Mattress with a Vented Cover

Abstract

A mattress to support a user that includes a core positioned within an interior space formed by a cover. The cover protects the core from damage that could result from contact with liquid or debris. A vent extends through the cover to allow airflow into and out of the interior space. The vent 40 includes a plurality of pores that allow the airflow, but limit ingress of liquid and debris.

Description

BACKGROUND

The present application is directed to a mattress and, more particularly, to a mattress with a vented cover for airflow into and out of an interior of the mattress.

A mattress provides support for a person that is lying down and often sleeping. A mattress traditionally includes a core which is the internal substrate that provides mattress loft. The core may include a rectangular body sized to support the person. In some applications, the core may also include a pillow operatively connected to the body to further support the head and neck of the user.

The mattress may also include a protective cover to protect the core from damage that may occur during use. The damage may be intentional, such as by the user ripping or tearing the mattress. Intentional damage is a major concern when the mattress is used in a correctional institution setting, such as a prison, jail, or detention facility. The user may intentionally damage the mattress to hide contraband or use the mattress as a weapon to either injure themselves or other persons.

The cover includes a vent that allows airflow into and out of the interior of the mattress but limit the introduction of liquid and debris in the interior. The limiting of liquid and debris may prevent mold or other harmful agents from forming within the interior. The airflow may also make the mattress more comfortable for the user as the amount of air that remains within the interior changes depending upon the size and weight of the user. The vent is constructed to prevent the user from removing the vent and gaining access to the interior of the mattress.

SUMMARY

The present application is directed to a mattress with a core contained within a cover. The core may include a first end and a second end and first and second sides that extend between the ends. The first and second sides may each be configured to support the user. The cover may form an enclosed interior space to contain the core. The cover may include an exterior surface that is visible to the user and an interior surface that faces towards the core. The mattress may also include a plurality of pores that each extend through the cover and are positioned in an area of the cover. The plurality of pores may provide for air to move into and out of the interior space formed by the cover, and may limit the ingress of liquid or debris into the interior space.

The various aspects of the various embodiments may be used alone or in any combination, as is desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cut-away perspective view of a mattress according to one embodiment.

FIG. 2 is a perspective view of a mattress according to one embodiment.

FIG. 3 is a section view of the mattress of FIG. 2 viewed along the line III-III.

FIG. 4 is an exploded back view of a vent illustrating an interior surface of a cover with pores that extend through the cover and a patch according to one embodiment.

FIG. 5A is a back view of a vent illustrating a patch attached to an interior surface of a cover according to one embodiment.

FIG. 5B is a front view of a vent illustrating an interior surface of a cover with pores that extend through the cover according to one embodiment.

FIG. 6 is a perspective front view of vent illustrating an exterior surface of a cover with raised pores according to one embodiment.

FIG. 7 is a side view of vent illustrating an interior surface of a cover with pores according to one embodiment.

DETAILED DESCRIPTION

The present application is directed to a mattress 10 for supporting a user. FIG. 1 includes an embodiment of a mattress 10 that includes a cover 30 that forms an interior space 31 that extends around a core 20. The cover 30 protects the core 20 from damage that could result from contact with liquid or debris. A vent 40 extends through the cover 30 to allow airflow into and out of the interior space 31. The vent 40 includes a plurality of pores that allow the airflow, but limits the ingress of liquid or debris.

The core 20 provides support for a user who rests on the mattress 10. In one embodiment as illustrated in FIG. 1, the core 20 is limited to include just a body 21. In another embodiment as illustrated in FIGS. 2 and 3, the core 20 includes a body 21 and a pillow 22. The body 21 and pillow 22 may be connected, or may be separate. Each of the body 21 and pillow 22 may be constructed from a single section or from multiple sections.

As illustrated in FIGS. 2 and 3, the body 21 may include a rectangular shape with a first end 23 and opposite second end 24. The body 21 also includes a top side 25 and a bottom side 26 that form the support surfaces for the user. One or both of the sides 25, 26 may be substantially flat (i.e., parallel to a centerline C of the body 21) or may include variations in one or both sides. The body 21 may be constructed from various materials, including but not limited to polyester, cotton, foam, inner springs, polyurethane, and latex. The body 21 may also be constructed from a combination of two or more of these materials.

The pillow 22 is positioned to support the neck and head of the user. The pillow 22 may be positioned at the second end 24 of the body 21. The pillow 30 includes a first end 27 that faces towards the body 20 and may contact or be spaced away from the second end 24. The pillow 22 also includes a first side 28 and an opposing second side 29. One or both sides 28, 29 may be substantially flat (i.e., parallel to a centerline C′ of the pillow 22), or may include variations (e.g., angle cut, slope, contour shape) in one or both sides. A height of the pillow 22 measured between the sides 28, 29 may be the same as or greater than a height of the body 21 measured between the sides 25, 26. In one embodiment, the pillow 22 includes a greater height than the body 21. In one specific embodiment, the height of the pillow 22 is twice the height of the body 21. The pillow 22 may also include one or more chamfers positioned at acute angles relative to the centerline C′. The pillow 22 may be constructed from various materials, including but not limited to polyester, cotton, foam, latex, and polyurethane. The pillow 30 may also be constructed from a combination of two or more of these materials.

The cover 30 forms the interior space 31 and extends around the core 20. In embodiments with a body 21 and pillow 22, the interior space 31 may be sized to allow for some movement of the pillow 22 relative to the body 21. The cover 30 protects the core 20 from damage by liquid and other debris. The cover 30 may provide an airtight and watertight exterior around the enclosed core 20. The cover 30 may be constructed from a variety of materials, including but not limited to polyvinyl chloride (PVC) vinyl.

The cover 30 may include one or more seams that may be formed in a variety of manners included but not limited to heat sealing, ultrasonic and RF welding. The seams generally include horizontal seams 32 and vertical seams 33 as illustrated in FIG. 2. The horizontal seams 32 extend along the length of the core 20 and are generally parallel with the centerlines C and C′. The vertical seams 33 extend along the height of the core 20 and are generally perpendicular to the centerlines C and C′. The vertical seams 33 may be isolated to the corners of the mattress 10 with a first pair of vertical seams 33 at the first end 23 and a second pair at the second end 24. In one embodiment, the vertical seams 33 include a smaller height than the core 20 to provide for a more aesthetically pleasing appearance to the cover 30.

The mattress 10 may be used with either the top side 25 or the bottom side 26 facing upward to support the user. In a first orientation, the top side 25 faces upward to support the user and the bottom side 26 contacting against a support surface, such as the ground, a bed frame, box spring, or the like. In an embodiment with the pillow 22 including a greater height, the top side 28 of the pillow extends above the top side 25 of the body 21 to better support the user's neck and head. The mattress 10 may be used in a second orientation with the bottom side 26 facing upward to support the user and the top side 25 facing downward and being in contact with the support surface. In the second orientation, the top side 29 of the pillow 22 may extend upward beyond the bottom side 26 to support the user's neck and head when the pillow 22 includes a greater height than the body 21.

Various embodiments of a mattress are disclosed in U.S. patent application Ser. No. 12/500,136 filed on the same day as the present application and herein incorporated by reference in its entirety.

A vent 40 extends through the cover 30 to provide airflow into and out of the interior space 31. The vent 40 may also allow air to exit from the interior space 31 when a user initially sits or lies on the mattress 10 as their weight causes the air to be forced through the vent 40. Conversely, air may enter back into the interior space 31 through the vent 40 once the user exits the mattress 10. This movement of air into and out of the interior space 31 may provide a more comfortable feel for a variety of users as volume of air in the interior space 31 adjusts depending upon the weight and movement of the user.

FIG. 4 includes a vent 40 with a patch 44 that extends over a plurality of pores 41 formed through the cover 30. The pores 41 are sized to allow the flow of air through the cover 30 yet limit entry of liquid and debris. The size of the pores 41 may vary. In some embodiments, the size ranges from about 24 gauge (6.1 microns) to about 60 gauge (15.2 microns). Each of the pores 41 may include the same size, or the pores 41 may include different sizes pores 41 may include the same size, or the pores 41 may include different sizes ranging from about 0.30 mm to about 50 mm. The vent 40 may also include various numbers of pores 41 and include different pore densities (the number of pores per a given area, such as a square inch). In some embodiments, the total number of pores 41 in a vent 40 ranges from about 1 to about 2400 pores per square inch. In some embodiments, a vent 40 with a larger overall size may include substantially the same number of pores 41 as a smaller vent 40. This is because the larger vent 40 includes a smaller density of pores 41 than the smaller vent 40. Therefore, each of the smaller and larger vents 40 is able to accommodate substantially the same amount of airflow into and out of the interior space 31. The arrangement of the pores 41 may also vary with some vents 40 formed from arrays of aligned rows and/or columns of pores 41 and other vents 40 formed from miscellaneous groupings.

The pores 41 may be formed in a punching, pressing, or rolling operation in which a pin/platen/roll is forced through the cover 30 to form each of the pores 41. One process includes punching, pressing, or rolling the element through the cover 30 from the interior surface 35 to the exterior surface 34, or in the opposite direction. This process forms a raised lip 46 on the exterior surface 34 or the interior surface 35 that surrounds each of the pores 41. The raised lips 46 extend outward beyond the un-punched surface 34 or 35. The raised lips 46 may be formed by the deformation of the cover 30 that occurs during the punching process.

FIG. 6 illustrates a magnified view of the raised lips 46 that extend around the pores 41. In this embodiment, the raised lips 46 extend outward beyond the exterior surface 34 of the cover 30. Other embodiments may include the lips 46 extending outward beyond the interior surface 35. Each of the lips 46 may be the same, or the lips 46 may be different dependent on the punching, pressing, or rolling operation. The raised lips 46 further shield the pores 41 and further limit the ingress of liquid and other debris.

The vent 40 may also include a patch 44 that extends over the pores 41 and is attached to the cover 30. The patch 44 is constructed of a material that allows airflow into and out of the interior space 31 but limits the ingress of liquid and debris. In one embodiment, the patch 44 is constructed from POREX 0.007 MUPOR microporous polytetrafluoroethylene (PTFE) membrane fabric from Porex Technologies. The patch 44 may also be constructed from other materials, including but not limited to eVent Fabric from BHA Group, Inc., and GORETEX protective vents from W.L. Gore & Associates, Inc.

The patch 44 may be attached to the interior surface 35 of the cover 35 as illustrated in FIG. 5A and is sized to extend over the pores 41. A seal 45 attaches the patch 44 to the cover 35. The seal 45 may be formed by a variety of applications, including but not limited to adhesive, stitching, heat sealing, and ultrasonic and RF welding. The seal 45 extends completely around the patch 44.

Positioning the patch 44 on the interior surface 35 hides the patch 44 from the user as illustrated in FIG. 5B and may provide several advantages. The patch 44 is not visible and therefore may increase the aesthetic appearance of the mattress 10. The positioning also protects the patch 44 from possible damage that could result during normal use of the mattress 10. One example of normal use damage includes the patch 44 snagging on an object such as the user clothing and being torn from the cover 44. The positioning also prevents the user from intentionally tampering with the patch 44 and attempting to gain access to the interior space 31. This aspect is of particular interest when the mattress 10 is used in a correctional institution.

The pores 41 are of such a small size as to not be readily noticeable when viewing the exterior surface 34 of the cover 30. The visible masking of the pores 41 may also include attaching a patch 44 that is substantially the same color as the exterior surface 34 of the cover 30. This aspect increases the aesthetic appearance of the mattress 10 and may further prevent tampering with the vent 40 in an attempt to gain access to the interior space 31.

In one embodiment the patch 44 is attached to the exterior surface 34 of the cover 30. The seal 45 provides a secure attachment to prevent removal of the patch 44 either by accidental or intentional tampering.

The vent 40 may be positioned at various locations about the mattress 10. In one embodiment, the vent 40 is positioned in a sidewall 58 between the top and bottom surfaces 25, 26. In an embodiment with the core 20 including both a body 21 and a pillow 22, the vent 40 is positioned at the first end 23 away from the pillow 22. Further, the size of the vent 40 may include extending along a substantial portion of the mattress 10. In one embodiment, the vent 40 extends along almost an entirety of the sidewall 58 between the first and second ends 23, 24.

The mattress 10 may also include more than one vent 40. The vents 40 may include the same or different shapes, sizes, and pore density. The vents 40 may also be positioned at the same or different locations on the mattress 10.

FIG. 7 includes another vent 40 that includes just the pores 41 without patch 44. The pores 41 are sized to allow airflow into and out of the interior space 31 and limit the ingress of liquid and debris.

The mattress 10 is constructed and designed for use in a variety of different contexts. One context is for use in a correctional institution such as a prison or detention center. The mattress 10 may also be used for but is not limited to recreational purposes such as camping, military uses, dorm facilities, and also for regular home use.

Spatially relative terms such as “under”, “below”, “lower”, “over”, “upper”, and the like, are used for ease of description to explain the positioning of one element relative to a second element. These terms are intended to encompass different orientations of the device in addition to different orientations than those depicted in the figures. Further, terms such as “first”, “second”, and the like, are also used to describe various elements, regions, sections, etc and are also not intended to be limiting. Like terms refer to like elements throughout the description.

As used herein, the terms “having”, “containing”, “including”, “comprising” and the like are open ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a”, “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise.

The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.

Claims

1. A mattress to support a user comprising:

a core that includes a first end and a second end and first and second sides that extend between the ends and are each configured to support the user;

a cover that forms an enclosed interior space to contain the core, the cover including an exterior surface that is visible to the user and an interior surface that faces towards the core; and

a vent including a plurality of pores that each extend through the cover and are positioned in an area of the cover, and a patch attached to the interior surface of the cover that extends over the area, the patch being constructed from a material that limits ingress of liquid into the interior space and allows airflow into and out of the interior space.

2. The mattress of claim 1, further comprising a continuous seal around the patch that attaches the patch to the interior surface of the cover.

3. The mattress of claim 1, wherein the plurality of pores range in size from about 0.30 mm to about 50 mm.

4. The mattress of claim 3, wherein each of the plurality of pores include a common size.

5. The mattress of claim 1, further comprising a second vent through the cover for moving air into and out of the interior space and limiting liquid from entering into the interior space, the second vent being spaced away from the vent and including a different pore density than the vent.

6. The mattress of claim 1, wherein each of the pores includes a raised lip that extends outward beyond an exterior surface of the cover.

7. The mattress of claim 1, wherein the core includes a body and a pillow positioned in an end-to-end configuration, the pillow including a greater height than the body.

8. A mattress to support a user comprising:

a core that includes a top surface and a bottom surface each configured to support the user;

a cover that forms an enclosed interior space to contain the core, the cover including an interior surface that faces towards the core and an exterior surface; and

a plurality of pores that each extend through the cover for moving air into and out of the interior space and limiting liquid from entering into the interior space, each of the plurality of pores including a raised lip that extends outward beyond the exterior surface of the cover.

9. The mattress of claim 8, further comprising a patch that extends over the plurality of pores and is attached to the interior surface of the cover, the patch constructed to allow airflow into and out of the interior space.

10. The mattress of claim 8, wherein the cover includes a vertical seam that is shorter than a height of the core.

11. The mattress of claim 9, wherein a surface of the patch that faces the interior surface of the cover and the exterior surface of the cover have a common color.

12. The mattress of claim 8, wherein each of the plurality of pores ranges in size from about 6 microns to about 15 microns.

13. The mattress of claim 9, wherein the cover is constructed from PVC vinyl and the patch is constructed from PTFE.

14. The mattress of claim 8, wherein the core includes a pillow.

15. A mattress to support a user comprising:

a core that includes a top surface and a bottom surface each configured to support the user;

a cover that forms an enclosed interior space to contain the core, the cover including an interior surface that faces towards the core and an exterior surface; and

a plurality of pores that each extend through the cover for moving air into and out of the interior space and limiting liquid from entering into the interior space, each of the plurality of pores including a size ranging from about 6 microns to about 15 microns; and.

a patch that extends over the plurality of pores and is attached to the cover, the patch constructed to allow airflow through the plurality of pores and into and out of the interior space.

16. The mattress of claim 15, wherein the patch is attached to the interior surface of the cover.

17. The mattress of claim 15, wherein each of the plurality of pores includes a raised lip.

18. The mattress of claim 17, wherein the raised lips extend outward from the exterior surface of the cover.

19. The mattress of claim 15, wherein the patch is constructed of PTFE material.

20. The mattress of claim 15, wherein the core includes a body and a pillow that are positioned to contact each other in a non-overlapping arrangement.