U.S. patent application number 15/660594 was filed with the patent office on 2017-11-16 for foam mattress having an adjustable mattress core for adjusting and customizing its firmness, assembling method and kit thereof.
The applicant listed for this patent is PERFECT PRESSURE INC.. Invention is credited to Earl Takefman, Philip Alan Torbet.
Application Number | 20170325596 15/660594 |
Document ID | / |
Family ID | 60296807 |
Filed Date | 2017-11-16 |
United States Patent
Application |
20170325596 |
Kind Code |
A1 |
Torbet; Philip Alan ; et
al. |
November 16, 2017 |
FOAM MATTRESS HAVING AN ADJUSTABLE MATTRESS CORE FOR ADJUSTING AND
CUSTOMIZING ITS FIRMNESS, ASSEMBLING METHOD AND KIT THEREOF
Abstract
It is disclosed a foam mattress having an adjustable mattress
core for adjusting and customizing its firmness. The foam mattress
has a foam base having an upper surface defining a top recess; and
a plurality of foam inserts each configured to be disposed and
assembled into the top recess to fill the top recess and form the
mattress core with a continued upper surface of the mattress. The
inserts are provided with at least two different firmness of the
foam, preferably with three different firmness of the foam selected
from firm, medium and soft, producing as such an inexpensive, novel
consumer-adjustable mattress in which the consumer can change the
firmness of the entire mattress and/or the firmness on either side
of the bed to accommodate each sleeper and/or the firmness under
certain "body zones" within the mattress for their own personalized
comfort preference and to reduce tossing and turning.
Inventors: |
Torbet; Philip Alan; (San
Rafael, CA) ; Takefman; Earl; (Montreal, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PERFECT PRESSURE INC. |
Montreal |
|
CA |
|
|
Family ID: |
60296807 |
Appl. No.: |
15/660594 |
Filed: |
July 26, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15461207 |
Mar 16, 2017 |
9770117 |
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15660594 |
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62335959 |
May 13, 2016 |
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62422154 |
Nov 15, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/18 20130101;
A47C 27/146 20130101; A47C 27/148 20130101; A47C 27/088 20130101;
A47C 27/14 20130101; A47C 27/15 20130101; A61G 7/05715 20130101;
A47C 27/144 20130101; A47C 27/00 20130101 |
International
Class: |
A47C 27/08 20060101
A47C027/08; A47C 27/14 20060101 A47C027/14; A47C 27/18 20060101
A47C027/18 |
Claims
1. A foam mattress having an adjustable mattress core for adjusting
and customizing a firmness of the mattress, the foam mattress
comprising: a foam base having an upper surface defining a top
recess; and a plurality of foam inserts each configured to be
disposed and assembled into the top recess to fill the top recess
and form the mattress core with a continued upper surface of the
mattress, wherein the inserts are provided with at least two
different firmness of the foam.
2. The foam mattress of claim 1, wherein the inserts are provided
according to three different firmness of the foam selected from
firm, medium and soft.
3. The foam mattress of claim 1, further comprising a pair of
longitudinal foam side rails to be placed into the top recess each
along one of one of the longitudinal edges of the base between a
head section and a foot section of the mattress, the inserts being
then configured to be placed into the top recess formed between the
head and foot sections and the pair of lateral rails, wherein the
foot section, the head section, the two longitudinal foam side
rails and the inserts once in placed form the continued upper
surface of the mattress.
4. The foam mattress of claim 3, wherein the foam base and the pair
of longitudinal foam side rails form a monoblock of foam.
5. The foam mattress of claim 1, wherein the inserts form two
longitudinal columns and a plurality of rows of inserts; each
column of insert corresponding to one lateral side of the
mattress.
6. The foam mattress of claim 3, wherein whole the inserts of one
side of the mattress have a different firmness than the inserts of
the other side of the mattress.
7. The foam mattress of claim 1, wherein the inserts are affixed
into the top recess using Velcro.RTM. bands.
8. The foam mattress of claim 1, wherein a lower surface of the
foam base defines lateral grooves allowing the mattress to
bend.
9. The foam mattress of claim 1, further comprising a foam topper
configured to cover and match the upper surface of the mattress
entrapping as such the inserts.
10. The foam mattress of claim 9, further comprising a sealable
cover configured to wrap the mattress and topper once
assembled.
11. The foam mattress of claim 10, wherein the sealable cover is
made of a flame retardant fabric.
12. A method for adjusting and customizing a firmness of a foam
mattress, the method comprising the steps of: i. providing a foam
base having an upper surface defining a top recess; ii. providing a
plurality of foam inserts each configured to be disposed and
assembled into the top recess, the inserts being provided at least
with two different firmness of the foam; iii. selecting the inserts
in accordance with the firmness thereof; and iv. disposing the
selected inserts into the top recess until to form a continued
upper surface of the mattress.
13. The method of claim 12, wherein in step ii) the inserts are
provided according to three different firmness of the foam selected
from firm, medium and soft.
14. The method of claim 12, further comprising between steps ii)
and iii) the steps of: a) providing a pair of longitudinal foam
side rails; b) placing the rails into the top recess each along one
of the longitudinal edges of the base between a head section and a
foot section of the mattress, the inserts being then configured to
be placed in step iii) into the top recess formed between the head
and foot sections and the pair of lateral rails, wherein the foot
section, the head section, the two longitudinal foam side rails and
the inserts once in placed form the foam mattress with a continued
upper surface.
15. The method of claim 12, wherein the inserts form two
longitudinal columns and a plurality of rows of inserts; each
column of insert corresponding to one lateral side of the mattress,
the method further comprising the step of v. selecting the inserts
of one side of the mattress with a different firmness than the
inserts of the other side of the mattress.
16. The method of claim 12, wherein the inserts form two
longitudinal columns and a plurality of rows of inserts; each
column of insert corresponding to one lateral side of the mattress,
the method further comprising the step of vi. selecting the inserts
of each column and/or row with a different firmness to customized
each side of the mattress.
17. The method of claim 12, further comprising the step of
entrapping the inserts forming the mattress core by placing a foam
topper configured to cover and match the upper surface of the
mattress.
18. The method of claim 17, further comprising the step of wrapping
the foam mattress with a sealable cover configured to wrap the
mattress and topper once assembled.
19. A kit for adjusting and customizing a firmness of a foam
mattress, the kit comprising: a foam base having an upper surface
defining a top recess; and a plurality of foam inserts each
configured to be disposed and assembled into the top recess to fill
the top recess and form the mattress core with a continued upper
surface of the mattress, wherein the inserts are provided with at
least two different firmness of the foam.
20. The kit of claim 19, wherein the inserts are provided according
to three different firmness of the foam selected from firm, medium
and soft, the kit further comprising a manual of use for assisting
a person to assemble the mattress and customize the firmness of the
mattress.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application is a continuation-in-part of
U.S. patent application Ser. No. 15/461,207 entitled "Mattress and
Topper with Variable Area Deflection Areas for Ultra-low Pressures
with Postural Alignment", filed at the U.S. Patent Office on Mar.
16, 2017 which claims the benefits of priority of U.S. Patent
Applications No. 62/335,959, entitled "Mattress and Topper with
Variable Area Deflection Means for Ultra-low Pressures with
Postural Alignment", and filed at the U.S. Patent Office on May 13,
2016, and No. 62/422,154, entitled "Mattress and Topper with
Variable and Adjustable Area Deflection Means for Ultra-low
Pressures with Postural Alignment", and filed at the U.S. Patent
Office on Nov. 15, 2016, the content of which is incorporated
herein by reference.
FIELD OF THE INVENTION
[0002] The present invention belongs to the field of mattresses and
relates in particular to modifications of foam mattresses having an
adjustable core for adjusting and customizing its firmness. The
core comprises inserts having different firmness forming as such
different deflective areas in the core of the mattress.
BACKGROUND OF THE INVENTION
[0003] It is known that the quality of sleep has a significant
effect on the quality of life. Multiple clinical studies have
correlated poor sleep quality with hypertension, obesity, stroke
and diabetes. It is also known that mattresses can significantly
affect sleep quality.
[0004] All existing consumer mattresses impart sleep-disturbing
side-lying interface pressures to the body. Mattress-induced
discomfort caused by excessive body pressures and postural
misalignment result in increased tossing and turning causing sleep
disruption and reduced sleep quality. An ideal mattress must have
the support and resiliency over the length of the body to support
the body in postural alignment while also providing ultra-low body
pressures on all parts of the body in contact with the mattress to
reduce mattress pressure-induced sleep disturbance.
[0005] The object of this invention is to eliminate
mattress-induced sleep quality degradation. The present invention
is the result of many years of university sleep research and
development. The construction of over 100 prototypes was required
to solve the heretofore unsolved equation of providing ultra-low
pressures with optimal postural alignment.
[0006] Ultra-low mattress body interface pressure can be defined as
at or below 0.6 PSI (32 mmHg), medically known as the ischemic
pressure threshold. This interface pressure between the mattress
and body allow the capillaries of the skin to remain open thereby
greatly reducing or eliminating the incidence of pressure-induced
sleep-disrupting movement. This pressure, if unrelieved, would
eventually cause a decubitus ulcer (bed sore) to form.
[0007] Side sleeping is the most common and desired sleep position.
Most existing consumer mattresses achieve back-lying body pressures
on most, but not all parts of the body, of 0.6 PSI. If the
back-lying area is about 900 square inches, that is usually
sufficient area to maintain low pressures on most parts of the
body. But the same side-lying body only presents about 500 square
inches of contact area which, under the same load, significantly
increases the unit area pressure to higher than 0.6 PSI on some
parts of the body, notably the shoulder and hip areas, also known
as bony prominences.
[0008] Achieving 0.6 psi or below on all body areas, including the
shoulder and hip areas, when side-lying on static conventional
mattresses--without certain mattress structural
modifications--cannot be achieved with current materials.
Prototypes leading to the present invention have achieved
side-lying pressures on the shoulder and hip--as well as the rest
of the body--of significantly less than 0.6 psi.
[0009] Since a recumbent body has both varying density and contour
in the longitudinal direction, the ideal mattress must conform
(deflect) to these variations in order to achieve correct postural
alignment. The deflection parameters of the mattress must vary
along its length to match the varying body density and contours
while maintaining interface pressures at or below 0.6 PSI.
[0010] Few would agree that a single mattress firmness is
comfortable for all users. What might be a medium firmness for one
may feel too firm or too soft for another. That is why many
mattress manufacturers provide mattresses with varying degrees of
firmness, yet this strategy does not provide a differing firmness
for each sleeper on the same bed. A firm mattress would be firm for
both sleepers as would be a soft or medium firmness.
[0011] A select few mattress manufacturers have marketed mattresses
in which the mattress cover can be unzipped to allow the customer
to interchange certain internal components of the mattress which
have a different firmness to suit a customer's comfort
preference.
[0012] These consumer adjustments are usually horizontal full-size
mattress layers of foam which can be rearranged vertically within
the mattress, i.e. to obtain a softer or firmer top-sleep layer.
Others are manufactured with other types of interchangeable
components, but they are very expensive.
[0013] Another object of the invention is a means of producing an
inexpensive, novel consumer-adjustable mattress in which the
consumer can change the firmness of the entire mattress and/or the
firmness on either side of the bed to accommodate each sleeper
and/or the firmness under certain "body zones" within the mattress
for their own personalized comfort preference and to reduce tossing
and turning.
[0014] New foam mattresses and toppers by the inventor using foam
deflection are disclosed in international application no. WO
2016/023109 A1 (Torbet) wherein the top portion of the mattresses
comprises a plurality of displacement tunnels at different body
part areas, such as shoulders or hip area, allowing the body part
area foam above the tunnel to displace downward to provide pressure
reduction and alignment for the body part such as shoulders or hip.
Although the invention disclosed in this international application
is pretty efficient, there is place for improvement in the shape,
number and location of the channels for improving or modulating
pressure reduction, alignment and comfort.
SUMMARY OF THE INVENTION
[0015] The shortcomings of the prior art are generally mitigated by
new foam mattresses comprising deflective areas for reducing
pressure reduction and alignment for the body parts in contact with
the deflective areas.
[0016] The invention is directed to a foam mattress having an
adjustable mattress core for adjusting and customizing a firmness
of the mattress, the foam mattress comprising: a foam base having
an upper surface defining a top recess; and a plurality of foam
inserts each configured to be disposed and assembled into the top
recess to fill the top recess and form the mattress core with a
continued upper surface of the mattress,
[0017] wherein the inserts are provided with at least two different
firmness of the foam.
[0018] The inserts having different firmness, they form different
deflective areas in the core of the mattress.
[0019] According to another preferred embodiment, the inserts are
provided according to three different firmness of the foam selected
from firm, medium and soft. The firmness of a foam mattress is
characterized by its Indentation Load Deflection or ILD. By "firm",
it is meant in the present application a foam having a ILD from 26
to 32. By "medium", it is meant in the present application a foam
having a ILD from 18 to 24. By "soft", it is meant in the present
application a foam having a ILD from 10 to 16. The density of the
foam is preferably from 1.6 to 2.2 lb/CuFt.
[0020] According to another preferred embodiment, the foam mattress
further comprises a pair of longitudinal foam side rails to be
placed into the top recess each along one of one of the
longitudinal edges of the base between a head section and a foot
section of the mattress, the inserts being then configured to be
placed into the top recess formed between the head and foot
sections and the pair of lateral rails, wherein the foot section,
the head section, the two longitudinal foam side rails and the
inserts once in placed form the continued upper surface of the
mattress.
[0021] According to another preferred embodiment, the foam base and
the pair of longitudinal foam side rails may form a monoblock of
foam.
[0022] According to another preferred embodiment, the inserts form
two longitudinal columns and a plurality of rows of inserts; each
column of insert corresponding to one lateral side of the
mattress.
[0023] According to another preferred embodiment, all the inserts
of one side of the mattress have a different firmness than the
inserts of the other side of the mattress.
[0024] According to another preferred embodiment, the inserts are
affixed into the top recess using Velcro.RTM. bands. Other ways to
fix the inserts and rails into the recess to form the core are
possible without departing from the present invention.
[0025] According to another preferred embodiment, a lower surface
of the foam base defines lateral grooves allowing the mattress to
bend, such as to be used in a medical bed.
[0026] According to another preferred embodiment, the mattress may
further comprise a foam topper configured to cover and match the
upper surface of the mattress entrapping as such the inserts.
[0027] According to another preferred embodiment, a sealable cover
configured to wrap the mattress and topper once assembled may be
provided. Preferably, the sealable cover can be made of a flame
retardant fabric.
[0028] The invention is also directed to a method for adjusting and
customizing a firmness of a foam mattress, the method comprising
the steps of: [0029] i. providing a foam base having an upper
surface defining a top recess; [0030] ii. providing a plurality of
foam inserts each configured to be disposed and assembled into the
top recess, the inserts being provided at least with two different
firmness of the foam; [0031] iii. selecting the inserts in
accordance with the firmness thereof; and [0032] iv. disposing the
selected inserts into the top recess until to form a continued
upper surface of the mattress.
[0033] According to a preferred embodiment, in step ii), the
inserts are provided according to three different firmness of the
foam selected from firm, medium and soft.
[0034] According to another preferred embodiment, the method may
further comprise between steps ii) and iii) the steps of: [0035] a)
providing a pair of longitudinal foam side rails; [0036] b) placing
the rails into the top recess each along one of the longitudinal
edges of the base between a head section and a foot section of the
mattress, the inserts being then configured to be placed in step
iii) into the top recess formed between the head and foot sections
and the pair of lateral rails, [0037] wherein the foot section, the
head section, the two longitudinal foam side rails and the inserts
once in placed form the foam mattress with a continued upper
surface.
[0038] According to another preferred embodiment, the inserts form
two longitudinal columns and a plurality of rows of inserts; each
column of insert corresponding to one lateral side of the mattress,
the method further comprising the step of [0039] v. selecting the
inserts of one side of the mattress with a different firmness than
the inserts of the other side of the mattress.
[0040] According to another preferred embodiment, the inserts form
two longitudinal columns and a plurality of rows of inserts; each
column of insert corresponding to one lateral side of the mattress,
the method further comprising the step of [0041] vi. selecting the
inserts of each column and/or row with a different firmness to
customized each side of the mattress.
[0042] According to another preferred embodiment, the method
further comprises the step of entrapping the inserts forming the
mattress core by placing a foam topper configured to cover and
match the upper surface of the mattress.
[0043] According to another preferred embodiment, the method
further comprises the step of wrapping the foam mattress with a
sealable cover configured to wrap the mattress and topper once
assembled.
[0044] The invention is yet directed to a kit for adjusting and
customizing a firmness of a foam mattress, the kit comprising:
[0045] a foam base having an upper surface defining a top recess;
and [0046] a plurality of foam inserts each configured to be
disposed and assembled into the top recess to fill the top recess
and form the mattress core with a continued upper surface of the
mattress, wherein the inserts are provided with at least two
different firmness of the foam.
[0047] According to another preferred embodiment, the inserts are
provided according to three different firmness of the foam selected
from firm, medium and soft, the kit further comprising a manual of
use for assisting a person to assemble the mattress and customize
the firmness of the mattress.
[0048] The preferred embodiments disclosed herein above for the
foam mattress or the method can be applied to the kit according to
the invention.
[0049] The present invention is preferably achieved by CNC
(Computer Numerical Control) cutting the structural modifications
(channels, slots and voids) into the mattress foam which support
each area of the body.
[0050] Other and further aspects and advantages of the present
invention will be obvious upon an understanding of the illustrative
embodiments about to be described or will be indicated in the
appended claims, and various advantages not referred to herein will
occur to one skilled in the art upon employment of the invention in
practice.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] The above and other aspects, features and advantages of the
invention will become more readily apparent from the following
description, reference being made to the accompanying drawings in
which:
[0052] FIG. 1 is a schematic perspective view in cross-section of
the core of the mattress in accordance with a first embodiment of
the invention;
[0053] FIG. 2 is an exploded schematic front elevation view in
cross-section of the core of the mattress in accordance with a
first embodiment of the invention;
[0054] FIG. 3 depicts the first embodiment of FIGS. 1 and 2 with
body area displacement modifications;
[0055] FIG. 4 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a second embodiment
of the invention;
[0056] FIG. 5 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a third embodiment
of the invention;
[0057] FIG. 6 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a fourth embodiment
of the invention;
[0058] FIG. 7 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a fifth embodiment
of the invention;
[0059] FIG. 8 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a sixth embodiment
of the invention;
[0060] FIG. 9 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a seventh embodiment
of the invention;
[0061] FIG. 10 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a eighth embodiment
of the invention;
[0062] FIG. 11 is a schematic front elevation view in cross-section
of the core of the mattress in accordance with a ninth embodiment
of the invention;
[0063] FIG. 12 is a schematic perspective view in cross-section of
the core of the mattress in accordance with the first embodiment of
the invention (FIG. 1);
[0064] FIG. 13 is a schematic perspective view in cross-section of
the core of the mattress in accordance with the first embodiment of
the invention (FIG. 1 or 12) without side-lying body contact;
[0065] FIG. 14 is a schematic perspective view in cross-section of
the core of the mattress in accordance with the first embodiment of
the invention (FIG. 1 or 12) with side-lying body contact;
[0066] FIG. 15 depicts the shoulder area of the first embodiment
without contact;
[0067] FIG. 16 depicts the shoulder area of the first embodiment
with contact;
[0068] FIG. 17 depicts the first embodiment of FIG. 1 without
back-lying body contact;
[0069] FIG. 18 depicts the first embodiment of FIG. 1 with
back-lying body contact;
[0070] FIG. 19 is a schematic perspective view in cross-section of
the core of the mattress with body area displacement modifications
in accordance with a tenth embodiment of the invention;
[0071] FIG. 20 is a schematic front elevation view in cross-section
of the core of the mattress with body area displacement
modifications in accordance with a tenth embodiment of the
invention;
[0072] FIG. 21 is a schematic perspective view in cross-section of
a topper with body area displacement modifications in accordance
with a eleventh embodiment of the invention;
[0073] FIG. 22 is a schematic front elevation view in cross-section
of the core of the topper of FIG. 21;
[0074] FIG. 23 is a schematic front elevation view in cross-section
of a mattress in accordance with a twelfth embodiment of the
invention
[0075] FIG. 24 is a schematic front elevation view in cross-section
of the core of the mattress of
[0076] FIG. 23 and a topper, including dimensions;
[0077] FIG. 25 shows a topper including an enhancer according to a
preferred embodiment of the invention;
[0078] FIG. 26 shows toppers including full-length enhancers
according to different preferred embodiments of the invention;
[0079] FIG. 27 shows a topper including half-length enhancers
according to preferred embodiments of the invention;
[0080] FIG. 28 compares a mattress of the prior art with a mattress
in accordance with a preferred embodiment of the invention;
[0081] FIG. 29 illustrates different slots or channels in the
mattress in accordance with four preferred embodiments of the
invention; and
[0082] FIG. 30 illustrates the difference of deflection between a
regular topper or mattress with no slots (left) with a topper or
mattress with slots in accordance with a preferred embodiment of
the invention;
[0083] FIG. 31 illustrates the different elements or sections of a
mattress having interchangeable inserts in accordance with another
preferred embodiment of the invention;
[0084] FIG. 32 illustrates a mattress having 18 interchangeable
inserts in accordance with the other preferred embodiment of the
invention;
[0085] FIG. 33 illustrates a mattress having 8 interchangeable
inserts in accordance with the other preferred embodiment of the
invention;
[0086] FIG. 34 illustrates a mattress having 6 interchangeable
inserts in accordance with the other preferred embodiment of the
invention;
[0087] FIG. 35 illustrates a mattress having 8 interchangeable
inserts and how to insert one of the inserts in accordance with the
other preferred embodiment of the invention;
[0088] FIG. 36 illustrates a mattress having 8 interchangeable
inserts and how to place a topper, in accordance with the other
preferred embodiment of the invention;
[0089] FIG. 37 illustrates mattresses having each 8 interchangeable
inserts and their relation with a body laid on the mattress for
different body heights, in accordance with the other preferred
embodiment of the invention;
[0090] FIG. 38 illustrates a mattress having 8 interchangeable
inserts with one side having firm insert and the other side having
soft, in accordance with the other preferred embodiment of the
invention;
[0091] FIG. 39 illustrates a mattress having 8 interchangeable
inserts with each side having customized insert firmness, in
accordance with the other preferred embodiment of the
invention;
[0092] FIG. 40 illustrates a mattress having 8 interchangeable
inserts with no lateral rails to form the core, in accordance with
the other preferred embodiment of the invention; and
[0093] FIG. 41 illustrates a foam base of a mattress where the head
section, the foot section and the lateral rails are fused to form a
monoblock, in accordance with the other preferred embodiment of the
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0094] A novel mattress and/or topper will be described
hereinafter. Although the invention is described in terms of
specific illustrative embodiments, it is to be understood that the
embodiments described herein are by way of example only and that
the scope of the invention is not intended to be limited
thereby.
[0095] All mattress and toppers embodiments shown are preferably
bi-directional, meaning that the head end and foot end of the
mattress are identical and symmetrical. This allows the mattress or
topper to be placed on the bed foundation in either direction
without affecting sleep performance. Of course, the present
invention cannot be limited to bi-directional mattresses and
toppers.
[0096] FIGS. 1 and 2 shows a first mattress base core in accordance
with a first embodiment of the invention. The mattress is formed of
two foam sections with a top section 1 adapted to be affixed on a
bottom base or core section 2. The base core section can be a 8''
base piece. The two sections can be glued but other methods known
in the art can be used to assemble the two sections together.
Mattress Deflection Areas
[0097] The core section 2 comprises various specific load
deflection areas 20-50 which correspond to different recumbent body
areas to reduce pressures to those areas while maintaining postural
alignment. The areas are preferably CNC contour cut to create
transversal longitudinal channels that can be either slots 3,
grooves 4 or void 5.
[0098] The shoulder area 20 may comprise a series of slots 3,
preferably parallel slots, for providing pressure reduction and
shoulder deflection for postural alignment. A V-groove 4 can be
placed between the torso area 30 and the pelvic area 40 to provide
pelvic deflection. The void 5 is placed at the longitudinal
mattress center to provide pressure reduction for the greater
trochanter.
[0099] FIG. 3 better identifies each of the deflection-modified
body areas: head area 10, shoulder area 20, torso area 30, pelvic
area 40 and trochanter area 50 with examples of general lengths for
each area. Since the mattress core in this example is
bi-directional in placement orientation and deflection parameters,
both areas 10, 20, 30 and 40 are identical in support and
deflection.
[0100] High side-lying trochanter pressure exists in all current
mattresses and is the most common cause of mattress-induced sleep
disruption. The hip area is comprised of both areas 40 and area 50.
Both areas 40, one supporting the pelvis and the other supporting
the upper thigh, act together to redistribute and relieve the high
pressure which would otherwise be placed on the greater trochanter.
Area 50 further reduces trochanteric pressure. Likewise, the torso
area 30 reduces pressure on the shoulder area 2.
Different Form of Channels
[0101] FIGS. 4 to 11 illustrate different configurations and forms
of the channels present in the mattress or topper in accordance
with different preferred embodiments. While referring to the
shoulder are in the following description, the same description of
the slots may apply for the lower body area when the mattress is
symmetrical.
[0102] FIG. 4 shows an embodiment where the trochanter area
comprises a void 54 deeper than the void visible on FIG. 1 or 2, to
reduce the possibility of trochanter contact with the bottom of the
void.
[0103] FIG. 5 shows an embodiment with four inverted shoulder slots
15 which are narrower at the top than at the bottom of the
slot.
[0104] FIG. 6 shows an embodiment with four inverted shoulder slots
16 having a drop-like shape closed at the top and in full contact
with the top layer. FIG. 7 shows an embodiment with five inverted
shoulder slots 17 instead of four slots as in FIG. 6, to further
decrease shoulder pressure.
[0105] FIGS. 8 and 9 show embodiments where the four shoulder
slots, while presenting the same shape has different depths. As
illustrated, the two external slots 28 or 29 are deeper than the
two internal slots 18 or 19. The deeper slots allow greater
deflection of the entire shoulder area 20.
[0106] FIGS. 10 and 11 show embodiments as above where the four
shoulder slots, while presenting the same drop-like shape has
different depths. In FIG. 10, there are two smaller internal slots
110 whereas in FIG. 11, there are three internal sluts 111, in both
case having two deeper external slots.
Foam Deflection and Body Alignment
[0107] FIG. 12 identical to FIG. 1 shows the first mattress core
embodiment in perspective view for reference.
[0108] FIG. 13 shows the first mattress core embodiment without
side-lying body compression. Shoulder support elements 3 are shown
uncompressed. The trochanter void 5 is shown uncompressed. FIG. 14
shows the first mattress core embodiment with side-lying body
compression. The slots are shown under various degrees of
compression. The trochanter void 5 is shown compressed. The
trochanter void 5 under compression allows the angled sides of the
void to deflect, dramatically reducing pressure on the trochanter
body area.
[0109] FIG. 15 details the shoulder area 20 uncompressed with the
shoulder slots 21-24 in their as-cut relaxed positions. FIG. 16
details the shoulder area compressed. During shoulder compression,
the shoulder support elements 20 compress independently. The
shoulder slots 21, 22, 23 and 24 under compression expand
horizontally to reduce the lateral foam tensile forces which would
otherwise occur if the shoulder slots were not there to release the
tensile forces. This lateral foam tensile force, if unrelieved,
would dramatically increase the unit area pressure on the
shoulder.
[0110] FIG. 17 shows the first mattress core embodiment without
back-lying body compression. The slots 3 and mattress areas are
shown uncompressed. The trochanter void 5 is also shown
uncompressed. FIG. 18 shows the mattress with back-lying body
compression. The shoulder support slots 3 are shown under various
degrees of compression. The trochanter void 5 is also compressed.
The trochanter void 5 under compression allows the angled sides of
the void to deflect, allowing the buttocks area to deflect into the
mattress. The deflection in this area creates significant
additional support in the lumbar area when back-lying as well as
allowing increased knee flexion which helps reduce low-back
pain.
Additional Embodiments
[0111] FIGS. 19 & 20 show another mattress embodiment comprised
of a top foam layer 6 and a bottom foam layer 7. The four identical
slots 8 extend from the upper surface through the mattress which
eliminates the horizontal tensile forces present in the top foam
layer 6 as shown in embodiments 1-9. This embodiment is comprised
of nine specialized deflection areas: head area 10, shoulder area
20, torso area 30, pelvic area 40 and trochanter area 50. Since the
mattress core is bi-directional in both placement orientation and
deflection parameters, both areas 40 are identical in support and
deflection. The hip area is comprised of both areas 40 and area 50.
Both areas 40, one supporting the pelvis and the other supporting
the upper thigh, act together to redistribute and relieve the high
pressure which would otherwise be placed on the greater
trochanter.
[0112] The shoulder or lower body area 20 also comprise a lateral
slot 25 located between two slots 8, and two channels 26 extending
from the lower surface of the mattress. The different slots 8, 25
and channels 26 collaborate for modifying the deflection of the
foam under the body. The lower channels 26 can be used also for
modulating such deflection by inserting inserts made of the same
foam, as detailed herein below.
[0113] FIGS. 21 and 22 show a CNC cut foam mattress topper
embodiment 200. As with all mattress embodiments, the topper is
comprised of nine specialized deflection areas: head area 10,
shoulder area 20, torso area 30, pelvic area 40 and trochanter area
50. The deflection channels 60 if the shoulder or low body area 20
provide shoulder elevation drop which reduces shoulder pressure by
redistributing some of that pressure to the torso area 30.
Torso/pelvic V-grooves 70, delimiting the torso and pelvic areas
30, 40 allows the heavier hip areas 40, 50 to deflect more than the
adjacent torso area. The trochanter channel 80 extending from the
lower surface reduces pressure on the greater trochanter 50.
[0114] FIGS. 23 and 24 illustrate another embodiment of the
mattress 230 comprising at least one internal lateral channel 231
operatively extending between two of said first lateral channels
232 inside the mattress. In the example illustrated on FIGS. 23 and
24, the foam mattress 230 comprises one internal lateral channel
231 between two of said first lateral channels 232, each internal
lateral channel having preferably an ovoid cross-section. The ovoid
channels 231 can be formed by cutting and removing the channel
plugs through the top cuts 233. The ovoid channels 231 allow
reducing shoulder pressure more than the vertically slotted
shoulder area 232 without them. As illustrated on FIG. 24, the
mattress 230 can be covered by a laminate or topper 234 before
being wrapped in a zipped sleep cover 235 or the like.
Mattresses or Toppers with Modulating Inserts
[0115] Referring to FIG. 25, it is shown a perspective view of the
mattress topper/enhancer 200 oriented as if lying on a mattress,
with the flat area being the top 210 of the topper/enhancer. The
zippered cover has been removed for clarity. Full width
topper/enhancer insert 300 can be placed into the central channel
60 of the shoulder area 20 of the topper/enhancer. The insert is
preferably a foam piece which has been contour cut to form the
shoulder channel 60 and would otherwise be discarded if not used as
the insert 300. Once the insert(s) have been placed in the
channel(s) the zippered cover would be closed to maintain the
topper and insert(s) all together.
[0116] Referring to FIG. 26, it is shown an insert placed into one
channel (A), two channels (B) or three channels (C) as decided by
the user's comfort preference. These inserts in this case are along
the full width of the topper/enhancer 300 or a half-length inserts
310 that can be placed on one side only of the topper/enhancer.
This would typically apply to a two-person-sized topper/enhancer
like a Full, Queen or King sized bed, allowing each sleeper to
customize the shoulder comfort on their side to his/her preference.
FIG. 27 shows different examples of the many combinations of insert
placements possible for individual customized comfort using
half-length inserts 301.
[0117] There are many ways a sleeper can vary the firmness:
[0118] a. nothing in the slots (see FIG. 22A);
[0119] b. one insert 310 in the central slot 60 (see FIG. 24A); or
into slot 61 or into slot 62;
[0120] c. two inserts 310 in the central slot 60 and slot 61 (see
FIG. 22B); the central slot 60 and slot 62; or the slots 61 and 62;
or
[0121] d. three inserts in slots 60, 61 and 62 on one side of the
bed (FIG. 24C) or the other side (FIG. 24D).
[0122] There are several advantages of the use of
inserts/enhancers. First, the enhancers can be made from the
cut-out of the foam mattress when cutting the channels reducing
foam waste. Second, the use of the enhancers allows precisely and
easily customizing the user's sleeping comfort, one side of the bed
or both sides.
Methods
[0123] The present invention also concerns a method for customizing
the comfort of a mattress, comprising at least the steps of: [0124]
a) providing a mattress or a topper as disclosed herein with the
plurality of slots and/or voids cut into the foam for supporting
each area of the person body in a specific way to control postural
alignment while providing ultra-low mattress-body interface
pressures for all body areas regardless of recumbent position;
[0125] b) providing cut-outs of foam obtained during the
manufacturing of the mattress or topper when making the slots
and/or voids; and [0126] c) reinserting one or several cut-outs in
the slots and/or voids at least along a section of the slots and/or
voids for customizing or adjusting the postural alignment.
[0127] Referring to FIG. 28, the deflection areas of the top
mattress section of the prior art: WO 2016/023109, may be prone to
several deficiencies: [0128] 1. The depth of the foam above the
shoulder "tunnel" is limited which allows the firmer base foam
(darker) to feel more prominent in that area than desired. [0129]
2. The height to width ratio of the shoulder "tunnel" tends to
allow a permanent non-recoverable body impression in that area
under heavier loads. [0130] 3. The vertical deflection capability
of the shoulder area is less than desired. [0131] 4. Since the top
mattress section requires a 3'' height to perform, and the desired
overall height is 10'', the base foam must be 7'' which is marginal
in preventing "bottoming out", or approaching a terminal firmness
which can defeat the ultra-low pressure parameter.
[0132] Still referring to FIG. 28, the mattress of the present
invention may solve the above-mentioned deficiencies of the prior
art: [0133] 1. The vertical tapered slots in the shoulder area
provide Indention/Force/Deflection (IFD) reduction of the foam to
prevent the firmer feel of an un-modified shoulder area. [0134] 2.
The top mattress section is supported by the un-slotted (land)
areas of the base foam, preventing any significant body impressions
to form. [0135] 3. The slotted shoulder area provides both the IFD
reduction and deflection desired for both back and side-lying
comfort. [0136] 4. The support provided by the slotted shoulder
area allows an 8'' base foam which prevents "bottoming out". [0137]
5. Moreover, the slotted design allows greater flexibility to fine
tune future support and firmness parameters.
[0138] How slot and void size/shape/placement affect foam support,
firmness and deflection: [0139] 1. Un-slotted foam has the most
support and firmness and most resistance to deflection. [0140] 2.
The width of a given vertical slot in relation to the width of the
adjacent un-slotted foam determines the IFD reduction of the foam
(softening). [0141] 3. The depth of a given vertical slot
determines the depth to which the IFD reduction (softening) acts.
[0142] 4. A vertical slot releases the horizontal tensile forces
inherent in un-slotted foam. [0143] 5. A vertical slot creates an
"edge effect" whereby the foam IFD is lower near the foam edge than
the foam middle.
[0144] 6. A void's shape determines the adjacent foam's compression
characteristics.
[0145] Referring to FIG. 29, pic A, the foam adjacent to the top of
the slot will compress more easily than at the bottom. Tensile
release occurs to the lowest point of the slot. The cross sectional
area of the slot relative to the adjacent cross sectional foam area
determines the IFD reduction.
[0146] Referring to FIG. 29, pic B, the foam adjacent to the bottom
of the slot will compress more easily than at the top. Tensile
release occurs to the lowest point of the slot. The cross sectional
area of the slot relative to the adjacent cross sectional foam area
determines the IFD reduction.
[0147] Referring to FIG. 29, pic C, the foam adjacent to the
"arrowhead" area will compress more easily than the foam adjacent
to the "arrow stem". With a larger arrowhead void area than either
pic A or B at the same depth, it will compress more easily at the
same depth under the same load. Tensile release occurs to the
lowest point of the void. The cross sectional area of the void
relative to the adjacent cross sectional foam area determines the
IFD reduction.
[0148] Referring to FIG. 29, pic D, the void is similar to the
arrowhead of pic C. But with smaller arrowhead angles, the adjacent
foam will compress more easily under the same load.
[0149] Tensile release occurs to the lowest point of the void. The
cross sectional area of the void relative to the adjacent cross
sectional foam area determines the IFD reduction.
[0150] FIG. 30 illustrates how foam without slots or voids (left)
compares to foam with tensile release slots (right). Even though
polyurethane and other flexible foams have a very low Young's
modulus, tensile release dramatically reduces the foam tensile
forces which act to restrict compression. The result is greater
deflection and greater contact area. Greater contact area equates
to lower pressure per unit area, which can be extremely important
in the present application.
[0151] The flexibility to control both area deflection and
mattress/body interface pressures by slot or void size, depth,
shape and placement comprises a new and better way to manufacture
mattresses and toppers. No other mattress or topper manufacturing
process has this ability to fine tune and control comfort
parameters, whether based on consumer preferences or other decision
factors.
[0152] Indentation force-deflection (IFD) is a process used in the
flexible foam manufacturing industry to assess the "softness" of a
sample of foam such as memory foam. To conduct an IFD test, a
circular flat indenter with a surface area of 323 square
centimeters (50 sq. inches--8'' in diameter) is pressed against a
foam sample usually 100 mm thick and with an area of 500 mm by 500
mm (ASTM standard D3574). The foam sample is first placed on a flat
table perforated with holes to allow the passage of air. It is then
"warmed up" by being compressed twice to 75% "strain", and then
allowed to recover for six minutes. The force is measured 60
seconds after achieving 25% indentation with the indenter. Lower
scores correspond with less firmness; higher scores with greater
firmness. U.S. measurements are given in pounds-force, and European
ones are given in Newton (N).
[0153] In the mattress case, the top 2'' foam layer would typically
be 19-21 IFD. The 8'' base layer would typically be 25-27 IFD.
Firmer or softer IFD's can be used, but quickly exit the "comfort
zone" for most people. The topper would typically be 19-21 IFD.
(see IFD definition below).
[0154] The foam used for the making of the mattresses or toppers
disclosed herein are selected from the foams generally used in the
art of making foam mattress or toppers. For instance, the foam may
comprise flexible polyurethane (including modified polyurethanes
such as visco-elastic PE foam), latex or any other type of flexible
foam.
Matresses with Interchangeable Inserts
[0155] As illustrated from FIGS. 31 to 41, the invention as claimed
is a foam mattress 400 having an adjustable mattress core 405 for
adjusting and customizing a firmness of the mattress, the foam
mattress comprises a foam base 410 having an upper surface defining
a top recess 415; and a plurality of foam inserts 430 each
configured to be disposed and assembled into the top recess to fill
the top recess and form the mattress core with a continued upper
surface of the mattress (See FIG. 31C for example). The inserts are
provided with at least two different firmness of the foam.
[0156] The inserts are provided according to three different
firmness of the foam selected from firm, medium and soft. The
firmness of a foam mattress is characterized by its Indentation
Load Deflection or ILD. By "firm", it is meant in the present
application a foam having an ILD from 26 to 32. By "medium", it is
meant in the present application a foam having an ILD from 18 to
24. By "soft", it is meant in the present application a foam having
an ILD from 10 to 16. The density of the foam is preferably from
1.6 to 2.2 lb/CuFt.
[0157] FIG. 40 shows a foam mattress according to the invention
with the core formed only of the inserts placed in the recess. As
illustrated in the other Figures, the foam mattress may further
comprise a pair of longitudinal foam side rails 420 to be placed
into the top recess 415 each along one of one of the longitudinal
edges of the base 410 between a head section 411 and a foot section
412 of the mattress, the inserts being then configured to be placed
into the top recess formed between the head and foot sections and
the pair of lateral rails, wherein the foot section, the head
section, the two longitudinal foam side rails and the inserts once
in placed form the continued upper surface of the mattress 435.
[0158] FIG. 31 shows the various foam components of the adjustable
mattress core (queen/king size shown) 400. All components, after
assembly, will be inserted into a preferably flame retardant
zippered mattress cover (not shown).
[0159] FIG. 31A shows a foam mattress base 410 which has been
preferably contour cut as shown to receive the other components.
The top recess is typically 2.5''-3'' deep.
[0160] FIG. 31B shows the addition, preferably by adhesive, of two
side rails 420 laterally spaced on either side of the base 410. The
side rails are preferably secondarily cut from the piece removed
from the recess of the base to provide adequate edge support for
sitting. Other ways of making can be considered. The side rails are
typically 2.5''-3'' high by 4''-5'' wide. The Base and the sides
rails can alternatively form a unique peace of foam.
[0161] FIG. 31C shows the addition of the foam inserts 430 of the
first embodiment which are preferably loose-laid, interchangeable
and removable from the base recess. Each side of the mattress shown
has its own set of inserts. The foam inserts are typically
2.5''-3'' thick.
[0162] FIG. 31D shows the addition of the top comfort layer 440
prior to placement over the base with side rails and inserts in
place. The top comfort layer is typically 2'' thick.
[0163] FIG. 32 shows a detail of the previous embodiment 400 with
interchangeable inserts 430 installed. If all firm, all medium or
all soft firmness inserts are desired, this embodiment (showing a
queen or king size core), preferably requires 18 inserts of firm
foam, 18 inserts of medium firmness foam or 18 inserts of soft
foam, 9 for each side of the mattress. If it is a twin, twin long
mattress, it would require 9 inserts for each firmness. If a
consumer desires a firmness other than the 3 provided it would
require an additional 9 or 18 inserts per firmness, depending on
mattress size. The lower surface of the foam base may define
lateral grooves 413 allowing the mattress to bend, for example to
be used in a medical bed.
[0164] FIG. 33 shows another embodiment with interchangeable
inserts installed. If all firm, all medium or all soft firmness
inserts are desired, this embodiment (showing a queen or king size
core), requires 8 inserts of firm foam, 8 inserts of medium
firmness foam and 8 inserts of soft foam, 4 for each side of the
mattress. If it is a twin, twin long mattress, it would require 4
inserts each firmness
[0165] If a consumer desires a firmness other than the three
provided it would require an additional 4 or 8 inserts per
firmness, depending on mattress size.
[0166] FIG. 34 shows a third embodiment with interchangeable
inserts installed. If all firm, all medium or all soft firmness
inserts are desired, this embodiment (showing a queen or king size
core), requires 6 inserts of firm foam, 6 inserts of medium
firmness foam and 6 inserts of soft foam, 3 for each side of the
mattress. If it is a twin, twin long mattress, it would require 3
inserts each firmness.
[0167] If a consumer desires a firmness other than the 3 provided
it would require an additional 3 or 6 inserts per firmness,
depending on mattress size.
[0168] FIG. 35 shows an example of an interchangeable insert of the
second embodiment as it would fit into the recess of the base with
adjacent inserts in place.
[0169] FIG. 36 shows the top foam layer in position ready for loose
(non-adhered) placement over the base, side rails and inserts prior
to cover closure.
[0170] FIG. 37 shows the size of a 4'11'', 5'6'' and 6' body in
relation to a mattress core (without side rails for clarity) of the
second embodiment to illustrate the mattress zone to body zone
relativity. As an example, the shoulder insert longitudinal length
should accommodate the shoulders of the three body lengths for any
size mattress.
[0171] FIG. 38 shows a mattress 400 having one side comprising only
firm inserts whereas the other side comprises only soft
inserts.
[0172] FIG. 39 shows a mattress 400 where on each side of the bed,
the customer can customized the firmness of the inserts 430 between
firm, medium and soft, and as such providing different body
alignment and comfort.
[0173] FIG. 40 illustrates a mattress 400 having 8 interchangeable
inserts but no lateral rails to form the core.
[0174] FIG. 41 illustrates a foam base 410 of a mattress where the
head section 411, the foot section 412 and the lateral rails 420
are fused to form a mono-block, in accordance with the other
preferred embodiment of the invention. In FIG. 41, the base is
symmetrical in that the head and foot sections are
interchangeable.
[0175] While illustrative and presently preferred embodiments of
the invention have been described in detail hereinabove, it is to
be understood that the inventive concepts may be otherwise
variously embodied and employed and that the appended claims are
intended to be construed to include such variations except insofar
as limited by the prior art.
* * * * *