U.S. patent application number 15/455093 was filed with the patent office on 2018-09-13 for mattress.
The applicant listed for this patent is Mel Godwin, Benoit Joseph Renaud. Invention is credited to Mel Godwin, Benoit Joseph Renaud.
Application Number | 20180255940 15/455093 |
Document ID | / |
Family ID | 63446699 |
Filed Date | 2018-09-13 |
United States Patent
Application |
20180255940 |
Kind Code |
A1 |
Renaud; Benoit Joseph ; et
al. |
September 13, 2018 |
Mattress
Abstract
A mattress including a base layer, at least one intermediary
layer, and a top layer. The base layer is constructed from a foam
material defining an Indentation Level Deflection (ILD) Rating from
25 to 35 pounds, and defines a thickness of between four and eight
inches (4''-8''), and having a density from 1 to 4 lb/ft.sup.3.
Each intermediary layer is constructed from a foam material
defining an ILD Rating of between 10 and 25 and defines a thickness
from 1.5'' to 3'', and having a density from .about.2 to .about.4
lb/ft.sup.3. A top layer is fabricated from a vertically-oriented
synthetic memory fiber blend comprised of bi-copolymer fibers and
fibers having spring-like molecular structure. The top layer
defines a thickness of between 0.75'' and 1.25'' and a weight of
between about 200 to about 500 grams per square yard. A cover layer
may be disposed above said top layer, the cover layer being
fabricated from a selected foam material, and defining a thickness
of up to about one inch. A cover member configured to closely and
selectively receive the various layers of the mattress may be
provided. The cover member may be being provided with at least one
handle for assisting in movement and transport of said
mattress.
Inventors: |
Renaud; Benoit Joseph; (Fort
Atkinson, WI) ; Godwin; Mel; (Bailey, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Renaud; Benoit Joseph
Godwin; Mel |
Fort Atkinson
Bailey |
WI
NC |
US
US |
|
|
Family ID: |
63446699 |
Appl. No.: |
15/455093 |
Filed: |
March 9, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/122 20130101;
A47C 27/22 20130101; A47C 27/15 20130101; A47C 31/006 20130101;
A47C 27/148 20130101 |
International
Class: |
A47C 27/14 20060101
A47C027/14; A47C 27/15 20060101 A47C027/15 |
Claims
1. A mattress including: a base layer constructed from a responsive
polymer structure and defining a top surface, a bottom surface, and
a perimeter wall between said top surface and said bottom surface;
and a top layer fabricated from a vertically-oriented synthetic
memory fiber blend and defining a top surface, a bottom surface,
and a perimeter wall between said top surface and said bottom
surface, said top layer bottom surface being secured to said base
layer top surface in a conventional manner.
2. The mattress of claim 1 wherein said base layer responsive
polymer structure is fabricated from a foam material defining an
Indentation Level Deflection (ILD) Rating of between about 25 and
about 35 pounds.
3. The mattress of claim 1 wherein said base layer defines a
thickness of between four and eight inches (4''-8'').
4. The mattress of claim 1 wherein said base layer has a density of
between about one and about four pounds per cubic feet (.about.1 to
.about.4 lb/ft.sup.3).
5. The mattress of claim 1 wherein said vertically-oriented
synthetic memory fiber blend is comprised of bi-copolymer fibers
and fibers having spring-like molecular structure.
6. The mattress of claim 1 wherein said top layer defines a
thickness of between 0.75'' and 1.25''.
7. The mattress of claim 1 wherein said top layer defines a weight
of between about 200 to about 500 grams per square yard.
8. The mattress of claim 1 further comprising at least one
intermediary layer defining a top surface, a bottom surface, and a
perimeter wall between said top surface and said bottom surface,
said at least one intermediary layer being disposed between said
base layer and said top layer; wherein said base layer top surface
is secured to said at least one intermediary layer bottom surface
in a conventional manner; and wherein said at least one
intermediary layer top surface is secured to said top layer bottom
surface in a conventional manner.
9. The mattress of claim 8 wherein said at least one intermediary
layer is fabricated from a foam material.
10. The mattress of claim 8 wherein said at least one intermediary
layer includes: a first intermediary layer defining a top surface,
a bottom surface, and a perimeter wall between said top surface and
said bottom surface; and a second intermediary layer defining a top
surface, a bottom surface, and a perimeter wall between said top
surface and said bottom surface; wherein said base layer top
surface is secured to said first intermediary layer bottom surface
in a conventional manner; wherein said first intermediary layer top
surface is secured to said second intermediary layer bottom surface
in a conventional manner; and wherein said second intermediary
layer top surface is secured to said top layer bottom surface in a
conventional manner.
11. The mattress of claim 10 wherein each of said first
intermediary layer and said second intermediary layer is
constructed from a foam material having a highly-open, cool, and
responsive polymer structure.
12. The mattress of claim 10 wherein each of said first
intermediary layer and said second intermediary layer defines a
thickness of about 1.5'' to about 3''.
13. The mattress of claim 10 wherein each of said first
intermediary layer and said second intermediary layer is
constructed of a foam material defining an ILD Rating of between
about 10 and about 25.
14. The mattress of claim 13 wherein said first intermediary layer
ILD Rating is greater than said second intermediary layer ILD
Rating.
15. The mattress of claim 10 wherein each of said first
intermediary layer and said second intermediary layer has a density
of between about two and about four pounds per cubic feet (.about.2
to .about.4 lb/ft.sup.3).
16. The mattress of claim 1 further comprising a cover member
configured to closely and selectively receive at least said base
layer and said top layer, said cover member including a
conventional closure member to allow for selective removal of said
cover, said cover member being provided with at least one handle
for assisting in movement and transport of said mattress.
17. The mattress of claim 1 further comprising a cover layer
defining a top surface, a bottom surface, and a perimeter wall
between said top surface and said bottom surface, said cover layer
being disposed above said top layer, being fabricated from a
selected foam material, and defining a thickness of up to about one
inch (1'').
18. The mattress of claim 17 wherein said top layer top surface is
secured to said cover layer bottom surface in a conventional
manner.
19. The mattress of claim 17 further comprising a cover member
configured to closely and selectively receive at least said base
layer, said top layer and said cover layer, said cover member
including a conventional closure member to allow for selective
removal of said cover, said cover member being provided with at
least one handle for assisting in movement and transport of said
mattress.
20. A mattress including: a base layer constructed from a
responsive polymer structure and defining a top surface, a bottom
surface, and a perimeter wall between said top surface and said
bottom surface, said responsive polymer structure being fabricated
from a foam material defining an Indentation Level Deflection (ILD)
Rating of between about 25 and about 35 pounds, said base layer
defining a thickness of between four and eight inches (4''-8''),
and having a density of between about one and about four pounds per
cubic feet (.about.1 to .about.4 lb/ft.sup.3); a first intermediary
layer defining a top surface, a bottom surface, and a perimeter
wall between said top surface and said bottom surface, said base
layer top surface being secured to said first intermediary layer
bottom surface in a conventional manner, said first intermediary
layer being constructed from a foam material defining an ILD Rating
of between about 10 and about 25 and having a highly-open, cool,
and responsive polymer structure, said first intermediary layer
defining a thickness of about 1.5'' to about 3'', said first
intermediary layer having a density of between about two and about
four pounds per cubic feet (.about.2 to .about.4 lb/ft.sup.3); and
a second intermediary layer defining a top surface, a bottom
surface, and a perimeter wall between said top surface and said
bottom surface, said first intermediary layer top surface being
secured to said second intermediary layer bottom surface in a
conventional manner, said second intermediary layer being
constructed from a foam material defining an ILD Rating of between
about 10 and about 25 and having a highly-open, cool, and
responsive polymer structure, said second intermediary layer
defining a thickness of about 1.5'' to about 3'', wherein said
first intermediary layer ILD Rating is greater than said second
intermediary layer ILD Rating, said second intermediary layer
having a density of between about two and about four pounds per
cubic feet (.about.2 to .about.4 lb/ft.sup.3); a top layer
fabricated from a vertically-oriented synthetic memory fiber blend
comprised of bi-copolymer fibers and fibers having spring-like
molecular structure, said top layer defining a top surface, a
bottom surface, and a perimeter wall between said top surface and
said bottom surface, said top layer bottom surface being secured to
said base layer top surface in a conventional manner, said top
layer defining a thickness of between 0.75'' and 1.25'' and a
weight of between about 200 to about 500 grams per square yard,
said second intermediary layer top surface is secured to said top
layer bottom surface in a conventional manner; a cover layer
defining a top surface, a bottom surface, and a perimeter wall
between said top surface and said bottom surface, said cover layer
being disposed above said top layer, being fabricated from a
selected foam material, and defining a thickness of up to about one
inch (1''); a cover member configured to closely and selectively
receive said base layer, said first intermediary layer, said second
intermediary layer, said top layer, and said cover layer, said
cover member including a conventional closure member to allow for
selective removal of said cover, said cover member being provided
with at least one handle for assisting in movement and transport of
said mattress.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Patent
Application No. 62/305,756, entitled "Mattress", filed on Mar. 9,
2016, the contents of which are incorporated herein by
reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure is directed to an improved mattress
construction. The improved mattress is of a multilayered
construction.
BACKGROUND
[0003] Traditional sleeping surfaces in the form of mattresses have
been used for many years. Mattresses have evolved to address many
problems associated with sleep, including weight distribution,
pressure points, temperature, and the like. Materials have also
been developed in an attempt to improve on the quality of sleep
provided for a particular user.
[0004] Common mattress constructions are numerous. While air
mattresses and water mattresses are common, the most common are
coil mattresses and, more recently, foam mattresses. Foam
mattresses include either single- or multi-layer constructions. In
multi-layer constructions, a soft top layer of a memory foam
mattress or bed topper can be a real advantage in pressure point
reduction. However, a foam layer that is too soft, or too thick of
a very soft surface layer, especially without enough support
underneath, can be problematic for low back sufferers. Thus, some
memory foam mattresses use a layered effect that properly offers a
supple enough surface to disburse pressure points, but gradually
firms up in the layers below, with a very resilient support base
used in the final layer.
BRIEF DESCRIPTION OF THE FIGURES
[0005] The accompanying figures, where like reference numerals
refer to identical or functionally similar elements throughout the
separate views, together with the detailed description below, are
incorporated in and form part of the specification, and serve to
further illustrate embodiments of concepts that include the claimed
invention, and explain various principles and advantages of those
embodiments.
[0006] FIG. 1 is an isometric cross-section view of a preferred
embodiment of a mattress of the present invention;
[0007] FIG. 2 is an isometric cross-section view of an alternate
embodiment of a mattress of the present invention;
[0008] FIG. 3 is an isometric cross-section view of a further
alternate embodiment of a mattress of the present invention;
[0009] FIG. 4 is a top isometric view of a mattress of the present
invention illustrating a cover encasing the mattress core;
[0010] FIG. 5 is an isometric view of the a mattress of the present
invention showing the bottom side of the cover of FIG. 4 further
illustrating handles and a zipper;
[0011] FIG. 6 is a perspective view of a mattress of the present
invention shown in a folded and compressed state and stored in a
container;
[0012] FIG. 7 is a perspective view of a mattress of the present
invention shown in a folded and compressed state;
[0013] FIG. 8 is a perspective view of a mattress of the present
invention shown in a folded state;
[0014] FIG. 9 is a perspective view of a mattress of the present
invention shown expanding from the folded state illustrated in FIG.
8;
[0015] FIG. 10 is a perspective view of a mattress of the present
invention shown installed on a conventional bed frame;
[0016] FIG. 11 is a perspective view of a mattress of the present
invention shown installed on a conventional bed frame; and
[0017] FIG. 12 is a perspective view of a mattress of the present
invention shown installed on a conventional bed frame.
[0018] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions of
some of the elements in the figures may be exaggerated relative to
other elements to help to improve understanding of embodiments of
the present invention.
[0019] The apparatus and method components have been represented
where appropriate by conventional symbols in the drawings, showing
only those specific details that are pertinent to understanding the
embodiments of the present invention so as not to obscure the
disclosure with details that will be readily apparent to those of
ordinary skill in the art having the benefit of the description
herein.
DETAILED DESCRIPTION
[0020] The present invention is a mattress 10 constructed with a
plurality of independent layers, each constructed to define a
selected characteristic. The mattress 10 defines a total thickness
of between approximately 4.75'' and approximately 15.25''. However,
it is envisioned that the mattress 10 could define a thickness of
less than 4.75'' or greater than 15.25''.
[0021] A bottom layer 20 is provided as a base or structure layer.
The base layer 20 is constructed from a responsive polymer
structure that is designed to offer a superior structure. The base
layer 20 defines a thickness of between four and eight inches
(4''-8''). However, it will be understood that the base layer 20
may define a thickness of less than four inches or greater than
eight inches.
[0022] The base layer 20 is constructed of a foam material defining
an Indentation Level Deflection (ILD) Rating of between 25 and 35
pounds. The ILD rating is an indication of how hard or soft a
material is. The ILD rating is the number of pounds required to
achieve a 25% compression of a foam layer using a 50 square inch
indentation. Thus, a higher ILD rating is indicative of a firmer
material and, conversely, the lower ILD rating is indicative of a
softer material. The ILD rating is synonymous with the Indentation
Force Deflection (IFD) Rating, which is still in use but was
developed for sole the purpose of grading polyurethane foam.
[0023] The density of the base layer 20 of the preferred embodiment
is between one and four pounds per cubic feet (1-4
lb/ft.sup.3).
[0024] A top layer 30 is secured to the base layer 20 in a
conventional manner. In the embodiment illustrated in FIG. 1, the
top layer 30 is the uppermost layer, closest to the body of the
person(s) lying on the mattress 10. The top layer 30 is constructed
with selected materials and in such as a way as to provide an
enhanced comfort layer. The preferred material is fabricated from a
vertically-oriented synthetic memory fiber blend. This material is
manufactured by orienting the fibers vertically as opposed to
horizontally, thereby enhancing various characteristics of the
material. Among these are its compressibility and breathability,
even in a compressed state. The top layer 30 provides gentle
resilience and sure shape recovery to the mattress. To this end,
the memory fibers blends bi-copolymer fibers with fibers having
spring-like molecular structure. It is the product of a world
leading advancement in polymer, fibers process technology and
expertise. The top layer 30 offers superior breathability that
provides for improved air flow and cooling factor, resulting in
less heat retention than existing standard foam mattresses. The
material comprising the top layer 30 of the preferred embodiment
provides other environmental advantages. Namely, it is
environmentally friendly, 100% recyclable and is hypoallergenic.
The top layer 30 does not emit dangerous fumes, is
mildew-resistant, mold-resistant, and flame-resistant. Because of
the vertical orientation of the fibers, the top layer 30 drains
fluids and is highly breathable. One satisfactory material is
Polyester.
[0025] The top layer 30 defines a thickness of between 0.75'' and
1.25''. The top layer 30 of the preferred embodiment defines a
weight of between approximately 200 to 500 grams per square
yard.
[0026] The mattress 10 of the present invention may further include
one or more intermediary layers of a selected foam material.
Illustrated in FIG. 2, an alternative construction of a mattress
10' includes a second layer 22 and a third layer 24 disposed
between the base layer 20 and the top layer 30. It will be
understood that either of the second and third layers 22,24 could
be eliminated in further alternate mattress embodiments. In these
embodiments, the top layer 30 and any intermediary layers 22,24
define a combined thickness at least equal to the cradle needed,
and, more preferably, thicker.
[0027] In the illustrated embodiment, the second layer 22 is
secured to the base layer 20 in a conventional manner, as will be
disclosed hereinafter. The second layer 22 is constructed to
provide comfort and pressure point distribution. The second layer
22 is constructed from a foam material having a highly-open, cool,
and responsive polymer structure that is designed to offer a
superior alternative to latex or coil springs while providing
outstanding pressure relief properties. The thickness of the second
layer 22 in the preferred embodiment is 1.5'', but may be as thick
as approximately 3''. However, it will be understood that the
second layer 22 may define a thickness of greater than three
inches. The second layer is constructed of a foam material defining
an ILD Rating of between 10 and 25. The density of the second layer
22 of the preferred embodiment is between two and four pounds per
cubic feet (2-4 lb/ft.sup.3).
[0028] A third layer 24 is secured to the second layer 22 in a
conventional manner. The third layer 24 is provided primarily to
adapt the mattress to the contour of the person or persons lying on
the mattress. The third layer 24 is constructed from a foam
material having a highly-open, cool, and responsive polymer
structure that is designed to offer a superior alternative to latex
or coil springs while providing outstanding pressure relief
properties. The thickness of the third layer 24 in the preferred
embodiment is 1.5'', but may be as thick as approximately 3''.
However, it will be understood that the third layer 24 may define a
thickness of greater than three inches. The third layer 24 is
constructed of a foam material defining an ILD Rating of between 10
and 25. In the preferred embodiment, the ILD Rating of the third
layer 24 is lower, or softer, than that of the second layer 22. The
density of the third layer 24 of the preferred embodiment is
between two and four pounds per cubic feet (2-4 lb/ft.sup.3).
[0029] In this type of construction, the top layer 30 is designed
to do all the work of forming a pressure relieving cradle and
supporting the recessed lumbar area. The base layer 20 and
intermediary layers 22,24 are provided for keeping the spine in
alignment by preventing any further sinking down by the heavier
parts of the body. Each individual layer 22, 24, 30 has all the
qualities that are necessary by itself, as it does not "borrow"
qualities from the layer 20, 22, 24, respectively, below it. For
pressure relief, it needs enough softness and point elasticity, and
for lumbar support it needs a higher sag factor and resiliency. For
example, for a 3'' cradle for good pressure relief, the top layer
30 and intermediary layers 22,24 are collectively configured to
define a thickness of between approximately 3''-3.5''. For a 2''
cradle for pressure relief, the top layer 30 and intermediary
layers 22,24 are collectively configured to define a thickness of
between approximately 2''-2.5''. The top layer 30 and intermediary
layers 22,24 of the preferred embodiment define a combined
thickness at least equal to the cradle needed, and, more
preferably, thicker. In one preferred embodiment, the mattress
includes a base layer 20 defining a thickness of six inches (6''),
an intermediary layer 22 defining a thickness of three inches
(3''), and a top layer 30 defining a thickness of one inch
(1'').
[0030] In a further preferred embodiment illustrated in FIG. 3, a
mattress 10'' a cover layer 32 is provided to be placed above the
top layer 30 in a conventional manner. The cover layer 32 is
provided for additional comfort. The cover layer 32 is fabricated
from a selected foam material and defines a thickness of up to one
inch (1''). The foam material is selected from memory foam, regular
foam, and latex. The cover layer 32 may be secured to the top layer
and integrally with the mattress. Alternatively, the cover layer 32
may be removably placed on top of either of the mattresses 10,10'
illustrated in FIGS. 1 and 2, respectively.
[0031] The individual layers 20, 22, 24, 30, 32 are secured to each
other as discussed above in a conventional manner. In one
embodiment, each successive layer 22, 24, 30, 32 is glued to the
preceding layer 22, 24, 30, 32 (the top layer 30 is secured to the
base layer 20, or the second or third layer 22,24 if either or both
are provided, etc.) using a water-based adhesive having low odor
and being a low-volatile, organic compound. In this assembly
method, the mattress 10, 10', 10'' is cured for from approximately
6 hours to approximately 18 hours. It is then inserted into a
fire-retardant sewn fabric. It is also covered by an aesthetic
cover made of special selected material that improves air flow,
cooling and wicking out the humidity coming from the body.
[0032] In one preferred embodiment of the present invention, as
best illustrated in FIG. 4, a cover 40 is provided to encase the
various layers 20, and 30, and optionally 22, 24, and 32, as
provided in the particular mattress 10, 10', 10''. The cover 40 of
the preferred embodiment is fabricated from a specially-weaved
fabric using a Micro Tencel.TM. fiber yarn. This new botanic fiber
renders the cover more absorbent than cotton, softer than silk and
cooler than linen.
[0033] The cover 40 fabric or the yarn from which the fabric is
produced is also treated with Ferran Ice.TM. to bring the
hydrophilic property to a higher level in order to have the best
comfort level.
[0034] The upper section 44 of the cover side walls 42 is composed
of a breathable mesh-type fabric to enhance air flow and
breathability qualities. The width of the upper section 44 is from
approximately one inch to approximately four inches The cover 40 of
the preferred embodiment is of a fabric weight of from
approximately 140 to approximately 900 grams per square yard. The
fabric may be designed with any pattern to the taste of the
user.
[0035] At least one handle 48 may be provided and secured to the
cover 40 in a conventional fashion. In the illustrated embodiment
of FIG. 5, four handles 48 are mounted on the bottom surface 46 of
the cover 40, with two handles 48 being spaced apart and mounted on
either of the long edges of the mattress 10. The handles 48 provide
a mechanism to handle the mattress 10 during transport, set up and
take down thereof. The handles 48 of the illustrated embodiment are
fabricated from conventional flexible materials such as but not
limited to nylon webbing, and may be folded under the mattress 10
in order to conceal them from view ad so as not to provide a
hindrance for the placement of a conventional mattress pad or bed
sheets. However, it will be understood by those skilled in the art
that the handles 48 do not alter the function of the mattress 10
and are therefore not required as a part of the present
invention.
[0036] A zipper 50 is secured in the cover 40 to assist with
inserting the mattress 10 core comprised of the various layers 20,
30, and optionally 22, 24 and 32. In the illustrated embodiment,
the zipper 50 is disposed along at least a portion of the periphery
of the bottom surface 46 of the cover 40.
[0037] FIGS. 6-12 are various illustrations of a mattress 10 of the
present invention. FIG. 6 illustrates a mattress 10 shown in a
folded and compressed state and stored in a box. In this
illustration, the box has been opened to remove the mattress 10, as
would be done for shipping. FIG. 7 illustrates the mattress 10 of
FIG. 6 having been removed from the box. After the packaging has
been removed from the mattress 10, it begins to decompress and then
unfold, as illustrated in FIGS. 8 and 9, until it lies flat, as
illustrated in FIGS. 10-12. In FIGS. 10-12, the mattress 10 is
installed on a conventional bed frame.
* * * * *