Breathable And Light Weight Mattress

Abstract

The problems of the prior art are addressed by a novel mattress for an infant play yard, crib, or bed. In one embodiment, a mattress for a play yard, crib, or bed, comprises a plurality of panels. Each panel can comprise a structural layer having a first surface area. The structural layer can comprise a plurality of structural components and a plurality of non-structural components. A supporting surface can be positioned above the structural layer and be in contact with and occupy a second surface area larger than the first surface area. A cushioning layer is supported by the supporting layer. The plurality of panels can be connected to one another to allow for folding and transport of the mattress. In certain embodiments, the structural components comprise ribs and the non-structural components comprise openings between the ribs. The panels may be formed of plastic, metal, wood, or other suitable materials.

Description

The present application claims priority to U.S. Provisional Patent Application Ser. No. 62/042,872 for “Breathable and Light Weight Mattress”, filed Aug. 28, 2014, the disclosure of which is incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to a mattress for a play yard, crib, or bed. In particular, the present disclosure relates to a mattress having a rigid substructure that is breathable, light-weight, and foldable.

BACKGROUND

Play yards are well known in the art. Play yards are structures designed to provide a safe environment for infants and children. Conventional play yards are designed to fold into a compact, generally rectangular structure. When erected, the play yard should be stable, and provide support to keep the structure standing upright. For maximum convenience, a foldable play yard should be readily collapsible to a storage position without the disassembly of any parts. When stored, the play yard should be easily transportable from one location to another.

Play yards typically include a mattress that may be removed and placed within an opened play yard. Play yard mattresses are designed to safely support a child or infant placed therein. Play yard mattresses are typically composed of a plurality of panels made from medium-density fiberboard (MDF), particle board, or other similar materials. The panels are connected at hinge points so that they may be folded over one another for ease of transportation. The panels may also be folded into a square tube, or wrapped around a folded play yard. To use, the panels are unfolded to form a rectangular mattress, which is then placed within an opened play yard to create a safe surface for play for an infant or child.

There are a number of issues with conventional play yard mattresses. Mattresses may be heavy or cumbersome, thus affecting the portability of the play yard. Infants may also expel bodily fluids onto a mattress, which may collect around the infant and lead to the mattress becoming unsanitary or unsafe. The mattress may retain odors or become stained, which may be minimized, but not eliminated, by the usage of a mattress sheet. Cleaning these mattresses may be cumbersome and sometimes ineffective, as bacteria, germs, and other matter may become embedded within the mattress. Further, rebreathing carbon dioxide is a contributing cause of Sudden Infant Death Syndrome (SIDS) and asphyxiation. Conventional crib mattresses, bedding, and materials may lead to rebreathing of carbon dioxide, and therefore may be a contributing environmental cause of SIDS and other ventilation concerns.

Currently, some of these issues are addressed in a variety of ways, with varying degrees of success. In some cases, the solutions to these issues are expensive, thereby raising the price of the play yard mattress. It would be beneficial if these issues could be addressed in a safe, convenient and cost effective manner.

SUMMARY

The problems of the prior art are addressed by a novel panel for a mattress. The panel may be used in mattresses for a play yard, crib, bed, or other furniture designed to accommodate an infant or child. In one embodiment, the problems of excess weight and lack of breathability are solved by a play yard mattress composed of a plurality of panels having structural components and non-structural components. The plurality of panels are connected to one another to allow for folding, thus creating a foldable play yard mattress. The combination provides sufficient structural support for the panel, yet results in a light-weight structure. Further, the non-structural components may increase breathability of both the panel and mattress.

An object of the invention is to provide a light weight and breathable mattress for use by an infant or child. To achieve this object, embodiments of the disclosure may comprise a mattress having a rigid substructure with perforations, covered by a soft fabric.

In some embodiments, the structural and non-structural components may comprise a design, which further may comprise a repeated pattern. The design may be any design, such as hexagons, triangles, circles, squares, cross-hatch, or herringbone patterns. The structural components may comprise ribs surrounding the non-structural components, and the non-structural components may be open spaces between the ribs. Alternately, the non-structural components may comprise areas of the panel having a thinner wall thickness than the structural components.

In some embodiments, the panels are formed of molded plastic. The panels may be formed using suitable plastic molding techniques, which may include gas assist injection molding, blow molding, and rotational molding. In other embodiments, the panels may be formed of metal, such as machined aluminum, or even wood.

In some embodiments, the panels are connected to one another using a hinge, such as a living hinge or metal hinge. The panels may also be covered in fabric and soft material, such as batting, foam, or rubber, thus making the contact surface of the panel soft and walkable. In a further embodiment, the fabric and soft material may be replaced in the event of stains or retained odors. The plurality of panels may comprise four, five, or any number of panels.

In some embodiments, each panel may be formed from an upper and a lower panel, each having an edge, structural components, and non-structural components. The panels are stacked on top of one another such that the edges of each panel are in contact, thus forming an interior space between the panels. In other embodiments, the structural components of the upper and lower panels are in contact. The panels may be connected using heat welding, screws, snaps, or a living hinge.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present disclosure, reference is made to the accompanying drawings, which are incorporated herein by reference and in which:

FIGS. 1A-D are top views of several embodiments of panels according to embodiments of the disclosure,

FIG. 2A is a cross-sectional view along the line A-A′ in FIG. 1A, and FIG. 2B is a cross-sectional view along the line B-B′ in FIG. 1A;

FIG. 3 is a cross-sectional view of a compound panel formed from an upper panel and a lower panel according to an embodiment of the disclosure;

FIGS. 4A-B are cross-sectional views of embodiments of panels according to the disclosure comprising ribs having interior spaces;

FIGS. 5A-D are top, bottom, perspective, and zoomed perspective views of a panel comprising a supporting surface for accommodating a foam backing or other material according to the disclosure;

FIGS. 6A-D are top, bottom, perspective, and zoomed perspective views of another embodiment of a panel comprising another embodiment of a supporting surface for accommodating a foam backing or other material according to the disclosure;

FIGS. 7A-B are top perspective and bottom perspective views, respectively, of the panel of FIGS. 6A-D and further comprising a foam backing adhered to the supporting surface;

FIG. 8A is a cross sectional view along line C-C′ of the panel of the embodiment of the panel of FIG. 7A, and FIGS. 8B-E are cross-sectional views of additional embodiments of panels comprising embodiments of supporting surfaces according to the disclosure;

FIG. 9 is a top view of a plurality of panels, such as the panel of FIG. 1A, hingedly attached to form the rigid substructure of a play yard mattress according to one embodiment of the disclosure;

FIGS. 10A-B are perspective views of the top and bottom, respectively, of an unfolded or opened play yard mattress comprising multiple panels of FIG. 8B, and FIGS. 10C-D are perspective and top views of the play yard mattress of FIGS. 10A-B in a folded or closed configuration; and

FIG. 11 is a perspective view of a play yard illustrating two positions for placement of a mattress.

DETAILED DESCRIPTION

FIG. 1 shows a front view of a single panel 100 of a mattress for a play yard, crib, or bed according to one embodiment of the instant disclosure. In this embodiment, the panel 100 is formed from molded plastic; however, a variety of materials may be used. For example, panels within the scope of the disclosure may be formed from plastic, metal, cardboard, rubber, wood, and the like. The panels may be molded, machined, or cast. As will be discussed in further detail below, the panel 100 may be combined with several similar panels according to the disclosure in order to form a mattress. In particular, the panel 100 serves as a rigid, yet light-weight substructure for the mattress, thus providing stability for the mattress. However, the panel 100 also allows for ventilation and transmission of fluids and gases, and certain embodiments further comprise soft surfaces for placing an infant or child thereon.

The panel 100 has an edge 102 forming its perimeter. The edge 102 may comprise the same material as the panel, or alternately may be composed of a different material. In certain embodiments, the edge 102 may be omitted. The panel 100 further comprises a plurality of structural components 106 and a plurality of non-structural components 108. The structural components 106 are configured to provide support, strength, and stability for the panel 100, whereas the non-structural components 108 are configured to reduce the weight of the panel 100. Further, as shown in this embodiment, the structural components 106 and non-structural components 108 may be arranged to comprise a pattern 104.

As shown in this embodiment, the pattern 104 can comprise a repeated hexagonal design. However, the hexagonal design is only exemplary, and it should be understood that other patterns or shapes may be used, such as triangles, circles, squares, cross-hatch, or herring-bone patterns. The pattern 104 may be repeating or non-repeating. Further, the pattern 104 may comprise any shape, design, or figure, and not just geometric shapes. In certain embodiments, the pattern 104 may comprise multiple shapes or patterns. The use of a pattern 104 is helpful in providing a design for the structural components 106; however, certain embodiments may also lack the use of a pattern 104 according to the disclosure.

The structural components 106 can comprise ribs surrounding the edges of each shape in the pattern 104, which as shown in this embodiment comprises a hexagonal design. However, in certain embodiments the structural components 106 can comprise other various internal features of the panel 100. In particular, the structural components 106 may be configured to provide support, strength, or stability for the panel 100. Preferably, the structural components 106 should comprise non-deformable or non-elastomeric materials, and thus be able to rely on their own tensile properties for support, as opposed to requiring another component or set of components to provide structural support for the panel 100. The structural components 106 should also preferably be able to maintain these properties when the weight of an infant or child is placed on the panel 100, such that the panel 100 may be used as a component of or as a mattress for a play yard, crib, or other enclosure.

As shown in this embodiment, the non-structural components 108 can comprise the width or distance between the structural components 106. For example, the non-structural components 108 can comprise a plurality of openings or cutouts in the panel, such as the hollow or open centers of each shape in the pattern 104. Accordingly, the non-structural components 108 create a channel between the top and bottom of the panel 100. The non-structural components 108 provide the benefits of reducing the weight of the panel 100, reducing material usage, and also allowing ventilation and drainage of gas and fluid when the panel 100 is used as part of a mattress for a play yard, crib, or other enclosure. Preferably, the non-structural components 108 are configured to provide these benefits without affecting the structural integrity of the panel 100.

In certain embodiments, the non-structural components 108 may simply be thinner portions of the panel 100, rather than hollow segments, openings, a width, or volume between the structural components 106. For example, the panel may be formed such that the wall thickness of the non-structural components is thinner than that of the structural components. Alternately, the pattern may comprise various combinations of both open and thinned non-structural components 108. Certain embodiments can taper between the structural and non-structural components. Various configurations and combinations of structural components and non-structural components are within the scope of the present disclosure.

As previously noted, panels 100 according to the disclosure may comprise a variety of materials. For example, suitable plastic materials include polypropylene, reinforced polypropylene, nylon, reinforced nylon, polyvinyl chloride, plastic blends (including blends comprising glass fibers and carbon fibers), and the like. Panels formed of metal may comprise aluminum, titanium, and the like. Still further embodiments may employ wood, cardboard, and other materials. Various embodiments and material usage are considered to be within the scope of the disclosure.

To achieve an optimal balance between weight and stability, a ratio between the panel surface area comprising the structural components 106 and the panel surface area comprising non-structural components 108 may be varied. Increasing the surface area of the panel occupied by the structural components 106 will increase stability of the panel 100, at the expense of increased weight. In contrast, increasing the surface area of panel occupied by the non-structural components 108 will decrease weight, yet also decrease stability. For example, one may vary both the dimensions of each shape in the pattern 104, the size of the ribs surrounding or forming the shape, and the spacing between the ribs or size of the openings or non-structural components 108. Increasing the average size of the shape in the pattern 104 leads to a larger open surface area, thus decreasing the overall weight of the panel. However, this also results in decreased stability and increased flexion, which can be undesirable when the panel is used to support an infant or child. These effects may be countered by increasing the width of the ribs forming each shape, which reduces the cumulative open surface area of the panel, thus increasing stability. In certain embodiments, these effects may also be moderated by choosing lighter or stronger materials for the structural components 106.

FIGS. 1B-1C illustrate further variations of panels 120, 140 according to embodiments of the disclosure. Similar to the panel 100, the panels 120, 140 comprise edges 122, 142; patterns 124, 144; structural components 126, 146; and non-structural components 128, 148, respectively. The panel 120 in FIG. 1B features a pattern 124 having repeated hexagons of a larger width than those in the panel 100 of FIG. 1A. As discussed above, this property leads to a larger percentage of the surface area of the panel 120 devoted to non-structural components 128. The increased open surface area of the panel results in a panel having both decreased weight and decreased stability. If the resulting decrease in stability is unacceptable, this effect may be compensated by increasing the percentage of the panel 120 devoted to structural components 126 by increasing the size of the ribs forming or surrounding each shape in the pattern 124, 144, by using a stronger material for the structural components 126, 146, or a combination of approaches.

Similarly, the panel 140 in FIG. 1C features a pattern 144 having smaller hexagons than the panel 100 of FIG. 1A, thus decreasing the surface area devoted to non-structural components 148 and increasing the surface area devoted to structural components 146. This increases both stability and weight. If the increase in weight is unacceptable, this effect may be compensated by decreasing the width of the ribs surrounding and forming each hexagon, by using a weaker material, or by using a combination of approaches. Accordingly, the ratio between structural and non-structural components may be varied until an acceptable balance between weight and stability is achieved. In certain embodiments, the percentage of surface area of the panel devoted to the openings or non-structural components 128 is greater than that devoted to the structural components 126. This feature is particularly useful to aid in both ventilation of air and drainage of liquids.

In these embodiments, the structural components 106, 126, 146 of panels 100, 120, 140 are approximately 8-10 mm tall. Each panel can be approximately 670 mm (26.4″) in length long and 240 mm (9.44″) in width. These particular dimensions are useful for connecting multiple panels together to form a mattress. However, in certain embodiments, various other dimensions and shapes may be used to accommodate a variety of play yards or other structures. For example, in certain embodiments a panel according to the disclosure may be circular, elliptical, triangular, rectangular, star-shaped, heart-shaped, and the like. In certain embodiments, the width of the structural components can be 1.8-2.0 mm and the width of the non-structural components can be about 25 mm. Further, in certain embodiments, panels can have a width that is greater than or equal to its length.

The panel 100 and structural components 106 may be formed using a variety of methods. For example, in certain embodiments a panel can comprise plastic, which may be formed using gas assist injection molding. In this case, the interior of the ribs may be cleared out in the gassed area, leaving an interior space. Gas assist injection molding may also be used to finely tune the wall thickness of the panel and rib size. Other suitable methods for molding may be used, such as blow molding and rotational molding. As previously noted, suitable plastic materials for molding include polyethylene, polypropylene, polycarbonate, nylon, and reinforced composites of these materials, for example.

As previously noted, in certain embodiments, panels according to the disclosure may also comprise other materials, such as metal, wood, and the like. FIG. 1D illustrates another embodiment of a panel 160 according to an embodiment of the disclosure. In this embodiment, the panel 160 comprises an aluminum sheet comprising an edge 162, a pattern 104, structural components 166, and non-structural components 168. As shown in this embodiment, the non-structural components 168 can comprise the perforations or holes formed in the aluminum, and the structural components 166 comprise the portions of the panel 160 which have not been perforated. In various embodiments, the size, number, arrangement, and shape of the perforations can be varied to achieve a desired ratio of stability and weight. In certain embodiments, aluminum may be preferred over plastic materials as it is a light weight and strong material. However, in certain embodiments plastic may be preferred, as it may take advantage of specialized molding techniques which may be used to include other features, as will be discussed in additional detail below.

FIG. 2A is a cross-sectional view along the line A-A′ of FIG. 1A and illustrates the structure of the structural components 106 and non-structural components 108 in the panel 100. As previously noted, in this embodiment, the structural components 106 comprise ribs surrounding the edges of the non-structural components 108. As shown in this embodiment, the ribs can have a thickness (i.e., the height between the top and bottom of the panel 100) that tapers from a maximum thickness 210 to a minimum thickness 205.

FIG. 2B illustrates a cross-sectional view along lines B-B′ of the panel 160 of FIG. 1D. As previously noted with respect to FIG. 1D, the panel 160 lacks ribs and a raised edge. In this embodiment, the structural components 166 comprise the wall thickness 215 (i.e., height) of the panel 160 between the non-structural components 168. For example, the non-structural components 168 of FIG. 2B may simply be openings, cutouts, perforations, or other features punched or machined into the panel 160, thus leaving the wall thickness of the panel 160 remaining as the structural components 106.

FIG. 3 illustrates another embodiment of a panel 300 according to the disclosure. As shown in this embodiment, the panel 300 can comprise multiple panels, such as an upper panel 310 and a lower panel 320, which may be stacked together or otherwise combined to form a combined panel 300. Similar to the panel 100, the panels 310, 320 further comprise structural components 306 and non-structural components 308. The panels are stacked such that an upper panel edge 302 on the upper panel 310 is in contact with a lower panel edge 303 on the lower panel 320, thus forming an interior space 330 between the two panels 310, 320. Further, as shown in this embodiment, the combination of the non-structural components 308 and interior space 330 creates a channel providing fluid communication between the top and bottom of the panel 300.

In certain embodiments, the structural components 306 of the upper and lower panels 310, 320 may first be aligned prior to stacking. In certain embodiments, the edges of the panels 310, 320 may be connected by a living hinge, welded, heat-sealed, screwed, or snapped together. In this way, the combined panel 300 has a thickness 340 (i.e., height) that is larger than the thickness of a single panel, yet the combined panel 300 can still be strong, breathable, and light weight. In certain embodiments, the ribs or structural components 306 of the two panels may also be connected. In other embodiments, the panels 310, 320 may be releasably attached for ease of assembly and disassembly.

In certain embodiments, structural components may further comprise a hollow or open interior. FIGS. 4A-B illustrate cross-sectional views of embodiments of panels 400, 405 according to the disclosure comprising structural components 406 and non-structural components 408, of which the structural components 406 further comprise interior spaces 412. FIG. 4A illustrates the panel 400 as comprising two sections 401, 402 that combine together to form the structural components 406 (i.e., as shown in this embodiment, ribs). Further, in this embodiment, the combination of the two sections 401, 402 leaves an interior space 412 within the rib itself, thus resulting in a rib that is thicker, yet having reduced weight due to an air pocket formed within the interior space 412.

In certain embodiments, an interior space 412 may be formed in structural components 406 through means other than stacking two separate sections. FIG. 4B illustrates a cross-sectional view of the panel 405 that has been formed using a gas-assist or blow molding technique. Accordingly, in this embodiment, the interior space 412 has been formed directly within the structural component 406 itself during fabrication, as opposed to by joining two separate sections together. In certain embodiments, this may be preferable as it helps to ensure integrity of the structural component 406 and thus prevent breaching of the interior space 412.

Further, the use of an interior space 412 may be particularly advantageous in embodiments of panels that require a wider rib, such as for attachment to another surface or foam backing, for example. Accordingly, in this embodiment, the structural components 406 can provide a contact surface area which may be used for attachment or support of a foam panel or other soft material.

As previously noted, panels according to the disclosure may serve as a mattress or a component of a mattress for a play yard, crib, or other enclosure. The mattress should preferably provide a soft and walkable surface for a caregiver to place a child or infant. In certain embodiments, panels according to embodiments of the disclosure may be covered in covered in fabric and soft material, thus making the contact surface of the panel soft and walkable. The soft material may comprise foam, breathable foam, three-dimensional mesh, spacer mesh, batting, rubber, or any other suitable material. A combination of soft materials may be used, e.g., a foam backing and a sheet or mattress cover. Further, the fabric and soft material may be removable such that if the materials begin to retain odor, or become stained, torn, or frayed, they may simply be removed for washing or replacement. However, in other embodiments, the fabric and soft material may not be replaceable to minimize the number of seams and/or failure points for the fabric, and depending on other considerations regarding longevity and intended use.

FIGS. 5A-D illustrate another embodiment of a panel 500 according to the disclosure. Similar to previous embodiments of panels disclosed herein, as shown in this embodiment, the panel 500 comprises an edge 502, a pattern 504, structural components 506, and non-structural components 508. Further, the panel 500 comprises a supporting surface 516 positioned above the structural components 506. The supporting surface 516 comprises a planar surface above the structural components 506 that increases the available surface area of the panel to support an additional cushioning layer, such as a soft material configured to support an infant or child. Suitable soft materials can comprise foam, mesh, padding, and the like. Additionally, as shown in this embodiment, the supporting surface 516 can comprise openings 518 or perforations positioned above the non-structural components 508, thus creating a channel between the top and bottom of the panel 500 and maintaining breathability of the panel 500.

In this embodiment, the panel 500 comprises injection molded plastic. Accordingly, the panel 500, structural components 506, and supporting surfaces 516 may be formed together as a single plastic component. However, in certain embodiments, supporting surfaces 516 according to the disclosure may also be added later as a separate component from the structural components 506. For example, the supporting surface 516 may comprise a sheet of plastic or other material that is adhered to the structural components 506; thus, the openings 518 in the supporting surface 516 may comprise holes, openings, or perforations punched into the supporting surface 516. Preferably, the openings 518 should be positioned over the non-structural components 508 to create a channel between the top and bottom of the panel 500, thus ensuring breathability and the ability to transfer gas, liquid, air, and other materials through the panel 500.

A supporting surface 516 provides a variety of benefits for a panel according to the disclosure. For example, as shown in this embodiment, the supporting surface 516 provides additional stability for the panel 500 by preventing twisting or torsion of the structural components 506. Additionally, the supporting surface 516 provides additional strength to the panel 500, thus allowing for the use of thinner structural components 506 or structural components 506 comprising materials that would otherwise not be practical or provide sufficient strength. Accordingly, while the first contact surface area of the structural components 506 may be insufficient to adhere to a cushioning layer, the provision of a second, larger, contact surface area by the use of a supporting layer or supporting surface 516 helps to attach the structural components 508 to a cushioning layer or other soft material without increasing the size of the structural components 506, thus helping to keep the panel light weight.

FIGS. 6A-D illustrate another embodiment of a panel 600 comprising an edge 602, structural components 606, and non-structural components 608, and a supporting surface 616 according to the disclosure. In contrast to the supporting surface 516 of the panel 500, as shown in this embodiment, the supporting surface 616 can comprise openings 618 having substantially the same shape (i.e., hexagonal) as the non-structural components 608. As shown in this embodiment, the feature may help to facilitate fabrication of the panel during fabrication, such as by injection molding or other plastic fabrication techniques. Further, having the openings substantially conform to the shape of the pattern 604 helps to maximize air flow and ventilation by maximizing the amount of open area between the top and bottom of the panel 600.

While in these embodiments, the supporting surfaces 516, 616 comprise features that are positioned above the structural components 506, 606, respectively, in certain embodiments supporting surfaces according to the disclosure may extend outwardly from structural components according to the disclosure. For example, in certain embodiments, a supporting surface may comprise protrusions that extend longitudinally from a structural component or rib according to the disclosures. The protrusions may have a surface along the same plane as the top of the structural components. Accordingly, the protrusions would similarly provide a larger surface area for attachment of an additional component as compared to only the structural components. Various embodiments and equivalents are considered to be within the scope of the disclosure.

FIGS. 7A-B illustrate the panel 600 of FIGS. 6A-D, and further comprising a cushioning layer, such as a foam backing 650 adhered to the supporting surface 616. As previously noted, the supporting surface 616 facilitates attachment of the foam backing 650 by increasing the available surface area on the top of the panel 600 (i.e., by reducing the amount of surface area on the top of the panel occupied by the non-structural components) available for attachment to the panel. The foam backing 650 allows for the panel 600 to be used as a soft surface for a caregiver to safely place a child or infant thereon. Ideally, the foam backing 650 should be chosen or configured such that the infant or child does not sufficiently come into contact with the structural components 608. Though in this embodiment the foam backing 650 is only attached to one side of the panel 600, in other embodiments foam backing or other soft material may be attached on both sides. Further, due to the non-structural components 608, the panel 600 will be breathable, promoting air flow and allowing for liquids placed on the foam backing 650 to drain. Preferably, the foam backing 650 will comprise a material that is gas and liquid permeable and washable. Examples of suitable materials for use as a foam backing 650 can comprise nylon foam, closed-cell or open-cell foam, EVA foam, 3D mesh, spacer mesh, polyurethane foam, and the like.

As shown in this embodiment, the foam backing 650 may be attached to the panel 600 and supporting surface 616 using glue, Velcro, by over-molding, or any other fastening means. However, in certain embodiments, the foam backing 650 may not be securely attached to the panel 600, and instead may simply be positioned over and supported by, or otherwise in contact with the panel 600 and/or supporting surfaces 616.

As shown in this embodiment, the foam backing 650 can further comprise openings 652 positioned over the openings 618 of the supporting surface 616, which in turn are positioned over the non-structural components 608, thus forming a channel between the upper and lower sides of the panel 600. As previously noted, this maintains the breathability of the panel, allowing for both air flow and drainage. As shown in this embodiment, the openings 652 match the size of the supporting surface 616, thus maximizing breathability. However, in certain embodiments, the openings 652 can be sized smaller or larger than the supporting surface 616. For example, in certain embodiments the soft material may be soft enough such that a child or infant placed thereon would contact the structural components 506. In these embodiments, it may be preferable to reduce the size of the openings 652 to slightly overlap the supporting surface 616 and structural components 606.

FIG. 8A illustrates a cross-sectional view of the panel 600 along line C-C′ in FIG. 7A. As shown in this embodiment, the supporting layer or surface 616 can be molded together as a component of the structural components 606. The use of the supporting surface 616 allows for the structural components 606 to be thinner, thus further decreasing the weight of the panel 600. Accordingly, the supporting surface 616 can be wider than the structural components 606, thus presenting a larger contact surface area for supporting or attaching the foam backing 650. In this embodiment, the width of the structural components 606 is 1.8-2 mm, the width of the non-structural components 608 is 25.4 mm, and the width of the supporting surface 616 is 5-6 mm. The height or thickness of the structural components 606 can be 10 mm, or even less. For example, if the panel 600 comprises reinforced polypropylene, the height of the rib can be 8 mm.

As shown in this embodiment, the combination of the non-structural components 608, openings 618, and openings 652 create a channel between the top and bottom of the panel 600, allowing fluid communication for gas and liquid. FIG. 8B illustrates a cross-sectional view of the panel 600 of FIG. 7A with the foam backing 650, and further comprising an outer layer 660. In the embodiment shown, the outer layer 660 completely surrounds both the panel 600 and foam backing 650. In certain embodiments, the outer layer 660 may comprise a thin mesh material.

The outer layer 660 serves as an additional layer for providing a soft surface for placing an infant or child. Additionally, the outer layer 660 can also prevent foreign objects or other materials from occupying or blocking the channel defined by the non-structural components 608, openings 618, and openings 652. Further, in certain embodiments, the outer layer 660 may be removable. In this way, the outer layer 660 may be removed to allow for cleaning or replacement of either the outer layer 660 or the panel 600. Further, in embodiments where the outer layer 660 comprises mesh or other breathable materials, the ventilation of the channel defined by the non-structural components 608, openings 618, and openings 652 will not be severely impacted.

FIG. 8C illustrates a cross-sectional view of the panel 600 comprising another embodiment of a cushioning layer or foam backing 670 according to the disclosure. As shown in this embodiment, the foam backing 670 may instead comprise a single continuous planar sheet of a soft material, and thus lack openings 652, as compared to the foam backing 650 of FIGS. 8A-B. In these embodiments, it may be preferable to use materials having increased breathability, thus continuing to allow the transfer of air and fluids between the upper and lower portions of the panel 600 through the non-structural components 608 and openings 618 of the supporting surface 616.

FIG. 8D illustrates a cross-sectional view of another embodiment of a panel 700 comprising structural components 706 and non-structural components 708, the structural components 706 further comprising a supporting surface 716 for a foam backing 760 that is thinner than the structural components 706. In particular, as shown in this embodiment, the supporting surface 716 comprises a protrusion extending from the structural components 706. Further, in this embodiment, the foam backing 760 further comprises a groove 718 that securely fits over the supporting surface 716. In certain embodiments, this feature helps to keep the foam backing 760 firmly attached to the panel 700. However, compared to the panel 600 of FIGS. 8A-C, the panel 700 requires structural components 706 that are relatively wider, potentially increasing the weight of the panel. In certain embodiments, the structural components 706 may further comprise interior spaces (e.g., the interior spaces 412 of FIGS. 4A-B) to decrease the weight of the panel 700 accordingly.

FIG. 8E illustrates a cross-sectional view of another embodiment of a panel 720 comprising structural components 726 and non-structural components 728, the structural components 726 further comprising a supporting surface 736 for a foam backing 770. In this embodiment, the supporting surface 736 comprises a groove sized to accommodate a protrusion 738 extending from the foam backing 770. For example, the foam backing 770 may be prefabricated and then pressed onto the supporting surface 736. In other embodiments, the foam backing 770 may instead comprise rubber or another moldable material, which may be over-molded directly into the supporting surface 736. Various embodiments are considered to be within the scope of the disclosure.

It should be noted that the individual features described herein may be combined with one another to present various embodiments of a mattress. For example, a mattress according to the instant disclosure may comprise two panels stacked on one another, and also feature ribs and a supporting surface to allow placement of a foam backing or other soft material. In certain embodiments, foam backings or other soft materials having openings or no openings may be adhered to a variety of supporting surfaces, or directly to a structural component or rib. Each of the above described features may be combined with one another to form various panels and mattress according to the disclosure.

FIG. 9 is a top view of a mattress 800 for a play yard, crib, or bed according to an embodiment of the instant disclosure. The mattress 800 can comprise four panels; in this embodiment, each panel is the panel 100 as shown in FIG. 1A. However, mattresses according to the disclosure may comprise various panels according to the disclosure, including different embodiments or combinations of panels. The panels are separated by a gap 810 and are connected by an attachment mechanism 820 which allows the panels to pivot with respect to one another.

The attachment mechanism 820 can comprise a hinge, allowing the panels 100 to pivot with respect to one another such that the mattress 800 may be folded. However, the attachment mechanism may be any means of attaching panels to one another, such as a living hinge, straps, snaps, movable joint, or other mechanism. The gap 810 and attachment mechanism 820 allow the panels to be folded against each other, or to form a square tube. This aids portability, as the panels may thus be wrapped around a folded play yard and used as a box. Alternately, the panels may be stacked on one another and stored with or adjacent to a folded play yard.

FIGS. 10A-B illustrate another embodiment of a mattress 900 according to the disclosure. Similar to the mattress 800, the mattress 900 comprises four panels. In this embodiment, the panels comprise the panel 600 of FIG. 7A, and accordingly comprise a foam backing 650 secured to supporting surfaces 616 and surrounded by an outer layer 660. The panels 600 serve as a rigid substructure for the foam backing 650 and outer layer 660, thus resulting in a light weight, breathable, yet soft, mattress 900. As previously noted, the foam backing 650 can comprise breathable foam, 3D mesh, spacer mesh, and the like to allow air flow and liquid drainage through the non-structural components 608. Finally, the outer layer 660 surrounds the panel 600 and foam backing 650, providing a soft surface for placing an infant or child thereon.

FIGS. 10C-D illustrate the mattress 900 when folded. As the mattress 900 comprises four panels 600, it may be folded along the gaps 810 into a rectangular structure, creating a volume 910 for receiving a collapsed play yard or other objects. Though the mattresses 800, 900 in this embodiment comprises only four panels, more or fewer panels may be used. For example, if the average panel width is shorter, more panels may be required to create a full-length mattress according to the disclosure. In some embodiments, a play yard mattress uses five panels. Four- and five-panel configurations are beneficial because they allow for easy folding into a box-like structure to contain the folded play yard. However, in certain embodiments, panels may simple be folded over onto one another into order to form a compact structure for storage or travel. However, in some embodiments the mattress may comprise only a single panel.

In some embodiments, mattresses according to the disclosure may be disassembled into individual panels for ease of storage, or for panel replacement. Alternately, the panels may be permanently attached.

As described above for panels according to the instant disclosure, the mattresses 800, 900 may be covered in fabric and soft material, thus making the contact surface soft and walkable. Further, the hollow or open surface area of the panels (e.g., the channel created by the non-structural components, openings in the supporting surface, and opening in the foam backing) leads to the unique property of increasing breathability for the mattresses 800, 900 thus providing for an air layer beneath the fabric and soft batting. Breathability is desired as it provides more air to an infant or child within the play yard, and also helps to prevent mold, bacteria, or odors from settling within the mattresses 800, 900. Further, the combination of layers, i.e., a mesh outer layer 660, foam backing layer (e.g., foam backing layer 650), and a rigid sublayer or structural layer (e.g., the panel 600), results in a mattress 800, 900 this is also sturdy and light weight.

In use, the mattresses 800, 900 may be unfolded flat and then placed within a play yard. As illustrated by FIG. 11, a mattress according to the present disclosure may be used in various locations of a play yard 1000. For example, infants who do not yet have the ability to pull themselves up or to stand may sleep comfortably on the mattress placed in the bassinet position 1010. However, older children with increased mobility will be safely contained if the mattress is placed in the floor position 1020 instead. Alternately, the mattresses 800, 900 may even be used without a play yard to simply provide a clean and soft surface to place an infant or child.

When not in use, mattresses according to embodiments of the disclosure may be folded and wrapped around a folded play yard, thus forming a convenient package for travel.

It should be noted that embodiments of panels according to the instant disclosure may comprise any form of structural and non-structural components in a panel. As discussed above, other shapes in a pattern may be used. Multiple patterns and designs may be used in a single panel. The panels may vary in their dimensions. The ribs or structural components may comprise a variety of shapes and configurations. Mattresses may be formed from a single panel or from multiple panels. The panels may be connected by hinges or other forms of attachment mechanisms.

Embodiments of the disclosure may be used in any kind of mattress. For example, embodiments of panels according to the disclosure may be used as a surface for resting by adults, such as for camping. Further, while various layers or components of panels are described hereinabove, these layers may be omitted or used in combination with other layers or features to form embodiments of panels according to the disclosure. Moreover, layers according to the disclosure do not need to be formed of different materials or manufactured separately; for example, a supporting layer or surface and a structural component according to the disclosure may comprise a single piece of molded plastic, metal, or other material.

The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Furthermore, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein.

Claims

1. A mattress for a play yard, crib, or bed, comprising:

a plurality of panels, wherein each panel of the plurality of panels comprises: a structural layer comprising a plurality of structural components and a plurality of non-structural components, each of the plurality of structural components and plurality of non-structural components having a width; a supporting surface positioned above the structural layer, the supporting surface in contact with the plurality of structural components and further comprising openings having a width smaller than the width of the non-structural components, the openings positioned over and in communication with the non-structural components; and a cushioning layer supported by the supporting surface;

wherein the plurality of panels are connected to one another to allow for folding of the mattress.

2. The mattress of claim 1, wherein the plurality of structural components comprise ribs, and the plurality of non-structural components comprise open spaces between the ribs.

3. The mattress of claim 1, wherein the plurality of structural components and the supporting surface are adhered together.

4. The mattress of claim 1, wherein the openings are in communication with the plurality of non-structural components of the structural layer.

5. The mattress of claim 4, wherein the cushioning layer further comprises a plurality of openings, each of the plurality of openings in communication with one of the openings in the supporting surface.

6. The mattress of claim 1, wherein the supporting surface comprises a planar surface.

7. The mattress of claim 1, wherein the cushioning layer comprises a foam material.

8. The mattress of claim 1, further comprising an outer layer enveloping each panel.

9. The mattress of claim 8, wherein the outer layer comprises mesh.

10. The mattress of claim 1, wherein the structural layer, supporting surface, and cushioning layer each have a length and width that is substantially the same.

11. The mattress of claim 1, wherein the plurality of structural components comprise a wall thickness of the panel surrounding the plurality of non-structural components.

12. A mattress for a play yard, crib, or bed, comprising:

a plurality of panels, wherein each panel of the plurality of panels comprises: a rigid layer having a first contact surface area, the rigid layer comprising a plurality of ribs and openings between the ribs; a cushioning layer supported by the rigid layer, the cushioning layer configured to prevent an infant or child from substantially contacting the rigid layer;

wherein the plurality of panels are hingedly connected to one another to allow for folding of the mattress.

13. The mattress of claim 12, wherein the cushioning layer further comprises openings in communication with the openings between the plurality of ribs.

14. The mattress of claim 12, wherein the plurality of ribs further comprises a design.

15. The mattress of claim 14, wherein the design is selected from the group consisting of hexagons, triangles, circles, squares, cross-hatch, and herringbone patterns.

16. The mattress of claim 14, wherein the design is a repeated design.

17. The mattress of claim 12, further comprising a supporting layer positioned above the ribs, the supporting layer in contact with the ribs and having a second contact surface area larger than the first contact surface area;

wherein the supporting layer supports the cushioning layer.

18. The mattress of claim 12, further comprising an open space in the interior at least one of the plurality of ribs.

19. The mattress of claim 12, wherein the plurality of structural components comprise a material selected from the group consisting of machined aluminum and molded plastic.

20. A panel for a play yard, crib, or bed, comprising:

a structural layer having a first contact surface area, the structural layer comprising a plurality of structural components and a plurality of openings;

a supporting layer positioned above the structural layer, the supporting layer in contact with the first contact surface area and occupying a second contact surface area larger than the first contact surface area, the supporting layer further comprising openings in fluid communication with the openings in the structural layer;

a cushioning layer supported by the supporting layer, the cushioning layer in contact with the second contact surface area and having openings in fluid communication with the openings in the supporting layer; and

a mesh layer surrounding the structural layer, supporting layer, and cushioning layer;

wherein the structural layer, supporting layer, and mesh layer each have a length and width that is substantially the same.