the transition layer 260 would typically have the same width
and length dimensions (e.g. depending on whether the mattress is a
twin, full/double, queen, king, etc.) as the base layer 242 (e.g.
including both the sculpted foam element 243 and the surrounding
edge support perimeter rails 244), although in other embodiments
(in which the foam pillars are lower than the surrounding edge
support perimeter rails, for example by a height approximately
equal to the thickness of the transition layer, the transition
layer 260 might be sized to fit over just the sculpted foam element
243 of the base layer 242 (e.g. so that it would be located within
the edge support perimeter rails 244 as well).
[0068] The middle sculpted foam layer 550 of FIG. 5A would
typically be sized (e.g. width and length) approximately the same
as the base layer 242 and/or the transition layer 260 (and
typically the same as the layers atop it as well), and would be
oriented with the sculpted surface (e.g. foam pillars 554)
facing/projecting downward. In the embodiment of FIG. 5A, the foam
pillars 554 would typically have a square/rectangular outer surface
(and/or cross-section) of about 4 inches by 4 inches, and the
gaps/grooves 557 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. So for example, the gaps/grooves 557 in the
middle sculpted layer 550 might typically have a depth ranging from
about 1/2 to 2/3 the total height for the middle sculpted layer
550, for example about 55-60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the middle
sculpted layer 550 typically would have a plurality of pinholes 555
(e.g. essentially vertical air passageways), as will be described
in greater detail below.
[0069] In the embodiment shown in FIG. 5A, the pinholes 555 of the
middle sculpted foam layer 550 may be spaced and/or
oriented/located the same (identically) as the pinholes 245 of the
base layer 242. And typically, at least some of the pinholes 555
may align with the pinholes 265 in the transition foam layer 260
(as well as the layers located above it), with some of the pinholes
265 aligning with the pinholes 555. For example, every other
pinhole 265 might align with a pinhole 255 in the middle sculpted
foam layer 550.
[0070] The middle layer 550 may also comprise an additional set of
pillars 552 located on the top surface of the middle layer 550. In
the embodiment of FIG. 5A, the top pillars 552 may be sized
differently than the bottom pillars 554 (for example, the top
pillar 552 might be 1/4 the (cross-section) size of the bottom
pillars 554, with four top pillars 552 for each corresponding
bottom pillar, although in other embodiments the top and bottom
pillars 552/554 could be the same size). In the embodiment of FIG.
5A, the pinholes 555 may align with every groove 557 in the bottom
pillars 554, while the pinholes 555 may align with every other
groove 553 in the top pillars 552. In some embodiments, the grooves
553 of the top pillars 552 may align with the pinholes 275, 285 of
the top layer 270 and second layer 280.
[0071] The second (penultimate) foam layer 280 and the upper (sleep
surface) foam layer 270 would typically each be a flat sheet of
foam with a plurality of pinholes 285, 275 respectively (e.g.
essentially vertical air passageways). In the embodiment of FIG.
5A, both the second (penultimate) foam layer 280 and the upper
(sleep surface) foam layer 270 would typically have the same width
and length dimensions (e.g. depending on whether the mattress is a
twin, full/double, queen, king, etc.) as the base layer 242, the
transition layer 260, and/or the middle sculpted layer 550. And,
the pinholes 285, 275 of the second (penultimate) foam layer 280
and the top (sleep surface) layer 270 respectively would typically
be spaced and/or oriented/located the same (identically) as the
pinholes 265 in the transition foam layer 260 and optionally the
pinholes 555 in the middle sculpted foam layer 550, with the
pinholes 285, 275 aligning vertically with the pinholes 265, 555.
Thus, the pinholes 265, 555, 285, and 275 of FIG. 5A would
typically align to form continuous airflow pathways from the upper
surface of the base layer 242 upward to the upper surface of the
mattress (although in other embodiments, only some of the pinholes
might align). And typically, at least some of the pinholes 285/275
would also align with the pinholes 245 in the base layer 242 (e.g.
the sculpted foam element 243 of the base layer). For example,
every other pinhole 285, 275 might align with a pinhole 245 (and
groove/gap 247) in the sculpted foam element 243 of the base layer
242. In other embodiments, the pinholes 265, 555, 285, and 275
might all align with the pinholes 245 in the base layer 242 (e.g.
the pinholes in all the layers could be spaced equally so they all
align to form continuous air flow pathways from the bottom surface
of the mattress to the upper surface of the mattress).
[0072] In FIG. 5A, the foam layers would typically vary in
firmness, from softest at the top to hardest/firmest at the bottom.
For example, the top (sleep surface) layer 270 would typically be
the softest layer of foam (for example, IFD of about 14), the
second (penultimate) layer 280 would typically be somewhat firmer
that the top layer (for example, IFD of about 20), the middle
sculpted foam layer 550 would typically be somewhat firmer than the
second (penultimate) layer 280 (for example, IFD of about 35), the
transition layer 260 typically would be somewhat firmer than the
middle sculpted layer 550 (for example, IFD of about 45), while the
base layer 242 might typically have the same firmness as the
transition layer 260 (for example, IFD of about 45). In other
embodiments, the base layer 242 might be somewhat firmer than the
transition layer 260. Typically, the edge support perimeter rails
244 would have the same firmness (e.g. IFD) and/or be formed of the
same foam as the sculpted foam element 243 of the base layer 242.
In other embodiments, the firmness of the various layers may differ
and/or may vary differently from the descriptions above. In some
embodiments, the thickness (e.g. lateral width) of the edge support
perimeter rails 244 typically would be about 4 inches (or in other
embodiments, about the same size as one of the foam pillar 248
square rectangular outer surface (and/or cross-section) sides).
[0073] The alignment of pinholes may allow continuous airflow
upward from the bottom surface of the mattress to the upper surface
of the mattress 540 and/or downward from the upper surface of the
mattress to the bottom surface of the mattress 540 (except along
the perimeter edges where the edge support perimeter rails may not
have pinholes, in some embodiments). In some embodiments, the
pinholes may be hole punched into the foam sheets/layers, while in
other embodiments the pinholes might be formed for example by
molding of the foam sheets/layers).
[0074] So in some embodiments, the mattress might comprise at least
two sculpted foam layers (with each having a sculpted surface with
a plurality of pillars) with a transition foam layer (and typically
only one such transition foam layer) therebetween. The upper
sculpted foam layer would typically be oriented with its sculpted
surface facing downward (although in other embodiments, it could
face upward and/or there might not be a foam (transition) layer
between the two sculpted foam layers and/or the upper sculpted foam
layer might have both an upper and lower sculpted surface), while
the lower/bottom sculpted foam layer (e.g. the base layer) would
typically be oriented with its sculpted surface facing upward. And
typically (although optionally), there would be one or more foam
layers located above the uppermost sculpted foam layer (e.g. the
middle sculpted foam layer), with these top foam layers having a
softer IFD than that of the middle sculpted foam layer. A series of
pinholes in the foam layers (perhaps in conjunction with the
gaps/grooves forming the sculpted surface of the sculpted foam
layers) would allow for airflow vertically throughout the mattress
(or at least through a plurality of foam layers of the mattress).
And typically, the foam layers would be enclosed/encased within a
cover, which typically would have a bottom/lower surface which is
air permeable (for example, formed of or comprising high airflow
mesh fabric, typically allowing airflow comparable to the upper/top
surface of the ventilation foundation upon which such a mattress
would typically operate). So as discussed above, the mattress
embodiment would typically have a bottom cover surface allowing
airflow therethrough (e.g. one or more panels restricting airflow
cubic feet per minute less than about 35% at 3 PSI), and the
ventilation foundation (upon/atop which the mattress embodiment
would typically be used) typically would also have an upper/top
cover surface allowing airflow therethrough (for example, similar
to the airflow allowed by the bottom surface of the cover of the
mattress), such that the joint mattress-foundation sleep/bedding
system embodiment typically would effectively allow airflow between
the foundation and the mattress (for example, based on an airflow
unit in or on the foundation).
[0075] FIG. 5B shows a similar foam mattress 542 formed of multiple
layers of foam (typically within a cover (not shown). The
embodiment of FIG. 5B is substantially the same in structure as the
embodiment of FIG. 5A, primarily differing in the construction of
the middle layer 560. In the embodiment of FIG. 5B the middle
sculpted foam layer 560 would typically be sized (e.g. width and
length) approximately the same as the base layer 242 and/or the
transition layer 260 (and typically the same as the layers atop it
as well), and would be oriented with the sculpted surface (e.g.
foam pillars 556) facing/projecting downward. In the embodiment of
FIG. 5A, the foam pillars 556 would typically have a square
rectangular outer surface (and/or cross-section) of about 2 inches
by 2 inches, and the gaps/grooves 557 forming the grid resulting in
the foam pillars might typically have a width of about 0.375 inches
and a depth of about 1.75 inches. So for example, the gaps/grooves
in the middle sculpted layer might typically have a depth ranging
from about 1/2 to 2/3 the total height for the middle sculpted
layer, for example about 55-60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the middle
sculpted layer 560 typically would have a plurality of pinholes 555
(e.g. essentially vertical air passageways), as will be described
in greater detail below. Typically, the pinholes 555 of the middle
sculpted foam layer 560 would be spaced and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer
260 (and typically also the same as the layers located above it),
with the pinholes 555 aligning vertically with the pinholes 265.
And typically, at least some of the pinholes 555/265 would also
align with pinholes in the base layer 242 (e.g. the sculpted foam
element 243 of the base layer). For example, every other pinhole
555, 265 might align with a pinhole (and groove/gap 247) in the
sculpted foam element 243 of the base layer 242.
[0076] The middle layer 560 may also comprise an additional set of
pillars 552 located on the top surface of the middle layer 560. In
the embodiment of FIG. 5A, the top pillars 552 may be sized the
same (identical) as the bottom pillars 554. In the embodiment of
FIG. 5A, the pinholes 555 may align with every groove 557 in the
bottom pillars 554, and the pinholes 555 may align with every
groove 553 in the top pillars 552.
[0077] FIGS. 6A-6B illustrate detailed views of the middle sculpted
foam layers 550 and 560. The middle sculpted foam layer 550 of FIG.
6A may comprise top pillars 552 and bottom pillars 554 that differ
in size. For example, the top pillars 552 may typically have a
square rectangular outer surface (and/or cross-section) of about 2
inches by 2 inches, while the bottom pillars 554 may typically have
a square rectangular outer surface (and/or cross-section) of about
4 inches by 4 inches. The middle sculpted foam layer 560 of FIG. 6B
may comprise top pillars 552 and bottom pillars 554 that are the
same in size. For example, the top pillars 552 may typically have a
square rectangular outer surface (and/or cross-section) of about 2
inches by 2 inches, and the bottom pillars 556 may also typically
have a square rectangular outer surface (and/or cross-section) of
about 2 inches by 2 inches. Typically, the foam pillars of the
middle sculpted foam layer would be sized with respect to the
pillars of the base layer of foam within a range including
1-to-1-4-to-1 with respect to cross-section (such that the foam
pillars of the middle sculpted foam layer each range in size from
being equally sized to the base layer pillars down to being a
quarter the size of the base layer pillars (i.e. four middle
sculpted layer pillars per one base layer pillar)), with each top
foam pillar of the middle sculpted foam layer often being equally
sized and each bottom foam pillar of the middle sculpted foam layer
often being equally sized. So for example, the base layer foam
pillars might be 4.times.4 inches in cross-section, and the middle
sculpted foam layer might have pillars that are 4.times.4 inches or
2.times.2 inches (for example, the bottom pillars of the middle
sculpted foam layer could be 4.times.4 inches or 2.times.2 inches,
while the top pillars of the middle sculpted foam layer could be
2.times.2 inches (or 4.times.4 inches)).
[0078] Additionally, the pinholes 555 in the middle sculpted layers
550 and 560 may align with the grooves 557 in the bottom pillars
554/556 in both embodiments. Therefore, the pinholes 555 of the
middle sculpted layer 550 of FIG. 6A may be fewer in number and
spaced differently than the pinholes 555 of the middle sculpted
layer 560 of FIG. 6B.
[0079] In the embodiment shown in FIG. 6A, the middle sculpted foam
layer 550 may be formed of one piece of foam, wherein the pillars
552/554 and pinholes 555 may be formed by sculpting and/or molding
a single piece of foam. In the embodiment shown in FIG. 6B, the
middle sculpted foam layer 560 may be formed of one piece of foam,
wherein the pillars 552/556 and pinholes 555 may be formed by
sculpting and/or molding a single piece of foam.
[0080] FIGS. 7A-7B illustrate alternative detailed views of the
middle sculpted foam layers 550 and 560. In FIGS. 7A-7B, the middle
layers 550 and 560 may comprise two different types of foam joined
together using adhesive. The middle layers 550 and 560 may be
similar to those described in FIGS. 6A-6B, except that the layers
may be formed of two pieces of foam instead of one.
[0081] In the embodiment shown in FIG. 7A, the middle sculpted foam
layer 550 may be formed of two pieces of foam, wherein the pillars
552 and partial pinholes 555 may be formed by sculpting and/or
molding a first piece of foam 720, and the pillars 554 and partial
pinholes 555 may be formed by sculpting and/or molding a second
piece of foam 722. Then, the two pieces of foam 720 and 722 may be
joined together and laminated to form the middle sculpted foam
layer 550.
[0082] In the embodiment shown in FIG. 7B, the middle sculpted foam
layer 560 may be formed of two pieces of foam, wherein the pillars
552 and partial pinholes 555 may be formed by sculpting and/or
molding a first piece of foam 720, and the pillars 556 and partial
pinholes 555 may be formed by sculpting and/or molding a second
piece of foam 724. Then, the two pieces of foam 720 and 724 may be
joined together and laminated to form the middle sculpted foam
layer 560.
[0083] FIG. 8 illustrates an exemplary base foam layer 242 similar
to that shown and described in FIG. 3.
[0084] For additional details that may be relevant for some
embodiments (particularly some mattress embodiments and/or systems
having mattress embodiments), U.S. patent application Ser. No.
14/681,278 (entitled "Independent Foam Spring Mattress" and filed
Apr. 8, 2015, along with related provisional patent application No.
61/977,989 entitled "Independent Foam Spring Mattress" and filed
Apr. 10, 2014) is hereby incorporated by reference for all purposes
as if reproduced in its entirety to the extent that it is
compatible (e.g. not inconsistent) with and/or does not directly
contradict disclosure herein (e.g. the explicit disclosure herein
would always govern/trump in instances of contradiction,
inconsistency, or incompatibility). Specifically, details about the
foam layers and/or formation of the foam layers from the
incorporated by reference U.S. patent applications might be used in
some embodiments (for example, within a mattress cover as described
herein).
[0085] While various embodiments in accordance with the principles
disclosed herein have been shown and described above, modifications
thereof may be made by one skilled in the art without departing
from the spirit and the teachings of the disclosure. The
embodiments described herein are representative only and are not
intended to be limiting. Many variations, combinations, and
modifications are possible and are within the scope of the
disclosure. Alternative embodiments that result from combining,
integrating, and/or omitting features of the embodiment(s) are also
within the scope of the disclosure. Accordingly, the scope of
protection is not limited by the description set out above, but is
defined by the claims which follow, that scope including all
equivalents of the subject matter of the claims. Each and every
claim is incorporated as further disclosure into the specification
and the claims are embodiment(s) of the present invention(s).
Furthermore, any advantages and features described above may relate
to specific embodiments, but shall not limit the application of
such issued claims to processes and structures accomplishing any or
all of the above advantages or having any or all of the above
features.
[0086] Additionally, the section headings used herein are provided
for consistency with the suggestions under 37 C.F.R. 1.77 or to
otherwise provide organizational cues. These headings shall not
limit or characterize the invention(s) set out in any claims that
may issue from this disclosure. Specifically and by way of example,
although the headings might refer to a "Field," the claims should
not be limited by the language chosen under this heading to
describe the so-called field. Further, a description of a
technology in the "Background" is not to be construed as an
admission that certain technology is prior art to any invention(s)
in this disclosure. Neither is the "Summary" to be considered as a
limiting characterization of the invention(s) set forth in issued
claims. Furthermore, any reference in this disclosure to
"invention" in the singular should not be used to argue that there
is only a single point of novelty in this disclosure. Multiple
inventions may be set forth according to the limitations of the
multiple claims issuing from this disclosure, and such claims
accordingly define the invention(s), and their equivalents, that
are protected thereby. In all instances, the scope of the claims
shall be considered on their own merits in light of this
disclosure, but should not be constrained by the headings set forth
herein.
[0087] Use of broader terms such as "comprises", "includes", and
"having" should be understood to provide support for narrower terms
such as "consisting of", "consisting essentially of", and
"comprised substantially of". Use of the terms "optionally," "may,"
"might," "possibly," and the like with respect to any element of an
embodiment means that the element is not required, or
alternatively, the element is required, both alternatives being
within the scope of the embodiment(s). Also, references to examples
are merely provided for illustrative purposes, and are not intended
to be exclusive.
[0088] While several embodiments have been provided in the present
disclosure, it should be understood that the disclosed systems and
methods may be embodied in many other specific forms without
departing from the spirit or scope of the present disclosure. The
present examples are to be considered as illustrative and not
restrictive, and the intention is not to be limited to the details
given herein. For example, the various elements or components may
be combined or integrated in another system or certain features may
be omitted or not implemented.
[0089] Also, techniques, systems, subsystems, and methods described
and illustrated in the various embodiments as discrete or separate
may be combined or integrated with other systems, modules,
techniques, or methods without departing from the scope of the
present disclosure. Other items shown or discussed as directly
coupled or communicating with each other may be indirectly coupled
or communicating through some interface, device, or intermediate
component, whether electrically, mechanically, or otherwise. Other
examples of changes, substitutions, and alterations are
ascertainable by one skilled in the art and could be made without
departing from the spirit and scope disclosed herein.
* * * * *