System and Method for Reducing Declivities

Abstract

A system and method to reduce declivities in a mattress utilizing a container having at least a top layer and a flexible bottom layer, and defining at least one chamber between the top layer and the bottom layer. The system further includes a fill material disposed within the at least one chamber and capable of being moved within the chamber by manipulation of the top layer. The fill material and the bottom layer therefore are capable of being moved by a human into declivities in the mattress to render the top layer more level.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 62/157,757 filed 6 May 2015. The entire contents of the above-mentioned application is incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to remediation of mattresses that develop one or multiple declivities and more particularly to assemblies and techniques that partially or completely fill or occupy the declivities.

BACKGROUND OF THE INVENTION

A common problem with mattresses of every type, including those with springs, foam, and hybrid combinations including springs and foam, is that they develop one or more declivities during extended use. The term “declivity” or “declivities” is utilized herein to refer to downward slopes such as sags or other depressions that occur over time. This condition can be the result of normal use, known as “body impressions” or “wear and tear” or “worn down” or “worn out” and/or as the result of poor quality or inexpensive materials and/or inferior workmanship. This situation causes the mattress to lose comfort and/or support and the mattress eventually needs to be replaced.

In addition, many consumers can find themselves unhappy or uncomfortable with the comfort level or feeling of their mattress even in the absence of noticeable declivities. Some consumers may decide that they want a different “feel” or resilience to their mattress.

In an attempt to alleviate the discomfort resulting from declivities, and/or to extend the life of the mattress or to alter its resilience, many people will buy a product known as a mattress “topper”. The most common toppers consist of a layer of foam which is available in a variety of densities and thicknesses, with or without “gel” or other cooling agents, with or without its own fabric cover or bag and with or without devices such as elastic straps or stretch “skirts” designed to hold this layer of foam or “topper” in place. A second common topper system includes a fiber-filled quilted “bag” or container made in a variety of fabrics, with or without devices such as elastic straps or stretch “skirts” designed to hold it in place. One type of mattress comfort topper is described by Warshaver in U.S. Patent Publication No. 2007/0234479. An air mattress with quilted pillow top is shown in U.S. Pat. No. 6,966,090 by McClintock et al.

Another product designed to alleviate declivities and to extend the life of the mattress include products made from a variety of materials that are placed under the entire mattress that attempt to provide firmness and support, such as a “sag stopper” disclosed by Firestone in U.S. Patent Publication No. 2007/0000060. Some of these products include mechanical devices or systems that are designed to “push” the entire mattress up from underneath. These products represent a type of modern application of the common practice used for countless generations of laying a sheet of plywood or other such material under the mattress.

The primary and common shortcoming of conventional mattress toppers that are placed on the mattress or products that are placed under the mattress, relative to addressing the situation where sagging or other declivities develop, is that they do not directly or effectively address the problem. Mattress toppers that are placed on top of the mattress sink, or fall into, or follow the declivity itself. Products that are placed under the mattress do not directly address or in many cases barely affect the declivity where it comes into direct contact with the consumer at the upper surface of the mattress.

A topper with individual tubes filled with shredded foam/fiber material is disclosed by Collard et al. in U.S. Pat. No. 6,574,814. A cushioning device having a reception cavity for filler is described by Schecter et al. in U.S. Pat. No. 6,988,286. Various fill materials are described by Lawson in U.S. Pat. No. 3,216,028 and by Pearce in U.S. Pat. No. 6,498,198, for example.

It is therefore desirable to have an improved mattress topper system that directly addresses and/or resolves one or multiple declivities such as in a mattress that has lost its ability to provide sufficient comfort or support.

SUMMARY OF THE INVENTION

An object of the present invention is to address and/or resolve a pre-existing issue where a mattress has developed one or multiple declivities.

Another object of this invention is to change the comfort, support, or feeling of the mattress and/or make it softer or firmer or just different.

This invention features a system to reduce declivities in a mattress, including a container having at least a top layer and a flexible bottom layer, and defining at least one chamber between the top layer and the bottom layer. The system further includes a fill material disposed within the at least one chamber and capable of being moved within the chamber by manipulation of the top layer such that the fill material and the bottom layer are capable of being moved by a human into declivities in the mattress by manipulation of the top layer.

In one embodiment, the fill material is resistant to movement when an average-sized human lies on the container. In some embodiments, the fill material includes a plurality of pieces that frictionally engage with each other when an average-sized human lies on the container. In certain embodiments, the fill material includes a plurality of pieces, each piece having a thickness and a length greater than the thickness. In one embodiment, the fill material includes a plurality of flat pieces, each piece having a thickness, a width, and a length greater than the thickness and greater than the width. In certain embodiments, the flat pieces are formed of at least one type of foam. In one embodiment, at least some of the flat pieces are formed of memory foam. In some embodiments, the container is sized at least as large as an average-sized human. In certain embodiments, the container is sized at least twenty five percent as large as a twin-sized mattress, or at least twenty five percent of the size of a mattress selected for remediation or enhancement according to the present invention. In one embodiment, the container is integral to the mattress.

This invention also features a method to reduce declivities in a selected mattress, including selecting a container at least twenty five percent as large as the selected mattress and having at least a top layer and a flexible bottom layer, the container defining at least one chamber between the top layer and the bottom layer, and selecting a fill material disposed within the at least one chamber. The bottom layer and the fill material are capable of being moved by a human into declivities in the mattress. The method further includes placing the container on top of the mattress, and manipulating the top layer to move a portion of the fill material and thereby the bottom layer into the declivities.

This invention further features a kit to reduce declivities in a selected mattress, including a container at least twenty five percent as large as the selected mattress and having at least a flexible top layer, a flexible bottom layer, and at least one side layer joining the top layer to the bottom layer. The container defines at least one chamber between the top layer and the bottom layer, and a fill material is disposed within the at least one chamber and capable of being moved within the chamber by manipulation of the top layer. The bottom layer and the fill material are capable of being moved by a human into declivities in the mattress by manipulation of the top layer. The kit further includes a foam sheet sized at least as large as an average-sized human and which is placeable on top of the container, and may further include a mattress protector sized at least as large as the foam sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

In what follows, preferred embodiments of the invention are explained in more detail with reference to the drawings, in which:

FIG. 1 is a schematic perspective view of a conventional mattress, without a “sag” or other declivity;

FIG. 2 is a schematic partial cross-sectional view of an outer container and fill components of a topper system according to the present invention and how they work together to fill a declivity in a mattress and create a level, more comfortable sleep surface;

FIG. 3 is a representative view of a blend of fill components, including foam, beads, tubes, and fiber, according to one aspect of the present invention that are placed into the outer container;

FIG. 4 is a schematic perspective view of a flat “conventional” foam mattress topper;

FIGS. 5, 7 and 8 are schematic views of additional fill components of a “blend” according to one aspect of the present invention, including fiber, tubes and beads, respectively;

FIG. 6A is a schematic view of different shapes of foam utilized according to the present invention;

FIG. 6B is a schematic top view of overlapping strips of foam utilized according to the present invention;

FIG. 9 is a schematic perspective, partial cross-sectional view of a container filled with blend according to another aspect of the present invention, highlighting elastic side-walls placed over a mattress;

FIG. 10A is a schematic perspective, partial cross-sectional view of a sagging mattress with a conventional, flat topper initially placed across the top of the sag;

FIG. 10B is a view similar to FIG. 10A showing how a conventional, flat topper will naturally fall into, or follow, the mattress's sag;

FIG. 11 is a schematic perspective, partial cross-sectional view of a sagging mattress showing how a container with fill according to the present invention is flexible and free to be placed anywhere on the mattress, and can fill sags anywhere on the mattress including a mattress with multiple sags, common with mattresses with two people sleeping on them;

FIG. 12 is a schematic perspective, partial cross-sectional view of one container according to the present invention having a zipper, with the top and bottom layers sewn together;

FIG. 13 is a view similar to FIG. 12 showing at least one side gusset joining the top and bottom layers;

FIG. 14 is a schematic perspective, partial cross-sectional view of a container according to the present invention divided into multiple length-wise chambers, with optional width-wise chambers illustrated in phantom;

FIG. 15 is a schematic perspective, partial cross-sectional view of a container according to the present invention having at least one internal gusset to establish two or more chambers within the topper system;

FIG. 16 is a schematic perspective, partial cross-sectional view of a topper system according to the present invention having at least one “skirt” deployable over a mattress;

FIG. 17 is a schematic partial cross-sectional view of a topper system according to the present invention having extended sides with an elastic edge deployable over a mattress;

FIG. 18 is an enlarged schematic perspective view of a topper system according to the present invention having securement straps at two or more of its corners;

FIG. 19 is a schematic perspective view of a topper system according to the present invention having independent securement straps;

FIG. 20 is a schematic perspective view of a topper system according to the present invention being adjusted on a mattress;

FIG. 21 is a schematic perspective, partial cross-sectional view of alternative system according to the present invention including additional layers of material;

FIG. 22 is a schematic perspective, partial cross-sectional view of an alternative system according to the present invention that is integrated into a mattress above a core; and

FIG. 23 is a view similar to FIG. 22 showing yet another system according to the present invention that obviates the need for a conventional mattress core.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

This invention may be accomplished by a system and method to reduce declivities in a mattress utilizing a container having a selected length and width, and having at least a top layer and a flexible bottom layer. The container defines at least one chamber between the top layer and the bottom layer. The system further includes a fill material disposed within the at least one chamber and capable of being moved within the chamber by manipulation of the top layer. The fill material and the bottom layer therefore are capable of being moved by a human into declivities in the mattress to establish the top layer in a more level condition.

According to some aspects of the invention, the system, also referred to herein as the “product”, resolves a pre-existing issue where a mattress has developed a declivity by at least partially filling or occupying the declivity with the bottom layer of the container filled with loose materials to establish the top layer in a more level condition. This product may or may not include an additional layer of foam as a topper, a mattress protector, and/or a mattress pad.

This product may be produced in separate parts, or layers, or combined, attached, or secured into one unit. This product may also be used to change the comfort, support, or feeling of the mattress by making it softer or firmer. In some constructions, the container includes multiple chambers, each chamber filled with loose or multiple materials and may include or be used in conjunction with a separate or attached layer of foam, placed below and/or on top of the container. In yet other constructions, such as described below in relation to FIGS. 22 and 23, the container is integral to the mattress.

Preferably, the fill material is resistant to shifting position when a user such as an average-sized human lies on the container. In other words, at least some of the components of the fill material preferably engage frictionally with each other sufficiently to avoid kinetic movement when subjected to the weight of the user. The frictional engagement typically is a “dry friction” arising primarily from surface roughness including topography, inter-surface adhesion and/or surface deformation among the fill material.

Most conventional mattresses, such as mattress 10, FIG. 1, have a level upper surface 12 when initially acquired. After usage, however, one or more declivities are created, such as declivity 22, FIG. 2, in mattress 20 which now has a sloping upper surface 24.

System 30, FIG. 2, includes an outer container 32 having a top layer 34 and a bottom layer 36 which define a chamber 38 containing fill components 40 to fill the declivity 22 in the mattress 20 and create a level, more comfortable sleep surface on top layer 34. In one construction, system 30 is covered with at least one separate foam layer 50 and/or a mattress protector 60. In other constructions, the foam layer 50 and/or the mattress protector 60 are included as part of a system 30a according to the present invention. A container according to the present invention with fill material is also referred to herein as a “bag”. When the fill material includes at least one type of foam, the combination may be referred to as a “bag of foam” or “bag filled with foam”.

When a person lies on the system 30, the weight of the person applies a force F that preferably causes at least some of the fill components 40 to frictionally engage each other. The frictional engagement resists movement of the fill components 40 and thereby resists displacement of fill components 40 out of the declivity 22.

FIG. 3 is a representative view of various fill components 40a, including one or more of: fiber 70, FIG. 5; foam 72, FIG. 6A; tubes 74, FIG. 7; and beads 76, FIG. 8, according to one aspect of the present invention that are placed into the container. Preferably, foam 72, FIG. 6A, includes elongated pieces 71 and 73 each of which has a length greater than its thickness, and preferably a length greater than its width. Pieces 71 and 73 are substantially flat. Also shown are pieces 75 with multiple curvatures and irregular pieces 77 and 79. The irregular pieces 77 and 79 can have varied surface topography to assist interlocking of fill components when the weight of a user compresses them. Other useful shapes include diamond-shaped and crosses or “X”-shaped pieces.

Elongated flat pieces 73a, FIG. 6B, tend to stack one upon another when placed in a container and utilized according to the present invention. Pieces 73a present large surface areas to each other which enhances frictional engagement when a user lies on the container. One preferred material is memory foam. In one construction, pieces 73a are approximately ¼ inch thick and approximately one to six inches in length, more preferably two inches to five inches in length, with a smaller width of at least 1/16 inch, preferably at least ⅛ inch, more preferably at least ¼ inch, or approximately ½ inch, for example.

FIG. 4 is a schematic perspective view of a flat “conventional” foam mattress topper 50a having an upper surface 52a and a lower surface 54a. Although lower surface 54a may lie within a declivity, upper surface 52a is constrained to also assume the shape of the declivity which does not provide a level sleeping surface to a consumer. However, such a topper 50a can be added on top of a system according to the present invention if additional height, uniformity and/or comfort is desired, such as described below in relation to FIG. 9.

System 30b, FIG. 9, includes an outer container 32b filled with fill components 40b, and elastic side-walls 80 placed by a user over a mattress 20b having a declivity 22b. In one construction, system 30b includes a flat foam layer 50b to provide additional cushioning, uniformity and/or height to enhance overall comfort for a user. Foam layer 50b also serves to reinforce top layer 34b and assists redistribution of fill 40b into the declivity 22b.

FIG. 10A is a schematic perspective view of a sagging mattress 20c having a declivity 22c and with a conventional, flat topper 50c initially placed across the top of the sag declivity 20c. FIG. 10B is a view similar to FIG. 10A showing how the conventional, flat topper 50c will naturally fall into, or follow, the mattress's sag 22c, which results in a non-level sleeping surface.

System 30d, FIG. 11, has a container 32d with fill 40d according to the present invention. Foam layer 50d reinforces and augments top layer 34d. Bottom layer 36d is flexible and can fill sags anywhere on the mattress 20d including a mattress with multiple sags 22d and 22e, common with mattresses with two people sleeping on them.

System 100, FIG. 12, according to the present invention includes a container 102 with a top layer 104 having a zipper 110 through which fill material can be added or removed. Top layer 104 and bottom layer 106 are sewn together at seam 108 along at least the lengths of top and bottom layers 104, 106. Container 102 appears to have an open end in FIG. 12 because it is shown in partial cross-section and without fill material for ease of illustration. Preferably, seam 108 extends around all four sides of the container 102, to establish chamber 107. Instead of a zipper 110, in other constructions a Velcro-type hook and loop closure or other access mechanism is utilized instead of a zipper 110 to access chamber 107.

System 120, FIG. 13, includes a container 122 that is similar to container 102, FIG. 12, with the addition of at least one side gusset 130 joining the top layer 124 to the bottom layer 126 to establish chamber 127. The gusset 130 typically is created from an additional strip of fabric, and is desirable when larger declivities are to be filled according to the present invention. In other words, one or more gussets 130 enable chamber 127 to have a greater height, “loft” or thickness, and to thereby carry more fill material.

System 140, FIG. 14, is divided into multiple length-wise chambers 160, 162 and 164 by seams 150 and 152 which join top layer 144 to bottom layer 146. In some constructions, an optional width-wise seam 156, shown in phantom, divides one or more of the chambers 160, 162 and 164. Each chamber preferably has its own zipper or other access mechanism. Multiple chambers may be preferred when multiple smaller declivities are expected.

System 170, FIG. 15, according to the present invention has a container 172 with at least one internal gusset 178 extending between top layer 174 and bottom layer 176 to establish two or more chambers 180 and 102 within the topper system. Container 172 also has at least one side gusset 186 in this construction to further increase the height of chambers 180 and 182. One or more of gussets 178, 186 can be created by folding and stitching a section of the outer fabric of layers 174 and/or 176, or by adding an additional piece or section of fabric. Alternatively, one or more strips of fabric or other material can be utilized as a structural “tie” to resist tension forces that may be applied before or during placement of the container 172 on a mattress.

System 190, FIG. 16, has a container 192 with a top layer 194, a bottom layer 196, an internal gusset 204, and with at least one “skirt” 200 deployable over a mattress. Skirt 200 can be attached to seam 198 extending around the periphery of container 192 and typically is made from a “stretch” fabric or another flexible fabric. Skirt 200 preferably includes an elastic band or strip 202 that is sewn into or attached to the lower border of shirt 200 in this construction. Elastic strip 202 helps secure or hold the container 192 in place on the mattress by pulling the outer edge of the skirt 200 under the sides of the mattress and gathering under the mattress itself.

System 210, FIG. 17, includes a container 212 having a top layer 214 which in one construction is larger than the bottom layer 216 and extends as a skirt 208 under a mattress 211; in another construction, a seam (not shown) retains fill material with the chamber 218 while both the top and bottom layers 214, 216 extend further to serve as the skirt 208. The extended sides of skirt 208 preferably have elastic material 222, 224 that, in one construction, forms a continuous elastic edge deployable around and under a mattress.

System 230, FIG. 18, includes a container 232 having a securement mechanism 231 such as securement straps 233, 234 at two or more of its corners to help secure the system 210 to a mattress 240. In this construction, fasteners 236 and 238 are provided on straps 233, 234, such as hook and loop fasteners. In another construction, the securement mechanism 231 is a continuous band or loop of elastic material and, in yet another construction, the securement mechanism 231 includes at least two straps of fabric or other material that can be tied together under the mattress 240 using a knot.

System 250, FIG. 19, includes a container 252 with independent securement straps 260 and 262 to secure the container 252 to a mattress 258. Strap 260 is tied together at ends 261 while strap 262 includes fastener mechanisms 263 such as hook and loop fasteners. The securement straps 260 and 262 can be provided as part of a “kit”, also referred to as a “set”, with container 252 or can be provided separately.

System 270, FIG. 20, includes a container 272 according to the present invention being adjusted on a mattress 280 prior to a user lying on the mattress 280 or between usage of the mattress 280. Container 272 optionally includes an internal gusset 274, shown in phantom. When fill material (not illustrated) is distributed evenly, the container 272 has an average height H. Lines 290 indicate a depression lower than height H where a user has gently “struck”, stroked or otherwise manipulated the top layer 273 to push fill material into a single mound 294 or, when internal gusset 274 is provided, on either side of the gusset 274, with the mound or mounds 294 being higher than height H and preferably centered over a declivity in the mattress 280. Lines 292 indicate a normal amount of fill material at height H. The user can continue adjusting or spreading the fill material within the container 272 as desired until top layer 273 is substantially level across most or all of the container 272, with the “excess” fill material of mound 294 and the bottom layer 275 nestling into the declivity. Also illustrated are securement straps 282 and 284 plus an additional layer 286 of material such as a foam sheet or a mattress pad.

In some constructions, the container is sized at least as large as an average-sized human. In certain constructions, the container is sized at least twenty five percent as large as a twin-sized mattress, or at least twenty five percent, preferably at least thirty percent, of the size of a mattress selected for remediation or enhancement according to the present invention.

Containers according to the present invention can be utilized as a sleep surface in some constructions and, in other constructions, one or more other layers are included in a “kit” or are provided separately. System 300, FIG. 21, includes a container 302 secured to a mattress 304 by securement straps 306. A bottom layer 310 includes a strap 312 in this construction and is provided independent of container 302; in another construction, bottom layer 310 is attached to container 302. Also in this construction, the upper surface of container 302 includes a pocket or pouch 320 with a securement strap 322. The pouch 320 carries a removable sheet 324 of foam or other material as desired. Also illustrated is a mattress protector 330, quilted or non-quilted as desired, with a securement strap 332 and a sheet 340 that can be provided with or independent of the container 302.

Construction, manufacture and assembly: This product may be produced in separate parts, or layers, or combined, attached, or secured into one unit. This product can be sized for a cot, a twin bed, a queen bed or a king-sized bed. Preferably, this product is at least five feet long and at least two feet wide, more preferably six feet long and at least three feet wide. This bag, container, or enclosure can be unsecured or secured to the mattress and/or any other separate layer, section, or piece of material, fabric, plastic, or foam with the purpose of holding the bag, container, or enclosure in place or in any position on or securing it in any way to the mattress.

In preferred constructions, the bags are breathable, allowing air to pass through. In some constructions, the bags are formed of non-woven fabric and include elastic corner strips or side-walls. Preferably, upgrade to higher quality fabrics that, in some constructions, include synthetic fibers, natural fibers, and blends thereof. This product includes any bag, container, or enclosure made from any natural, synthetic, or blended fabric, plastic, or foam that is sewn, glued, or molded with one of more chambers that either allow or prevent fill from being shared. This container system may be sewn and or glued, and/or tied, and/or clipped closed and may or may not have one or multiple zippers. When one or more side-walls are provided, this container system may or may not include, attached or unattached any kind of materials including elastics, fabric, plastic, foam, ties, ropes, zippers, clips, or tapes, designed to secure or hold it in place on the mattress or to secure, attach, or hold it to any other materials or separate layer or section of fabric, plastic, or foam material with the purpose of holding the bag, container, or enclosure in place or in any position on or securing it in any way to the mattress.

Most Likely Bag: #1. (Good) Entry Level Bag

Blend of urethane foams in a variety of shapes and sizes ranging from 0.5 PCF to 10 PCF (Pounds per Cubic Foot).

#2. (Better) Upgrade Bag

Blend of urethane foams in a variety of shapes and sizes ranging from 0.5 PCF to 10 PCF with (type/data) Beads

#3. (Best) Upgrade Bag

Blend of urethane foams in a variety of shapes and sizes or one consistent shape and size ranging from 1.4 to 3.5 PCF with (type/data) Beads

#4. (Green) Upgrade Bag

Blend of (USA “Green”) urethane foams in a variety of shapes and sizes or one consistent shape and size ranging from 2.0 to 3.5 PCF with (type/data) Beads

#5. (Latex) Upgrade Bag

Blend of Latex foam in a variety of shapes or one consistent shape and size ranging from 0.5 PCF to 10 PCF

Fill

Different suitable fill materials include Imported and/or Domestic Loose urethane foam (Shredded, various sizes, shapes, and densities), loose urethane foam (Shredded, various sizes, shapes, and densities) blended with beads, loose urethane foam (Shredded, various sizes and shapes, consistent [high] density) blended with or without beads, or loose urethane (US “Green”) foam (Die-cut, consistent sizes and shapes, consistent [high] density) blended with or without beads. This container system is entirely or partially filled with any amount of any loose materials in consistent and/or varying shapes and sizes and densities used exclusively or blended with any other materials, or combination of materials including any cellular materials, plastics, foam, including urethane, latex, rubber, plastics, any EPS, EPE, EPP materials in any shape, size, or configuration, any cooling or temperature regulating materials or gels, or organic materials such as cotton, wool, etc. in any size, shape, amount, or configuration separate from and/or including/blended with any synthetic or natural fibers fills. Note that EPE/EPP/EPS beads have a density of 0.5-4.0 PCF with ratios of foam to beads in blends at preferably 30%-70%, more preferred 40%-70%, and most preferred about 50:50.
This bag, container, or enclosure may be used separately or in conjunction with a separate or attached layer, sheet, slab, or strip of material.
Min/max sizes of materials can range from 0.001 to 15 pound density materials.
Min/max % can range from 0 to 100% of any and all materials in any and all combinations

Topper

Imported and/or Domestic Memory Foam in 1 inch thickness (Low Density), 1.5, inch thickness (High Density), 1.5 inch thickness, (High Density) w/gel, 2 inch thickness (High Density), 2 inch thickness (High Density) w/gel, 3 inch thickness (High Density), 3 inch thickness (High Density) w/gel. Another material is Domestic “Green” in 1.5 inch thickness (High Density), 3 inch thickness (High Density) w/gel. Yet another material is Latex in 1.5 inch thickness (High Density) and 3 inch thickness (High Density) w/gel. This product may or may not include a separate or attached section, layer, sheet, slab, or strip of material in consistent and/or varying shapes, thickness, and sizes, used exclusively or blended with any other, or combination of materials including any cellular materials, plastics, foam, including urethane, and/or latex, rubber, plastics, any EPS, EPE, EPP materials in any shape, size, configuration, any cooling or temperature regulating materials or gels, or organic materials such as cotton, wool, etc. in any size, shape, amount, or configuration separate from and/or including or blended with any synthetic or natural fibers fills with the purpose of laying over or under the bag, container, or enclosure.

Top Protector

Mattress protectors can be flat and/or quilted, with one or more chambers or channels, filled with loose materials including but not limited to foam, fiber, and feathers. The styles include Basic, Basic/quilted, High Performance, High Performance/Quilted. Any fabrics woven or treated to provide a barrier against allergens and/or to protect the mattress from stains, such as Micron 1™ available from Clean Brands of Rhode Island. Other material includes Cotton and/or cotton blends. This product may or may not include an attached or separate cover, blanket, spread, quilt, sheet, mattress pad or protector designed to cover, encase, enclose or secure in any way the bag, container, or enclosure and the section, layer, sheet, slab, or strip of material to the mattress or to provide protection from stains or provide any kind of heat and/or moisture management.
Most likely Topper: #1. (Good) A layer of urethane foam ranging from 0.5 inch to 5 inches thick with a PCF ranging from 0.5 to 6.0 PCF (Pounds per Cubic Foot).
#2. (Better) A layer of memory foam ranging from 1 inch to 5 inches thick with a PCF ranging from 1.5 to 6.0 PCF.
#3. (Better) A layer of (USA “Green”) urethane foam ranging from 1 to 5 inches thick with a PCF ranging from 1.5 to 6.0 PCF.
#4. (Better) A layer of Latex foam ranging from 1 to 5 inches thick with a PCF ranging from 1.5 to 6.0 PCF.

Sources of fill components include: EFP Corporation at http://www.efpcorp.com/material-info.cfm and from the Bean Bag Outlet at https://www.thebeanbagchairoutlet.com/understanding-chair-fillings.htm.

Description 1—

without an additional layer or layers of foam or other materials normally associated as a mattress pad, or topper, or protector, including but not limited to cotton or fiber quilted or un-quilted covers. This product is a single bag or container, or a bag or container divided into any number of sections or multiple bags or containers, attached or unattached to each other or the mattress, or any kind of fabric or materials designed to hold multiple sections into place, made of fabric or similar materials including but not limited to foam, that is filled with a blend of loose foam or other loose materials that may or may not have been or can be cut, shredded, or fabricated in any way, with or without EPS, EPE, EPP beads, blended or un-blended with fillers such as but not limited to fiber or cotton blended in, that you lay or place on an existing mattress.

This bag(s) or container(s) can also be or not be made of any material that naturally or via any treatment or additional or attached materials creates a surface that will hold itself or “cling” to the mattress. This bag or container may or may not have elastic or non-elastic sidewalls or other types of securing materials including but not limited to elastic bands, Velcro, or tying or binding straps of any type or nature designed to hold the bag(s) or container(s) down or secure it or them into place on the mattress in any way. This bag of container can also have no additional materials or devices to hold it in place.

The consumer would lay or place this bag(s) or container (s) down on the mattress, or on a layer of any materials including but not limited to foam or fabrics placed between the bag (s) or containers (s) and the mattress and spread or place the loose materials across the mattress in any way they choose including but not limited to evenly or selectively “piling” the materials anywhere on the mattress. This material will then “fill” the sag or declivity in any variety of amounts ranging but not limited to “none at all” in any particular area of the bag (s) or container (s) and/or mattress to a pile of any size anywhere in any particular area of the bag (s) or container (s) on the mattress. This material would then provide a new sleep surface. The consumer can then but does not need to, place a mattress pad, protector, or topper of any kind over the top of the entire product. The consumer can then but does not need to place a sheet over the top of the product.

Description 2—

with an additional layer or layers of foam or other materials normally associated as a mattress pad, or topper, or protector, including but not limited to cotton or fiber quilted or un-quilted covers.

This product is a single bag or container, or a bag or container divided into any number of sections or multiple bags or containers, attached or unattached to each other or the mattress, or any kind of fabric or materials designed to hold multiple sections into place, made of fabric or similar materials including but not limited to foam, that is filled with a blend of loose foam or other loose materials that may or may not have been or can be cut, shredded, or fabricated in any way, with or without EPS, EPE, EPP beads, blended or un-blended with fillers such as but not limited to fiber or cotton blended in, that you lay or place on an existing mattress. This bag(s) or container(s) can also be or not be made of any material that naturally or via any treatment or additional or attached materials creates a surface that will hold itself or “cling” to the mattress. This bag or container may or may not have elastic or non-elastic sidewalls or other types of securing materials including but not limited to elastic bands, Velcro, or tying or binding straps of any type or nature designed to hold the bag(s) or container(s) down or secure it or them into place on the mattress in any way. This bag of container can also have no additional materials or devices to hold it in place.

The consumer would lay or place this bag(s) or container (s) down on the mattress, or on a layer of any materials including but not limited to foam or fabrics placed between the bag (s) or containers (s) and the mattress and spread or place the loose materials across the mattress in any way they choose including but not limited to evenly or selectively “piling” the materials anywhere on the mattress. This material will then “fill” the sag or declivity in any variety of amounts ranging but not limited to “none at all” in any particular area of the bag (s) or container (s) and/or mattress to a pile of any size anywhere in any particular area of the bag (s) or container (s) on the mattress.

This bag (s) or container (s) and the material then provides a layer of “support” by occupying the space on top of the mattress and under an additional layer or layers of materials of any kind including but not limited to those used to make mattress toppers or pads or mattress protectors including any type of foam or fabric, quilted or un-quilted, with or without any type of fiber or loose particle fills that would then be placed on top of this layer of loose materials to provide a new sleep surface.

Another aspect of the present invention relates to declivity systems incorporated into a mattress so that it is integral to the mattress. In one construction, the mattress has a permanently attached top that utilizes the same principles, materials and processes as described above. This mattress has a base, or core made of any kind of foam, fibers, or combination of materials in any variety of sizes and densities. It can be one solid piece or any number of pieces or layers in the same or varying sizes or densities. This core and/or the top can be made with or without gel or any other additives. This base or core of one mattress according to the present invention, referred to herein as “Mattress #1”, can also be made using the materials and manufacturing process found in the manufacturing of a conventional or “hybrid” spring and foam mattress including any kind of springs or metal supports and foam, fibers, and/or padding or any combination. Mattress system 400, FIG. 22, is one construction of an alternative system according to the present invention that is integrated into a mattress above a core 404. Cover 410 serves as a container according to the present invention to establish at least one chamber 411 to hold fill material 420. The fill material 420 is sometimes referred to herein as a “top” or “top layer” that rests on the core 404. In this construction, a foam layer 422 is provided above the fill material 420. In some constructions, the foam layer 422 is removable by a consumer so that it can be replaced as desired. Container 410 has a quilted top layer 412 and an access zipper 414. Mattress system 400 sits on or is fastened to a foundation box spring 430 in this construction.

In general, this Mattress #1 construction has a top, which can be permanently attached or removable, includes a layer of loose materials including but not limited to shred or die cut foam, fiber fills, EPE, EEP, EPP beads, or any combination of materials. This layer of lose materials is located on top of the base, or mattress core, and under a layer of foam, fiber, or any combination of materials; this layer of loose materials are located between the mattress base and the top layer of foam, fiber, or any combination. These loose materials can be confined in a container, or bag that has been sealed or sewn, or divided into chambers, or multiple containers or bags. This container may be attached or unattached to each other containers, or the mattress core, or the fabric on top of the core, or the top layer of foam and/or fibers, and/or the top fabric in any way. These loose materials may also be not contained in anything other than the mattresses' outer fabric, cover, or “ticking” itself. These containers and these layers that make up the mattresses “top” may or may not have elastic sidewalls, zippers, or any other fastening system that will hold them down or in place or secure them to each other or the mattresses core or foundation in any way. This product may be produced in separate parts, or layers, or combined, attached, or secured in any way. This top might also be a self-container unit, (loose materials and foam layer in a separate container or bag) that can be dropped into the mattress ticking, on top of the core. The core or base would have a re-sealable opening, such as but not limited to a zippered opening. You would be able to open, or un-zip the mattresses ticking and insert this topper or comfort layer unit inside and on top of any and all kind of mattress core, and then close the opening (re-zipper) making it a finished product.

Mattress system 500, FIG. 23, obviates the need for a conventional mattress core. Cover 510 serves as a container according to the present invention to establish at least one chamber 511 to hold fill material 520. In this construction, a foam layer 522 is provided above the fill material 520. In some constructions, the foam layer 522 is removable by a consumer so that it can be replaced as desired, as indicated by raised top layer 512a drawn with dotted lines after access zipper 514 is utilized to detach one or more edges of top layer 512 from the remainder of container 510. Mattress system 500 sits on or is fastened to a foundation or platform 530 in this construction and is secured to it by fasteners 532. Platform 530 includes an optional headboard 534.

In general, this second type of mattress system according to the present invention, referred to as “Mattress #2”, has a fill material that serves as a base or core and is typically made of any kind of loose materials including but not limited to shred or die cut foam, fiber fills, EPE, EEP, EPP beads, or any combination of materials. These loose materials can be confined in a container, or bag that has been sealed or sewn. This container may be divided into chambers, or multiple containers or bags that may be attached or unattached to each other or the top layer—to be described—or bottom layer—to be described—or to the products shell, or cover, or ticking—to be described—in any way. A layer of foam, fiber, or any combination of materials is placed on top of the loose materials. An additional layer of foam, fiber, or any combination of materials may also be placed on the bottom, or under these lose materials. These top and bottom layers may or may not be attached to each other in any way including but not limited to sewn or glued. They may or may not also be attached in any way to the container, or products cover, or ticking in any way. Any and all parts or parcels can be self encased, or covered in any kind of encasement or not. These loose materials along with the layer (s) may also be contained only in, and in nothing other than the mattresses fabric cover, or “ticking” itself. This mattress and these layers may or may not have elastic sidewalls, zippers, straps, or any other fastening system that will hold it down and secure it into place on a platform bed or any conventional mattress foundation, box-spring, storage units, slats, bunky-board, or comparable support system. This product may be produced in separate parts, or layers, or combined, attached, or secured in any way.

Most Likely

Mattress #1.

The top, or comfort layer has almost the identical construction story to the topper; a layer of foam supported by a layer of loose materials, foam and beads. However there will most likely be a layer of foam or some kind of “stabilizing” material to give the product form and structure under the loose materials as well. There may also be some kind of foam or material used on the sides of the unit to give the unit form, structure, and stability.
The unit will be encased in a mattress ticking that will accent or match that of the mattresses core.
The topper will be secured to the core with a zipper, or comparable fastener.

Mattress #2.

The top, or comfort layer has almost the identical construction story to the topper; a layer of foam supported by a layer of loose materials, foam and beads. However there will most likely be a layer of foam or some kind of “stabilizing” material to give the product form and structure under the loose materials as well. There may also be some kind of foam or material used on the sides of the unit to give the unit form, structure, and stability.

There will most likely be some kind of non-skid material, fabric, or treatment on the bottom layer of the ticking as well as a system; elastic, straps, etc to secure this mattress to foundations such as but not limited to platform beds, box-springs, mattress foundations, bunky-boards, etc.

Although specific features of the present invention are shown in some drawings and not in others, this is for convenience only, as each feature may be combined with any or all of the other features in accordance with the invention. While there have been shown, described, and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions, substitutions, and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit and scope of the invention. For example, it is expressly intended that all combinations of those elements and/or steps that perform substantially the same function, in substantially the same way, to achieve the same results be within the scope of the invention. Substitutions of elements from one described embodiment to another are also fully intended and contemplated. It is also to be understood that the drawings are not necessarily drawn to scale, but that they are merely conceptual in nature.

It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. Other embodiments will occur to those skilled in the art and are within the following claims.

Claims

1. A system to reduce declivities in a mattress, comprising:

a container having at least a top layer and a flexible bottom layer, the container defining at least one chamber between the top layer and the bottom layer; and

a fill material disposed within the at least one chamber and capable of being moved within the chamber by manipulation of the top layer, wherein the fill material and the bottom layer are capable of being moved by a human into declivities in the mattress by manipulation of the top layer.

2. The system of claim 1 wherein the fill material is resistant to movement when an average-sized human lies on the container.

3. The system of claim 1 wherein the fill material includes a plurality of pieces that frictionally engage with each other when an average-sized human lies on the container.

4. The system of claim 1 wherein the fill material includes a plurality of pieces, each piece having a thickness and a length that is greater than the thickness.

5. The system of claim 1 wherein the fill material includes a plurality of flat pieces, each piece having a thickness, a width, and a length greater than the thickness and greater than the width.

6. The system of claim 5 wherein the flat pieces are formed of at least one type of foam.

7. The system of claim 6 wherein at least some of the flat pieces are formed of memory foam.

8. The system of claim 1 wherein the top layer includes a sheet of foam material.

9. The system of claim 1 wherein the container is at least twenty five percent of the size of a twin-sized mattress.

10. The system of claim 1 wherein the container is sized at least as large as an average-sized human.

11. The system of claim 1 wherein the container is integral to the mattress.

12. A method for reducing declivities in a selected mattress, comprising:

selecting a container at least twenty five percent as large as the selected mattress and having at least a top layer and a flexible bottom layer, the container defining at least one chamber between the top layer and the bottom layer;

selecting a fill material disposed within the at least one chamber, the bottom layer and the fill material capable of being moved by a human into declivities in the mattress;

placing the container on top of the mattress; and

manipulating the top layer to move a portion of the bottom layer and the blend into the declivities to render the top layer more level.

13. The method of claim 12 wherein the fill material is resistant to movement when an average-sized human lies on the container.

14. The method of claim 12 wherein the fill material includes a plurality of pieces that frictionally engage with each other when an average-sized human lies on the container.

15. The method of claim 12 wherein the fill material includes a plurality of pieces, each piece having a thickness and a length greater than the thickness.

16. The method of claim 12 wherein the container is sized at least as large as an average-sized human.

17. A kit to reduce declivities in a mattress, comprising:

a container having at least a flexible top layer, a flexible bottom layer, and at least one side layer joining the top layer to the bottom layer, the container defining at least one chamber between the top layer and the bottom layer, and a fill material disposed within the at least one chamber and capable of being moved within the chamber by manipulation of the top layer, the bottom layer and the fill material are capable of being moved by a human into declivities in the mattress by manipulation of the top layer; and

a foam sheet sized at least as large as an average-sized human and which is placeable on top of the container.

18. The kit of claim 17 further including at least one mattress protector sized at least as large as the foam sheet.

19. The kit of claim 17 wherein the container is at least twenty five percent of the size of a twin-sized mattress.

20. The kit of claim 17 wherein the container is sized at least as large as an average-sized human.