U.S. patent application number 17/691009 was filed with the patent office on 2022-09-15 for adjustable mattress side rails.
The applicant listed for this patent is Purple Innovation, LLC. Invention is credited to Jordan Campbell, Aubree Carter, Brett Pearson.
Application Number | 20220287469 17/691009 |
Document ID | / |
Family ID | 1000006239516 |
Filed Date | 2022-09-15 |
United States Patent
Application |
20220287469 |
Kind Code |
A1 |
Pearson; Brett ; et
al. |
September 15, 2022 |
ADJUSTABLE MATTRESS SIDE RAILS
Abstract
A side rail of a mattress that may be used with an adjustable
bed may include a main body that facilitate adjustment of the
mattress while maximizing contact between a bottom of the mattress
and an upper supporting surface of an adjustable bedframe. More
specifically, the main body of the side rail may include a top edge
with one or more upper recesses therein and a bottom edge with one
or more lower recesses therein. An upper insert may be secured
within each upper recess, while a lower insert may be secured
within each lower recess. The material from which each upper insert
and lower insert is formed may be more compressible than a material
from which the main body of the side rail is formed to enable the
side rail and the mattress to bend with the supporting surface of
the adjustable bedframe.
Inventors: |
Pearson; Brett;
(Taylorsville, UT) ; Carter; Aubree; (Lehi,
UT) ; Campbell; Jordan; (Lehi, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Purple Innovation, LLC |
Lehi |
UT |
US |
|
|
Family ID: |
1000006239516 |
Appl. No.: |
17/691009 |
Filed: |
March 9, 2022 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
63158753 |
Mar 9, 2021 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 21/026
20130101 |
International
Class: |
A47C 21/02 20060101
A47C021/02 |
Claims
1. A side rail for a mattress for an adjustable bed, comprising: a
main body comprising a first material having a first rigidity and a
first compressibility; at least one upper recess extending into a
top edge of the main body, partially into a height of the main
body, and across an entirety of a width of the main body, the at
least one upper recess including: a base adjacent to but spaced
apart from a bottom edge of the main body; a head surface extending
at a non-perpendicular angle to the top edge, to the base and
toward a foot end of the main body; and a foot surface extending at
a non-perpendicular angle to the top edge, to the base and toward a
head end of the main body; at least one upper insert substantially
filling the at least one upper recess, the at least one upper
insert comprising a second material and including a top edge
coplanar with the top edge of the main body, a base adjacent to the
base of the at least one upper recess, a head surface adjacent to
the head surface of the at least one upper recess, and a foot
surface adjacent to the foot surface of the at least one upper
recess; at least one lower recess extending into the bottom edge of
the main body, partially into the height of the main body, and
across the entirety of the width of the main body, the at least one
lower recess including: a top adjacent to but spaced apart from the
top edge of the main body; a head surface extending at an angle to
the bottom surface, to the top; and a foot surface extending at an
angle to the bottom surface, to the top; and at least one lower
insert substantially filling the at least one lower recess, the at
least one lower insert comprising a third material and including a
bottom edge coplanar with the bottom edge of the main body, a top
adjacent to the top of the at least one lower recess, a head
surface adjacent to the head surface of the at least one lower
recess, and a foot surface adjacent to the foot surface of the at
least one lower recess.
2. The side rail of claim 1, wherein the at least one upper recess
is positioned at a location where an upper surface of the mattress
is expected to bend concavely.
3. The side rail of claim 1, wherein the at least one lower recess
is positioned at a location where the upper surface of the mattress
is expected to bend convexly.
4. The side rail of claim 1, comprising a plurality of upper
recesses, a plurality of upper inserts, a plurality of lower
recesses, and a plurality of lower inserts.
5. The side rail of claim 4, wherein the plurality of upper
recesses and the plurality of upper inserts are grouped
together.
6. The side rail of claim 4, wherein the plurality of lower
recesses and the plurality of lower inserts are grouped
together.
7. The side rail of claim 1, wherein the base of the at least one
upper recess is defined by a junction between the head surface and
the foot surface of the at least one upper recess.
8. The side rail of claim 1, wherein the base of the at least one
upper recess is elongated.
9. The side rail of claim 8, wherein the base of the at least one
upper recess is substantially parallel to the bottom edge of the
main body.
10. The side rail of claim 1, wherein the top of the at least one
lower recess is defined by a junction between the head surface and
the foot surface of the at least one lower recess.
11. The side rail of claim 1, wherein the top of the at least one
lower recess is elongated.
12. The side rail of claim 11, wherein the top of the at least one
lower recess is substantially parallel to the top edge of the main
body.
13. The side rail of claim 1, wherein the second material and the
third material are less rigid and more compressible than the first
material.
14. A mattress for an adjustable bed, comprising: a foundation
including a base, a head rail, a foot rail, and a pair of side
rails defining a receptacle, each side rail including: a main body
formed from a first compressible material and including a top edge
with at least one upper recess therein and a bottom edge with at
least one lower recess therein; at least one upper insert formed
from a second compressible material secured within the at least one
upper recess; at least one lower insert formed from a third
compressible material secured within the at least one lower recess;
a cushioning element within the receptacle defined by the
foundation; and a cover over the cushioning element, the head rail,
the foot rail, and the pair of side rails of the foundation.
15. The mattress of claim 14, wherein the at least one upper recess
and the at least one upper insert has a shape of a triangular
prism.
16. The mattress of claim 15, wherein the at least one lower recess
and the at least one lower insert has a shape of a triangular
prism, a trapezoidal prism, or a rectangular prism.
17. The mattress of claim 14, wherein the second compressible
material and the third compressible material are more compressible
than the first material.
18. The mattress of claim 14, further comprising: a gel cushion
over the cushioning element and comprising interconnected walls
formed from an elastomeric material and defining an array of
columnar voids.
19. The mattress of claim 14, wherein the cushioning element
comprises an array of coils and/or at least one pressurizable
bladder.
20. An adjustable bed, comprising: an adjustable frame including: a
support surface including a plurality of support elements; at least
one concavely bending joint between a head support element and an
intermediate support element of the plurality of support elements;
and at least one convexly bending joint between the intermediate
support element and a foot support element of the plurality of
support elements; and a mattress on a support surface of the
adjustable frame and including: a foundation including a base, a
head rail, a foot rail, and a pair of side rails defining a
receptacle, each side rail including: a main body formed from a
first compressible material and including a top edge with at least
one upper recess therein, the upper recess positioned over the at
least one concavely bending joint of the adjustable frame, and a
bottom edge with at least one lower recess therein, the at least
one lower recess positioned over the at least one convexly bending
joint of the adjustable frame; at least one upper insert formed
from a second compressible material secured within the at least one
upper recess; at least one lower insert formed from a third
compressible material secured within the at least one lower recess;
a cushioning element within the receptacle defined by the
foundation; and a cover over the cushioning element, the head rail,
the foot rail, and the pair of side rails of the foundation.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] A claim for priority to the Mar. 9, 2021 filing date of U.S.
Provisional Patent Application No. 63/158,753, titled ADJUSTABLE
MATTRESS SIDE RAILS ("the '753 Provisional Application"), is hereby
made pursuant to 35 U.S.C. .sctn. 119(e). The entire disclosure of
the '753 Provisional Application is hereby incorporated herein.
TECHNICAL FIELD
[0002] This disclosure relates generally to internal side edges, or
side rails, for mattresses and, more specifically, to side rails
for mattresses that may be used with adjustable beds. Even more
specifically, this disclosure relates to side rails with main
bodies that impart lateral structure to a mattress of which they
are a part and compressible inserts that facilitate adjustment of
the mattress while maximizing contact between a bottom of the
mattress and an upper supporting surface of an adjustable bedframe.
This disclosure also relates to mattresses, to adjustable beds, and
to associated methods.
RELATED ART
[0003] Adjustable beds provide for adjustment of the mattresses
thereon and of each individual laying on the mattress. An
adjustable bed typically bends at two or more locations across its
width to provide three sections that may be oriented for a variety
of purposes. By way of example, an upper, or head, section of a
mattress on an adjustable bed may be oriented to position an
individual's head and back in a somewhat upright orientation, in
more reclined orientations, or in a substantially horizontal
orientation. As another example, a lower, or foot, section of a
mattress on an adjustable bed may be oriented to position an
individual's feet between inclined, horizontal, and reclined
orientations. An intermediate section of the mattress on an
adjustable bed may provide a transition between the head section
and the foot section.
[0004] Conventionally, adjustable beds have found wide use in
hospitals, care centers, and at other locations where individuals
may need assistance in sitting up as they convalesce, where it may
be desirable to occasionally change an individual's orientation as
he or she lays in bed, or for other purposes. Individuals also use
adjustable beds at home, as they many people enjoy laying in
non-flat orientations as they rest or sleep. In addition, many
people have found adjustable mattresses to provide certain
additional benefits in helping them obtain a good night's rest, as
well as health benefits, including, without limitation, the ability
to improve breathing during sleep (e.g., by elevating the
individual's head, neck, and back, etc.).
[0005] As a mattress is adjusted, or bent, by an adjustable
bedframe, the side rails of the mattress are compressed at
locations where the top of the mattress is bent concavely and
stretched at locations where the top of the mattress is bent
convexly. Conventional mattresses, however, resist such bending,
compression, and stretching somewhat. As a result, the bottom of a
conventional mattress usually does not conform well to the upper
supporting surface of an adjustable bedframe, particularly at
corners where the upper supporting surface of the adjustable
bedframe is bent concavely, where the bottom of the mattress
remains suspended above the concavely bent upper supporting surface
of the adjustable bedframe.
[0006] One attempted solution has been to provide
mattress-retaining brackets at the head and foot ends of adjustable
bedframes. Due to their locations, such brackets are unable to
influence bending at intermediate locations along the length of the
mattress. Other attempted solutions have been to provide weakened
regions (e.g., cutouts, accordion-like features, etc.) along the
internal side edges, or side rails, of the mattress. Although
weakened regions reduce the mattress's resistance to bending, they
also reduce the structural integrity of the side rails.
SUMMARY
[0007] In various embodiments, a side rail of an adjustable
mattress according to this disclosure has a configuration that
enables its bottom edge and, thus, a bottom of a mattress of which
it is a part, to conform to bends in an upper supporting surface of
an adjustable bedframe.
[0008] A side rail according to this disclosure may include a main
body with at least one upper recess and at least one lower recess,
an upper insert within the at least one upper recess, and a lower
insert within the at least one lower recess. In some embodiments,
the side rail may include a plurality of upper recesses and
corresponding upper inserts and/or a plurality of lower recesses
and corresponding lower inserts.
[0009] Each upper recess may extend downwardly into a top edge of
the main body, partially into the height of the main body, and
across an entirety of a width of the main body. Each lower recess
may extend upwardly into a bottom edge of the main body, partially
into the height of the main body, and across an entirety of a width
of the main body. Without limitation, an upper recess may have the
shape of a triangular prism, a substantially triangular prism
(accounting for more radiused or truncated corners, curvatures in
surfaces, etc.), a trapezoidal prism, a substantially trapezoidal
prism (accounting for more radiused or truncated corners,
curvatures in surfaces, etc.), or the like. A lower recess may have
the shape of a triangular prism, a substantially triangular prism
(accounting for more radiused or truncated corners, curvatures in
surfaces, etc.), a trapezoidal prism, a substantially trapezoidal
prism (accounting for more radiused or truncated corners,
curvatures in surfaces, etc.), a rectangular prism, a substantially
rectangular prism (accounting for more radiused or truncated
corners, curvatures in surfaces, etc.), or the like.
[0010] The shape, dimensions, and location of each upper recess and
each lower recess in the main body of a side rail may enable the
upper recess and/or lower recess to accommodate bending of a
mattress of which the side rail is a part, as well as enable a
bottom of the mattress to maintain optimal contact with an upper
supporting surface of an adjustable bedframe that carries the
mattress. More specifically, each upper recess may be located at a
position where an upper supporting surface of the adjustable
bedframe and, thus, a top of a mattress thereon are expected to be
bent at a concave angle. Each lower recess may be located at a
position where the upper supporting surface of the adjustable
bedframe and the top of the mattress thereon are expected to be
bent at a convex angle.
[0011] The main body may comprise a material having a rigidity that
imparts the side rail with sufficient structural integrity to
laterally support a remainder of the mattress of which the side
rail is a part. The material of the main body may also be
compressible to prevent it from detracting from the overall
compressibility and comfort provided by the mattress of which the
side rail is a part.
[0012] An upper insert may be provided in each upper recess of the
side rail, while a lower insert may be provided in each lower
recess of the side rail. Each upper insert may substantially fill
its corresponding upper recess. Thus, each upper insert may have a
shape or configuration that complements, is the same as, or is
substantially the same as a shape or configuration of the upper
recess in which the upper insert is positioned. Each upper insert
may be secured within its corresponding upper recess in a suitable
manner (e.g., with a suitable cement or other adhesive material,
etc.). Each lower insert may substantially fill its corresponding
lower recess. Thus, each lower insert may have a shape or
configuration that complements, is the same as, or is substantially
the same as a shape or configuration of the lower recess in which
the lower insert is positioned. Each lower insert may be secured
within its corresponding lower recess in a suitable manner (e.g.,
with a suitable cement or other adhesive material, etc.).
[0013] A shape of each upper insert and each lower insert and a
material from which each upper insert and each lower insert is
formed may enables the side rail to readily flex when the mattress
of which it is a part is bent in a corresponding direction. For
example, the shape and material of each upper insert may enable the
side rail to readily flex when a top of the mattress is bent
concavely at a location where the upper insert is located. As
another example, the shape and material of each lower insert may
enable the side rail to readily flex when a top of the mattress is
bent convexly at a location where the lower insert is located.
Without limitation, the shape of each upper insert may be a
triangular prism, a substantially triangular prism, or the like,
while the shape of each lower insert may be a triangular prism, a
substantially triangular prism, a trapezoidal prism, a
substantially trapezoidal prism, a rectangular prism, a
substantially rectangular prism, or the like.
[0014] The material from which each upper insert and each lower
insert is formed may be readily compressible, but have sufficient
rigidity to impart the side rail with acceptable structural
integrity. By way of example only, each upper insert and each lower
insert may comprise a compressible, resilient material. The
compressible, resilient material may comprise a foam.
[0015] In another aspect, this disclosure includes mattresses that
include side rails according to this disclosure. The side rails of
such a mattress may, along with a base, a head rail, and a foot
rail, define a foundation for a cushioning element of the mattress.
More specifically, the elements of the foundation may define a
receptacle for the cushioning element. The cushioning element may
comprise coil springs, pressurizable bladders, memory foam, or any
other suitable cushioning element for a mattress, or a combination
of cushioning elements.
[0016] Additionally, such a mattress may include a gel cushion,
such as those disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and
8,919,750, the entire disclosures of which are hereby incorporated
herein. Such a gel cushion may include a plurality of resiliently
compressible interconnected or intersecting walls defining an array
of interconnected, resiliently buckling columns, with a void in
each column. Stated another way, the interconnected or intersecting
walls may define an array of hollow columns, or voids. Such a gel
cushion may be formed from any of a variety of compressible,
resilient materials, including cushioning foams and elastomeric
materials, such as the extended A B A triblock copolymers disclosed
by U.S. Pat. Nos. 6,413,458, 6,797,765, and 7,964,664, the entire
disclosures of which are hereby incorporated herein.
[0017] In addition, the mattress may include a cover over the
foundation, cushioning element, and any gel cushion over the
foundation and cushioning element.
[0018] As another aspect, adjustable beds are disclosed. An
adjustable bed of this disclosure includes an adjustable bedframe
and a mattress that includes side rails according to this
disclosure.
[0019] Other aspects of the disclosed subject matter, as well as
features and advantages of various aspects of the disclosure,
should be apparent to those of ordinary skill in the art through
consideration of the preceding disclosure, the description that
follows, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the drawings:
[0021] FIG. 1 is a side view of an embodiment of a side rail that
may be included in an adjustable mattress;
[0022] FIG. 2 is an enlarged view of the upper recesses and upper
inserts of the embodiment of the side rail shown in FIG. 1;
[0023] FIG. 3 is a side view of the embodiment of the side rail
shown in FIG. 1, with the top edge of the side rail bent concavely
between the two upper recesses and upper inserts shown in FIG.
2;
[0024] FIG. 4A is a perspective view another embodiment of a side
rail that may be included in an adjustable mattress;
[0025] FIG. 4B is a top view of the embodiment of the side rail
shown in FIG. 4A;
[0026] FIG. 4C is a side view of the embodiment of the side rail
shown in FIG. 4A;
[0027] FIG. 4D is an end view of the embodiment of the side rail
shown in FIG. 4A;
[0028] FIG. 5A is a perspective view of yet another embodiment of a
side rail that may be included in an adjustable mattress;
[0029] FIG. 5B is a top view of the embodiment of the side rail
shown in FIG. 5A;
[0030] FIG. 5C is a side view of the embodiment of the side rail
shown in FIG. 5A;
[0031] FIG. 5D is a bottom view of the embodiment of the side rail
shown in FIG. 5A; and
[0032] FIG. 6 is a perspective view of the interior of an
embodiment of a mattress that includes the embodiment of the side
rail shown in FIGS. 4A-4D.
DETAILED DESCRIPTION
[0033] With reference to FIGS. 1 and 2, an embodiment of a side
rail 10 for an adjustable mattress (not shown in FIG. 1 or FIG. 2)
is depicted. The side rail 10 includes a main body 20 with a top
edge 22, a bottom edge 24, a head end 26, and a foot end 28. One or
more upper recesses 30 may open to the top edge 22 of the main body
20 and extend toward the bottom edge 24 of the main body 20. One or
more lower recesses 40 may open to the bottom edge 24 of the main
body 20 and extend toward the top edge 22 of the main body 20. An
upper insert 60 may be provided in each upper recess 30. A lower
insert 70 may be provided in each lower recess 40.
[0034] A height of the main body 20 and, thus, of the side rail 10
extends between the top edge 22 and bottom edge 24 of the main body
20. The main body 20 also includes an interior surface 21, which
faces an interior of a mattress (not shown in FIG. 1 or FIG. 2) of
which the side rail 10 is a part, as well as an exterior surface
29, which is opposite from the interior surface 21 and faces
outwardly when the side rail 10 is assembled with other components
of the mattress. Both the interior surface 21 and the exterior
surface 29 extend between the top edge 22 and the bottom edge 24 of
the side rail 20. A width of the main body 20 and, thus, of the
side rail 10 extends between the interior surface 21 and exterior
surface 29 of the main body 20.
[0035] The main body 20 may be formed from a material having a
rigidity that imparts the side rail 10 with sufficient structural
integrity to laterally support a remainder of the mattress (not
shown in FIG. 1 or FIG. 2) of which the side rail 10 is a part. The
material of the main body 20 may also be compressible to prevent it
from detracting from the overall compressibility and comfort
provided by the mattress of which the side rail 10 is a part. In a
specific embodiment, the main body 20 may comprise a so-called
"structured foam," which may comprise a compressible foam material
with an indentation load deflection (ILD) rating of about 35 to
about 65 (e.g., 40, 45, 50, 55, 60, 65, etc.). An ILD rating is the
amount of pressure, converted to weight in pounds, it takes to
indent a circular area of 50 square inches (i.e., lbs/50 in.sup.2)
over a four inch thick piece of the structured foam by 25% (i.e.,
one inch). In a specific embodiment, the main body 20 may comprise
a high density polyethylene (HDPE) foam.
[0036] Each upper recess 30 may extend downwardly into the top edge
22 of the main body 20, partially into the height of the main body
20, and across an entirety of the width of the main body 20. Each
upper recess 30 may include: a base 32 adjacent to but spaced apart
from the bottom edge 24 of the main body 20; a head surface 34
extending at a non-perpendicular angle to the top edge 22, from the
top edge 22 to the base 32 and toward the foot end 28 of the main
body 20; and a foot surface 36 extending at a non-perpendicular
angle to the top edge 22, from the top edge 22 to the base 32 and
toward the head end 26 of the main body 20. The base 32 of the
upper recess 30 may be defined by a junction between the head
surface 34 and the foot surface 36 of the upper recess 30. In some
embodiments, that junction may be radiused (e.g., it may comprise
an arc of a circle, etc.) or otherwise rounded. Alternatively, the
base 32 of the upper recess 30 may be elongated. An elongated base
32 may be substantially parallel to the bottom edge 24 of the main
body 20.
[0037] Each upper recess 30 may be positioned at a location along
the length of the main body 20 of the side rail 10 where the top of
the mattress (not shown in FIG. 1 or FIG. 2) is expected to be bent
concavely. For example, each upper recess 30 may be positioned at a
location that will be superimposed over a joint between a head
section and an intermediate section of an adjustable bedframe (not
shown in FIG. 1 or FIG. 2). Alternatively, a plurality of upper
recesses 30 may be positioned locations that will be superimposed
with an area on both sides of a joint between the head section and
the intermediate section of the adjustable bedframe. As illustrated
by FIGS. 1 and 2, the upper recesses 30 are positioned between or
at a transition between a head portion 12 of the side rail 10 and
an intermediate portion 14 of the side rail 10.
[0038] The side rail 10 may include a main body 20 with a plurality
of upper recesses 30. In the embodiment shown in FIGS. 1 and 2, the
side rail 10 may include two upper recesses 30. In the embodiment
of side rail 10' shown in FIGS. 4A-4D, the main body 20' may
include four upper recesses 30'. Regardless of how many upper
recesses 30 are included, they may be grouped together.
[0039] With continued reference to FIGS. 1 and 2, each lower recess
40 in the bottom edge 24 of the main body 20 of the side rail 10
extends upwardly from the bottom edge 24 into the main body 20,
partially into the height of the main body 20, and across an
entirety of the width of the main body 20. Each lower recess 40 may
include: a top 42 adjacent to but spaced apart from the top edge 22
of the main body 20; a head surface 44 extending at an angle (e.g.,
a non-perpendicular angle, a perpendicular angle, etc.) to the
bottom edge 24, from the bottom edge 24 to the top 42 of the main
body 20 and, in embodiments where the angle is a non-perpendicular
angle, toward the foot end 28 of the main body 20; and a foot
surface 46 extending at an angle (e.g., a non-perpendicular angle,
a perpendicular angle, etc.) to the bottom edge 24, from the bottom
edge 24 to the top 42 and, in embodiments where the angle is a
non-perpendicular angle, toward the head end 26 of the main body
20. The top 42 of the lower recess 40 may be defined by a junction
between the head surface 44 and the foot surface 46 of the upper
recess 40. In some embodiments, that junction may be radiused or
otherwise rounded. Alternatively, the top 42 of the lower recess 40
may be elongated. An elongated top 42 may be substantially parallel
to the top edge 22 of the main body 20.
[0040] Each lower recess 40 may be positioned at a location along
the length of the main body 20 of the side rail 10 where the top of
the mattress (not shown in FIG. 1 or FIG. 2) is expected to be bent
convexly. For example, each lower recess 40 may be positioned at a
location that will be superimposed over a joint between an
intermediate section and a foot section of an adjustable bedframe
(not shown in FIG. 1 or FIG. 2). Alternatively, a plurality of
lower recesses 40 may be positioned at locations that will be
superimposed with an area on both sides of a joint between the
intermediate section and the foot section of the adjustable
bedframe. As illustrated by FIG. 1, the lower recess 40 is
positioned between or at a transition between the intermediate
portion 14 of the side rail 10 and a foot portion 16 of the side
rail 10.
[0041] The side rail 10 may include one or more lower recesses 40.
In the embodiment depicted by FIGS. 1 and 2, the side rail 10 may
include a single lower recess 40. In the embodiment of side rail
10' shown in FIGS. 4A-4D, the main body 20' may include two lower
recesses 40'. Regardless of how many lower recesses 40 are
included, they may be grouped together.
[0042] An upper insert 60 may be provided in each upper recess 30
of the main body 20 of the side rail 10. Each upper insert 60 may
substantially fill its corresponding upper recess 30 and include a
top edge 62 that is coplanar or substantially coplanar with the top
edge 22 of the main body 20, a base 64 adjacent to the base 32 of
the corresponding upper recess 30, a head surface 66 adjacent to
the head surface 34 of the corresponding upper recess 30, and a
foot surface 68 adjacent to the foot surface 36 of the
corresponding upper recess 30. An entirety of each of the base 64,
head surface 66, and foot surface 68 of the upper insert 60 may
contact and be secured to (e.g., with a suitable cement or other
adhesive material, etc.) its corresponding base 32, head surface
34, and foot surface 36 of the corresponding upper recess 30. Thus,
a shape or configuration of each upper insert 60 may complement, be
the same as, or be substantially the same as a shape or
configuration of the upper recess 30 in which the upper insert 60
is positioned.
[0043] A lower insert 70 may be provided in each lower recess 40 of
the main body 20 of the side rail 10. Each lower insert 70 may
substantially fill its corresponding lower recess 40 and include a
bottom edge 72 that is coplanar or substantially coplanar with the
bottom edge 24 of the main body 20 of the side rail 10, a top 74
adjacent to the top 42 of the corresponding lower recess 40, a head
surface 76 adjacent to the head surface 44 of the corresponding
lower recess 40, and a foot surface 78 adjacent to the foot surface
46 of the corresponding lower recess 40. An entirety of each of the
top 74, head surface 76, and foot surface 78 of the lower insert 70
may contact and be secured to (e.g., with a suitable cement or
other adhesive material, etc.) its corresponding top 42, head
surface 44, and foot surface 46 of the corresponding lower recess
40. Thus, a shape or configuration of each lower insert 70 may
complement, be the same as, or be substantially the same as a shape
or configuration of the lower recess 40 in which the lower insert
70 is positioned.
[0044] A shape of each upper insert 60 and each lower insert 70 and
a material from which each upper insert 60 and each lower insert 70
is formed may enable the side rail 10 to readily flex when the
mattress (not shown in FIG. 1 or FIG. 2) of which it is a part is
bent in a corresponding direction. For example, the shape and
material of each upper insert 60 may enable the side rail 10 to
readily flex when a top of the mattress is bent concavely at a
location where the upper insert 60 is located. As another example,
the shape and material of each lower insert 70 may enable the side
rail 10 to readily flex when a top of the mattress is bent convexly
at a location where the lower insert 70 is located.
[0045] The material from which each upper insert 60 and each lower
insert 70 is formed may be readily compressible, but have
sufficient rigidity to impart the side rail 10 with acceptable
structural integrity. By way of example only, each upper insert 60
and each lower insert 70 may comprise a compressible, resilient
material. The compressible, resilient material may comprise a foam.
The compressible, resilient material of each upper insert 60 and
each lower insert 70 may be more readily compressible than the
compressible, resilient material of the main body 20 to which the
upper insert 60 and lower insert 70 are secured. For example, an
ILD rating of the compressible, resilient material of each upper
insert 60 and each lower insert 70 of a side rail 10 may be less
than an ILD rating of the compressible, resilient material from
which the main body 20 of the side rail 10 is formed. An ILD rating
of the compressible resilient material may be 18 to about 24 (e.g.,
18, 20, 22, 24, etc.). In a specific embodiment, each upper insert
60 and/or each lower insert 70 may be formed from a medium density
polyethylene (MDPE) foam.
[0046] While FIGS. 1 and 2 show each upper recess 30 with an upper
insert 60 therein and each lower recess 40 with a lower insert 70
therein, one, more than one, or all of the upper recesses 30 and/or
lower recesses 40 may lack a corresponding upper insert 60 or lower
insert 70 and, thus, remain open, comprising a relief cut in the
main body 20 of the side rail 10.
[0047] FIG. 3 shows how the upper inserts 60 of an embodiment of a
side rail 10 may compress and, thus, give way more readily than the
main body 20 of the side rail 10. As illustrated, the top edge 22
of the main body 20 of the side rail 10 is bent concavely at a
location where two upper recesses 30 and their corresponding upper
inserts 60 are located. While the upper inserts 60 compress from
between their head surfaces 66 and their foot surfaces 68,
shortening their top edges 62, the top edge 22 of the main body 20
remains substantially unbent and otherwise unaffected. Moreover,
the upper recesses 30 and the upper inserts 60 therein control the
location at which the bottom edge 24 of the main body 20 bends and
limits the distance along a length of the bottom edge 24 along
which bending occurs.
[0048] The embodiment of side rail 10' depicted by FIGS. 4A-4D
includes a main body 20' with four upper recesses 30a', 30b', 30c',
30d' (each also referred to as an upper recess 30') and two lower
recesses 40a' and 40b' (each also referred to as a lower recess
40'). An upper insert 60a', 60b', 60c', 60d' (each also referred to
as an upper insert 60') is secured in place within a corresponding
upper recess 30a', 30b', 30c', 30d'. A lower insert 70a', 70b'
(each also referred to as a lower insert 70') is secured in place
within a corresponding lower recess 40a', 40b'.
[0049] The four upper recesses 30' and corresponding upper inserts
60' are grouped together at a location where a top of a mattress
(not shown in FIGS. 4A-4D) of which the side rail 10' is a part
will be bent concavely (e.g., between or at a transition between a
head region and an intermediate region along the length, or height,
of the mattress, etc.). For example, the upper recesses 30' may be
positioned between or at a transition between a head portion 12' of
the side rail 10' and an intermediate portion 14' of the side rail
10'. The two lower recesses 40' and corresponding lower inserts 70'
are grouped together at a location where a top of the mattress of
which the side rail 10' is a part will be bent convexly (e.g.,
between or at a transition between an intermediate region and a
foot region along the length, or height, of the mattress, etc.).
For example, the lower recesses 40' may be positioned between or at
a transition between the intermediate portion 14' of the side rail
10' and a foot portion 16' of the side rail 10'.
[0050] While FIGS. 4A-4D show a side rail 10' with each upper
recess 30' including an upper insert 60' therein and each lower
recess 40' including a lower insert 70' therein, one, more than
one, or all of the upper recesses 30' and/or lower recesses 40' may
lack a corresponding upper insert 60' or lower insert 70' and,
thus, remain open, comprising a relief cut in the main body 20' of
the side rail 10'.
[0051] FIGS. 5A-D depict yet another embodiment of a side rail
10''. The side rail 10'' includes a main body 20'' with at least
one upper recess 30'' (five upper recesses 30a'', 30b'', 30c'',
30d'', 30e'' are depicted) in the top edge 22'' of the main body
20''. In addition, the side rail 10'' includes at least one lower
recess 40'' (a single lower recess 40''is depicted) in a bottom
edge 24'' of the main body 20''. As depicted, each upper recess
30'' and lower recess 40'' may have the same or substantially the
same dimensions. Alternatively, the dimensions of the upper
recess(es) 30'' and lower recess(es) 40'' may differ from each
other.
[0052] The upper recesses 30'' and/or lower recesses 40'' of the
side rail 10'' may be grouped. As shown in FIGS. 5A-5D, a first
group 31A'' of upper recesses 30a'', 30b'', 30c'' may be located
between or at a transition between a head region 12'' and an
intermediate region 14'' of the side rail 10''. A second group
31B'' of upper recesses 30d'', 30e'' may be positioned between or
at a transition between the intermediate region 14'' of the side
rail 10'' and a foot region 16'' of the side rail 10''. The lower
recess 40'' may also be positioned between or at a transition
between the intermediate region 14'' and the foot region 16'',
closer to the foot end 28'' of the main body 12'' of the side rail
10'' than the second group 31B'' of upper recesses 30d'', 30e''.
Alternatively, the lower recess 40'' may be positioned at an
intermediate location along the length of the foot portion 16'' of
the side rail 10''.
[0053] While FIGS. 5A-5D show a side rail 10'' with each upper
recess 30'' and lower recess 40''lacking an insert and, thus,
remaining open, comprising a relief cut in the main body 20'' of
the side rail 10'', one, more than one, or all of the upper
recesses 30'' and/or lower recesses 40'' may include an insert.
[0054] FIGS. 4A-4D and FIGS. 5A-5D illustrate specific shapes and
dimensions for the embodiments of side rails 10' and 10'' depicted
thereby and the elements of the depicted embodiments of the side
rails 10' and 10'', including the main body 20', 20'', each upper
recess 30', 30'', upper insert 60', 60'', lower, recess 40', 40'',
and lower insert 70', 70''. Although FIGS. 4A-4D and FIGS. 5A-5D
provide specific shapes and dimensions for each of the features of
the illustrated side rails 10' and 10'', the details provided by
FIGS. 4A-4D and FIGS. 5A-5D are merely representative.
[0055] Turning now to FIG. 6, an embodiment of a mattress 100 is
depicted with a side rails 10' (see also FIGS. 4A-4D) positioned
along each side 102 of the mattress 100. The side rails 10', along
with a base (not shown), a head rail (not shown), and a foot rail
(not shown), may define at least part of a foundation 110 of the
mattress 100. The foundation 110 may define a receptacle (not
shown) for at least one cushioning element (not shown) of the
mattress.
[0056] The cushioning element (not shown) of the mattress 100 may
comprise coil springs (not shown) (see, e.g., U.S. Patent
Application Publication US 2019/0150632 A1, the entire disclosure
of which is hereby incorporated herein), one or more pressurizable
bladders (see, e.g., U.S. Pat. No. 11,213,139, the entire
disclosure of which is hereby incorporated herein), memory foam,
and/or any other suitable cushioning element for a mattress, or a
combination of cushioning elements.
[0057] An intermediate layer 120 may be positioned over the
foundation 110. A top cushioning element 130 may be positioned over
the intermediate layer 120. The top cushioning element 130 may
comprise a gel cushion (not shown). The gel cushion of the top
cushioning element 130 may include a plurality of resiliently
compressible intersecting or interconnected walls defining an array
of interconnected, resiliently buckling columns, with a void in
each column, as described by U.S. Pat. Nos. 7,060,213, 7,076,822,
and 8,919,750. Stated another way, the interconnected or
intersecting walls may define an array of hollow columns, or voids.
Such a gel cushion may be formed from any of a variety of
compressible, resilient materials, including cushioning foams and
elastomeric materials, such as the extended A-B-A triblock
copolymers described by U.S. Pat. Nos. 6,413,458, 6,797,765, and
7,964,664. While such a gel cushion may extend to the periphery of
the inner assembly of the mattress 100, such a gel cushion may be
surrounded by foam edge pieces 135. Although not shown in FIG. 6,
the depicted inner assembly of the mattress 100 may be enclosed
within a mattress cover.
[0058] In FIG. 6, a side rail 10' of the mattress 100 is shown in a
bent arrangement, in which a top 104 of the mattress 100 and the
top edge 22' (FIGS. 4A-4C) of the main body 20' of the side rail
10' are bent concavely at a location between a head region 106 of
the mattress 100 and an intermediate region 107 of the mattress
100. The upper inserts 60' of the side rail 10', especially upper
inserts 60a' and 60b', are shown in compressed states. In addition,
the top 104 of the mattress 100 and the top edge 22' of the main
body 20' of the side rail 10' are bent convexly at a location
between the intermediate region 107 and a foot region 108 of the
mattress 100. The lower inserts 70' of the side rail 10',
particularly the lower insert 70a', is in a compressed state.
[0059] In addition to illustrating an embodiment of a side rail 10'
and an embodiment of a mattress 100, FIG. 6 depicts an embodiment
of an adjustable bed 200, with the mattress 100 resting upon an
adjustable bedframe 210. The adjustable bedframe 210 may include a
support surface 212 that includes a plurality of support elements
214, 216, and 218. More specifically, the support surface 212 may
include a head support element 212, an intermediate support element
214, and a foot support element 216. As illustrated, at least one
concavely bending joint 215 may be located between the head support
element 212 and the intermediate support element 216. At least one
convexly bending joint 217 may be located between the intermediate
support element 216 and the foot support element 218. Specifically,
the adjustable bedframe 210 may comprise the PURPLE POWERBASE
adjustable bedframe available from Purple Innovation, LLC, of Lehi,
Utah. See, e.g., U.S. Patent Application Publication US
2018/0168359 A1, the entire disclosure of which is hereby
incorporated herein. Of course, a bed according to this disclosure
may include any other embodiment of adjustable bedframe with
support elements and joints that differ from those (in number,
location, etc.) shown in FIG. 6, as well as a mattress with side
rails that include upper and lower recesses and upper and lower
inserts that are positioned for use with the arrangement of support
elements and joints of the adjustable bedframe.
[0060] Although the preceding disclosure provides many specifics,
these should not be construed as limiting the scope of any of the
claims that follow, but merely as providing illustrations of some
embodiments of elements and features of the disclosed subject
matter. Other embodiments of the disclosed subject matter, and of
their elements and features, may be devised which do not depart
from the spirit or scope of any of the claims. Features from
different embodiments may be employed in combination. Accordingly,
the scope of each claim is limited only by its plain language and
the legal equivalents thereto.
* * * * *