FOAM MATTRESS ASSEMBLY WITH INCREASED AIRFLOW AND INDEPENDENT SUSPENSION
Mattress assemblies that provide user comfort via independent suspension and increased airflow generally include a first foam layer; a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about similar lengths from the floor; and a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly. In some embodiments, the first foam layer further includes a plurality of channels extending from a top planar surface to a bottom planar surface.
Latest DREAMWELL, LTD. Patents:
This application claims the benefit of U.S. Provisional Application No. 61/513,091, filed on Jul. 29, 2011, incorporated herein by reference in its entirety.
BACKGROUNDThe present disclosure generally relates to foam mattress assemblies exhibiting increased airflow and independent suspension.
Foam mattresses such as those formed of polyurethane foam, latex foam, and the like, are generally known in the art. One of the ongoing problems associated with foam mattress assemblies is user comfort. To address user comfort, these mattresses are often fabricated with multiple foam layers having varying properties such as density and hardness, among others, to suit the needs of the intended user. More recently, manufacturers have employed so called memory foam, also commonly referred to as viscoelastic foams, which are generally a combination of polyurethane and one or more additives that increase foam density and viscosity, thereby increasing its viscoelasticity. These foams are often open cell foam structures having both closed and open cells but in some instances may be reticulated foam structures. The term “reticulated” generally refers to a cellular foam structure in which the substantially all of the membrane windows are removed leaving a skeletal structure. In contrast, open cell structures typically include both open cell (interconnected cells) and closed cells.
When used in a mattress, the memory foam conforms to the shape of a user when the user exerts pressure onto the foam, thereby minimizing pressure points from the user's body. The memory foam then returns to its original shape when the user and associated pressure are removed. However, the return to the original shape is a relatively slow process because of the viscoelastic cellular structure of these types of foams.
Unfortunately, the high density of the various types of foams used in current mattress assemblies, particularly those employing memory foam layers, generally prevents proper ventilation. As a result, the foam material can exhibit an uncomfortable level of heat to the user after an extended period of time. Additionally, these foams can retain a high level of moisture, further causing discomfort to the user and potentially leading to foul odors.
Reticulated memory foams, i.e., foams in which the cellular walls are substantially removed, are known to provide greater airflow. However, because substantially all of the cellular walls have been removed leaving behind a skeletal structure, these foams are inherently weak, provide less load-bearing capabilities relative to other non-reticulated viscoelastic foams, and are subject to fatigue at a rate faster than partially or completely closed cell foam structures. Moreover, reticulated viscoelastic foams require special processing to remove the cellular walls to form the skeletal structure making these foams relatively expensive.
Still further, as noted above, prior mattress assemblies generally include multiple stacked layers. The layers typically have planar top and bottom surfaces. In some instances, these mattresses may have convoluted surfaces. These surfaces are generally static in terms of motion response to a user.
Accordingly, it would be desirable to provide a mattress assembly, with an improved airflow to effectively dissipate user heat. Still further, it would be desirable to provide foam mattress assemblies with motion separation so as to independently respond to each specific body part for increased user comfort.
BRIEF SUMMARYDisclosed herein are mattress assemblies exhibiting increased airflow and independent suspension. In one embodiment, a mattress assembly comprises a first foam layer; a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about similar lengths from the floor; and a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly.
In another embodiment, a mattress assembly comprises a first foam layer comprising top and bottom planar surfaces, the first foam layer further comprising a plurality of channels extending from the top to the bottom planar surfaces; a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about equal lengths from the floor; and a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly.
In another embodiment, a mattress assembly comprises a first foam layer comprising top and bottom planar surfaces, the first foam layer further comprising a plurality of channels extending from the top to the bottom planar surfaces; a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about equal lengths from the floor; and a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly.
The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.
Referring now to the figures wherein the like elements are numbered alike:
Disclosed herein are mattress assemblies that provide user comfort with improved airflow to effectively dissipate user heat during use and motion separation to independently respond to each specific body part for increased user comfort.
The core foam layer can be formed of open or closed cell natural latex foam although other foams can be used, including without limitation, viscoelastic foams, non-viscoelastic foams, polyurethane foams, and the like. In one embodiment, the foam core layer 102 is pre-stressed. That is, the foam core layer is subjected to a pre-stressing process such as disclosed in U.S. Pat. No. 7,690,096 to Gladney et al., incorporated herein by reference in its entirety. By way of example, a force can applied to at least a section of the foam core layer in an amount sufficient to temporarily compress its height so as to permanently alter a mechanical property of the foam layer to provide a pre-stressed foam layer having a firmness that is different from the firmness of a similar foam that was not pre-stressed.
The foam core layer 102 has a density of 1 pound per cubic foot (lb/ft3) to 6 lb/ft3. In other embodiments, the density is 1 lb/ft3 to 5 lb/ft3 and in still other embodiments, from 1.5 lb/ft3 to 4 lb/ft3. By way of example, the density can be about 1.5 lb/ft3.
The hardness of the foam core layer, also referred to as the indention load deflection (ILD) or indention force deflection (IFD), is within a range of 20 to 40 pounds-force, wherein the hardness is measured in accordance with ASTM D-3574 and is generally defined as the amount of force in pounds required to indent a 50″ disc into a 15″×15″×4″ foam sample and make a 1″ indentation. In other embodiments, the hardness is about 20 to 30 pounds-force.
Foam layer 104 configured with an independent response system overlays the base foam core layer 102. Advantageously, the independent response system as will be described in greater detail below provides motion separation to an end user of the mattress assembly as well as improved airflow. The foam layer 104 may be fabricated from a viscoelastic foam or non-viscoelastic foam depending on the intended application. The foam itself can be of any material including without limitation, latex foams, natural latex foams, polyurethane foams, combinations thereof, and the like. Foam layer 104 generally has a thickness equal to or less than 6 inches in some embodiments, equal to or less than 4 inches in other embodiments, and equal to or less than 3 inches in still other embodiments. In other embodiments, the thickness is greater than or equal to 1 inch. The density is generally within a range of 2 to 6 lb/ft3 in some embodiments, and 3 to 5 lb/ft3 in other embodiments. Hardness is generally within a range of 10 to 20 pounds-force.
As shown more clearly in
By way of example, which is not intended to be limiting, a foam layer 104 configured for use in queen sized mattress can have a thickness of 3 inches, a width of 59.5 inches and a length of 79.5. The perimeter wall has a width of 3 inches and the upright support structure has a truncated cone shape having a height of 1.5 inches (i.e., the recess floor has a thickness of 1.5 inches) and a diameter of 2 inches. The upright support structures are equally spaced apart at a distance of about 1 inch as measured from the base and linearly arranged by columns and rows.
Referring back to
The various multiple stacked mattress layers 102, 104, and 106 may be adjoined to one another using an adhesive or may be thermally bonded to one another or may be mechanically fastened to one another as may be desired for different applications.
The mattress assembly 100 further includes a side rail assembly 120 about all or a portion of the perimeter of the mattress assembly defined by foam layers 102, 104, 106. The side rails that define the assembly may be attached to or placed adjacent to at least a portion of the perimeter of the stacked mattress layers 102, 104, 106, and may include metal springs, spring coils, encased spring coils, foam, latex, natural latex, latex w/ gel, gel, viscoelastic gel, or a combination, in one or more layers. The side rails may be placed on one or more of the sides of the stacked mattress layers, e.g., on all four sides of the stacked mattress layers, on opposing sides, on three adjacent sides, or only on one side of the stacked mattress layers. In certain embodiments, the side rails may comprise edge supports with a firmness greater than that provided by the stacked mattress layers. The side rails may be fastened to the stacked mattress layers via adhesives, thermal bonding, or mechanical fasteners.
In one embodiment, the side rail assembly is formed of a natural latex foam having a density generally less than 3 lb/ft3 to 0.5 lb/ft3 and a hardness greater than 30 pounds-force to 80 pounds-force. In one embodiment, the side rails are formed of natural latex foam having a density of 1.65 lb/ft3 and a hardness of 45 pounds-force.
In some embodiments, the side rail assembly 120 may be formed of multiple layers as is generally shown in
In another embodiment, the side rail assembly 120 is formed of open cell polyurethane foam having a non-random large cell structure or a random cellular structure with many large cells. The large cell structure can be defined by the number of cells per linear inch. In one embodiment, the large cell structure is about 10 to 40 cells per inch, with about 15 to 30 cells per inch in other embodiments, and with about 20 cells per inch in still other embodiments. The open cell foam structure includes a plurality of interconnected cells, wherein the windows between the adjacent cells are broken and/or removed. In contrast, in closed cell foam there are substantially no interconnected cells and the windows between the adjacent cells are substantially intact. In reticulated foams, substantially all of the windows are removed. By using an open cell structure with a large open cellular structure, movement of moisture and air through a side rail can occur. Also, if the side rail is adhesively or thermally attached to the mattress layers, e.g., 102, 104, and 106, the skeletal struts of the open cell foam will bond to the mattress layers, thereby facilitating air and moisture transfer from the mattress layers through the side layers to the environment. In one embodiment, the side rail assembly includes a natural latex foam, which may be viscoelastic or non-viscoelastic depending on the intended application.
For ease in manufacturing the mattress assembly, the side rail assembly may be assembled in linear sections that are joined to one another to form the perimeter about the mattress layers. Alternatively, the ends may be mitered or have some other shape, e.g., lock and key type shape.
An optional fabric layer (e.g., 16 in
By way of example, an exemplary mattress assembly illustrative of the embodiment shown in
Foam layer 204 configured with the independent response system as described above is disposed on the base core foam layer 202.
A cover foam layer 206 as described above is disposed on foam layer 204.
The mattress assembly may further include the side rail assembly and the optional fabric border as described above.
By way of example, an exemplary mattress assembly illustrative of the embodiment shown in
The various mattress layers in the mattress assemblies described above may be adjoined to one another using an adhesive or may be thermally bonded to one another or may be mechanically fastened to one another. The mattress assemblies may further include one or more upholstery layers to cover mattress assemblies, which may include an outermost ticking layer.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims
1. A mattress assembly comprising:
- a first foam layer;
- a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about similar lengths from the floor; and
- a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly.
2. The mattress assembly of claim 1, wherein the first, second and third foam layers comprise natural latex foam.
3. The mattress assembly of claim 1, wherein the first foam layer has a density equal to or less than 4 lb/ft3 and a hardness equal to or less than about 30 pounds-force.
4. The mattress assembly of claim 1, wherein the spaced apart support structures comprises a truncated cone.
5. The mattress assembly of claim 1, wherein the first foam layer is at a thickness within a range of 4 inches to 10 inches; the second foam layer is at a thickness within a range of 1 inch to 4 inches; and the third foam layer is at a thickness within a range of 0.5 to 2 inches.
6. The mattress assembly of claim 1, wherein the first foam layer has a density within a range of 1 pound per cubic foot (lb/ft3) to 6 lb/ft3 and a hardness within a range of 20 to 40 pounds-force; the second foam layer has a density within a range of 2 to 6 lb/ft3 and a hardness within a range of 10 to 20 pounds-force; and the third layer has a density within a range of 1 to 5 lb/ft3 and hardness within a range of 10 to 20 pounds-force.
7. The mattress assembly of claim 1, further comprising a foam side rail assembly disposed about a perimeter of the first, second and third foam layers, wherein the side rail assembly has a thickness about equal a total thickness of the first, second and third layers.
8. The mattress assembly of claim 7, wherein the side rail assembly is formed of natural latex foam.
9. The mattress assembly of claim 1, wherein the first foam layer includes planar top and bottom surfaces, and a plurality of channels extending from the planar top surface to the planar bottom surface.
10. The mattress assembly of claim 1, wherein the second foam layer comprises a recessed portion defining a perimeter wall about the floor and the upright support structures.
11. The mattress assembly of claim 1, further comprising a spacer fabric about a perimeter of the first, second and third foam layers.
12. The mattress assembly of claim 1, further comprising a spacer fabric overlaying the third foam layer and extending about a perimeter of the first, second and third foam layers.
13. The mattress assembly of claim 1, wherein the upright support structures are oriented to face a user resting on the mattress assembly.
14. A mattress assembly, comprising:
- a latex first foam layer having planar top and bottom surfaces;
- a latex second foam layer overlaying the latex first foam layer, the second foam layer comprising a planar bottom surface and a top surface configured with a recessed portion defining a perimeter wall, and a plurality of upright foam support structures extending from a floor of the recessed portion to a height substantially equal to that of the perimeter wall, wherein the upright foam support structures comprise a truncated cone shape to provide motion separation to a user of the mattress assembly during use thereof; and
- a latex third foam layer having top and bottom planar surfaces overlaying the second foam layer, the third foam layer.
15. The mattress assembly of claim 14, wherein the latex first foam layer further comprises a plurality of open channels extending from the top planar surface to the bottom planar surface.
16. The mattress assembly of claim 14, further comprising a side rail assembly formed of a latex material comprising one or more layers disposed about a perimeter of the first, second, and third foam layers.
17. The mattress assembly of claim 14, wherein the layers defining the side rail assembly and the latex first foam layer are pre-stressed.
18. The mattress assembly of claim 14, wherein the upright foam support structures comprise a truncated cone shape to provide motion separation to a user of the mattress assembly during use thereof
19. The mattress assembly of claim 14, wherein the first foam layer further comprises a plurality of channels extending from the planar top surface to the planar bottom surface.
20. The mattress assembly of claim 14, further comprising a spacer fabric overlaying the third foam layer and extending about a perimeter of the first, second and third foam layers.
21. A mattress assembly comprising:
- a first foam layer comprising top and bottom planar surfaces, the first foam layer further comprising a plurality of channels extending from the top to the bottom planar surfaces;
- a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about equal lengths from the floor; and
- a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly.
22. The mattress assembly of claim 21, wherein the plurality of channels are at a density of about 100 to about 800 open channels per square foot.
23. The mattress assembly of claim 21, wherein each one of the plurality of channels has circularly shaped cross section.
24. The mattress assembly of claim 21, the first, second and third foam layers comprise natural latex foam.
25. The mattress assembly of claim 21, wherein the spaced apart support structures comprises truncated cones.
26. The mattress assembly of claim 21, wherein the first foam layer is at a thickness within a range of 4 inches to 10 inches; the second foam layer is at a thickness within a range of 1 inch to 4 inches; and the third foam layer is at a thickness within a range of 0.5 to 2 inches.
28. The mattress assembly of claim 21, further comprising a foam side rail assembly disposed about a perimeter of the first, second and third foam layers, wherein the side rail assembly has a thickness about equal a total thickness of the first, second and third layers.
29. The mattress assembly of claim 28, wherein the side rail assembly is formed of natural latex foam.
30. The mattress assembly of claim 21, further comprising a spacer fabric about a perimeter of the first, second and third foam layers.
31. The mattress assembly of claim 30, further comprising a spacer fabric overlaying the third foam layer and extending about a perimeter of the first, second and third foam layers.
32. The mattress assembly of claim 21, wherein the upright support structures are oriented to face a user resting on the mattress assembly.
Type: Application
Filed: Jul 25, 2012
Publication Date: Jan 31, 2013
Applicant: DREAMWELL, LTD. (LAS VEGAS, NV)
Inventors: JAMES GERARD RUEHLMANN (CINCINNATI, OH), RICHARD FERRELL GLADNEY (FAIRBURN, GA)
Application Number: 13/558,092
International Classification: A47C 27/15 (20060101);