MATTRESS REINFORCEMENT SYSTEM

Info

Publication number: 20240115058
Type: Application
Filed: Oct 9, 2023
Publication Date: Apr 11, 2024
Inventors: Daniel VerBockel (St. Louis Park, MN), Kody Lee Karschnik (Plymouth, MN), Chris Jones (Lexington, SC), Daniel Shirtz (Sandy, UT)
Application Number: 18/377,932

Abstract

A mattress system includes microclimate control capabilities for providing quality sleep experience. The mattress system includes a first side rail, a second side rail, a core positioned between the first side rail and the second side rail, a layer positioned under the core, and multiple straps extending from at least one of the first side rail and the second side rail and connected to the layer.

Description

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 63/414,289, filed Oct. 7, 2022. The entirety of the disclosure of the prior application is considered part of (and is incorporated by reference in) the disclosure of this application.

TECHNICAL FIELD

This document relates to bed systems, and more particularly to techniques for assembling mattresses and beds.

BACKGROUND

In general, a bed is a piece of furniture used as a location to sleep or relax. Many modern beds include a soft mattress on a bed frame. The mattress may include springs, foam material, and/or an air chamber to support the weight of one or more occupants. Various features and systems have been used in conjunction with beds, including heating and cooling systems for heating and cooling a user of a bed. An increasing number of components in the bed may warrant a mechanism for assembling all the components in reliable, secured, and efficient ways.

SUMMARY

Some embodiments described herein include a bed system with microclimate control capabilities for providing quality sleep experience. The bed system can include a microclimate control system configured to supply conditioned air (e.g., heated or cooled air) to a mattress to achieve a desired temperature at a top of the mattress. Reinforcement straps can be used to hold various components of the microclimate control system within the mattress. For example, the mattress may include one or more mattress cores, airflow pads, and a rail structure. One or more airflow pads may be arranged under a mattress top and above a mattress bottom and configured to distribute conditioned air supplied from a thermal module toward the top of the mattress or draw ambient air from the top of the mattress. The rail structure defines an interior of the mattress configured to receive the mattress cores and the airflow pads. The reinforcement straps extend from the rail structure under the mattress bottom to thereby hold the mattress cores and the airflow pads within the interior defined by the rail structure between the mattress top and the mattress bottom.

According to implementations of the present disclosure, the reinforcement straps are designed to be attached to and extend between the rail structure and the mattress bottom. For example, one end of the reinforcement strap may be attached to the rail structure and the other end of the reinforcement strap may be attached to the mattress bottom. As such, the reinforcement straps may be shorter in length than the distance between the opposite sides of the rail structure to which the reinforcement straps are attached to. Therefore, each of the reinforcement straps may not extend all the way across the mattress bottom between the opposite sides of the rail structure.

In some examples, one or more (e.g., two) first reinforcement straps are attached to one of the opposite sides of the rail structure and also attached to the mattress bottom to thereby extend therebetween. Similarly, one or more (e.g., two) second reinforcement straps are attached to the other side of the rail structure and also attached to the mattress bottom to thereby extend therebetween. The position at the mattress bottom to which the first reinforcement straps are attached may be spaced apart from the position at the mattress bottom to which the second reinforcement straps are attached. In some implementations, the first reinforcement straps are arranged symmetrically to the second reinforcement straps.

In some implementations, a mattress includes a first side rail, a second side rail, a core positioned between the first side rail and the second side rail, a layer positioned under the core, and multiple straps extending from at least one of the first side rail and the second side rail and connecting to the layer.

In some implementations, the straps include at least one first side strap connected to the first side rail and the layer and at least one second side strap connected to the second side rail and the layer. In some cases, at least one first side strap may extend under the layer and have (i) an end connected to the first side rail and (ii) an opposite end connected to the layer and at least one second side strap may extend under the layer and have (i) an end connected to the second side rail and (ii) an opposite end connected to the layer.

In some implementations, at least one first side strap includes a first first-side strap and a second first-side strap that may be positioned in a longitudinal middle section of the mattress with the second first-side strap being spaced from the first first-side strap. In some cases, the first first-side strap may extend in parallel with the second first-side strap. In some cases, the first first-side strap may extend at an angle relative to the second first-side strap.

In some implementations, at least one second side strap includes a first second-side strap and a second second-side strap that are positioned in the longitudinal middle section of the mattress with the second second-side strap being spaced from the first second-side strap. In some cases, the first second-side strap and the second second-side strap align with the first first-side strap and the second first-side strap, respectively, along a transverse direction extending between the first side rail and the second side rail.

In some implementations, at least one second side strap aligns with the at least one first side strap along a transverse direction extending between the first side rail and the second side rail.

In some implementations, at least one second side strap extends in parallel with the at least one first side strap.

In some implementations, at least one second side strap extends at an angle relative to at least one first side strap.

In some implementations, a shortest length between the first side rail and the second side rail is longer than a total of a length of each of at least one first side strap and a length of each of at least one second side strap.

In some implementations, the first side rail defines a first cutout and the first first-side strap and the second first-side strap connect the first side rail with the layer on opposite sides of the first cutout. In some cases, the second side rail defines a second cutout and a first second-side strap and a second second-side strap connect the second side rail with the layer on opposite sides of the second cutout. In some implementations, the first cutout may structurally weaken the first side rail at the first cutout and the second cutout may structurally weaken the second side rail at the second cutout.

In some implementations, the first side rail defines a first cutout such that the first side rail may be structurally weakened at the first cutout and at least one first side strap connects the first side rail with the layer proximate the first cutout.

In some implementations, the second side rail defines a second cutout such that the second side rail may be structurally weakened at the second cutout and at least one second side strap connects the second side rail with the layer proximate the second cutout.

In some implementations, the first side rail, the second side rail, and the layer include one or more foam materials.

In some implementations, the core includes an inflatable air chamber to, when inflated, press at least one of the first side rail and the second side rail outwards.

In some implementations, the mattress further includes a first air chamber hose extending through the first side rail between the first first-side strap and the second first-side strap.

In some implementations, the mattress, further includes a second chamber air hose extending through the second side rail between the first second-side strap and the second second-side strap.

In some implementations, the mattress further includes multiple fastening elements to attach the straps to the first side rail, the second side rail, and the layer. In some cases, the fastening elements may include a first fastening element to attach the end of at least one first strap onto the first side rail and a second fastening element to attach the opposite end of at least one first strap onto the layer. In some cases, the fastening elements may include at least one of an adhesive tape or a hook and loop fastener.

In some implementations, the mattress further includes a first layer having a first layer top and a first layer bottom and extending from a first layer edge to a second layer edge. The first side rail may be attached to the first layer bottom proximate the first layer edge and the second side rail may be attached to the first layer bottom proximate the second layer edge.

In some cases, the core may be positioned under the first layer bottom between the first side rail and the second side rail. In some cases, the layer is a second layer having a second layer top and a second layer bottom and positioned under the core such that the second layer top faces the core. In some cases, the second layer extends between the first side rail and the second side rail. In some cases, the mattress further includes a foot rail and a head rail. The first layer, the first side rail, the second side rail, the foot rail, and a head rail define an upside-down foam tub that receives the core. In some cases, the mattress further includes a mattress cover enclosing the first layer, the first side rail, the second side rail, the core, at least one first strap, and at least one second strap.

In another aspect, a bed includes a mattress having a first foam layer, a second foam layer, at least one first side strap, and at least one second side strap. The first foam layer has a top surface and an opposite bottom surface, an inflatable chamber arranged opposite to the top surface of the first foam layer, a foam rail structure including a top foam rail, a bottom foam rail, a first side foam rail, and a second side foam rail opposite the first side foam rail. The foam rail structure extends between the top and bottom foam rails. The foam rail structure extends from a periphery of the first foam layer and configured to surround the inflatable chamber. The second foam layer may be positioned under the inflatable chamber. At least one first side strap may extend under the inflatable chamber and have (i) an end connected to the first side foam rail and (ii) an opposite end connected to the second foam layer. At least one second side strap may extend under the inflatable chamber and have (i) an end connected to the second side foam rail and (ii) an opposite end connected to the second foam layer.

In some implementations, at least one first side strap and at least one second side strap are arranged to extend across a portion of a bottom of the mattress. The portion of the bottom of the mattress may be shorter than a shortest length between the first side foam rail and the second side foam rail.

In some implementations, the bed further includes a foundation to support the mattress. At least one first side strap and at least one second side strap may be disposed between a bottom of the mattress and a top of the foundation.

In some implementations, the bed further includes multiple fastening elements to attach at least one first side strap and at least one second side strap onto the respective side foam rails and onto the second foam layer. In some cases, the fastening elements includes adhesive tapes applied to the opposite ends of each of at least one first side strap and at least one second side strap. In some cases, the fastening elements include hook and loop fasteners.

In some implementations, the foam rail structure includes a notch, and at least one of at least one first side strap or the at least one second side strap may be attached to the foam rail structure adjacent the notch.

In yet another aspect, a mattress includes a rail structure, a layer, and a strap connecting the rail structure to the layer.

In some implementations, the rail structure includes a first side rail and a second side rail. In some cases, the strap includes a first side strap and a second side strap. The first side strap may be connected to the first side rail and the layer, and the second side strap may be connected to the second side rail and the layer.

In still yet another aspect, a mattress includes a rail structure surrounding a core, a bottom layer under the core, and multiple straps connecting the rail structure to the bottom layer.

In some implementations, the rail structure, the bottom layer, and the straps are positioned to hold the core in place.

In some implementations, the straps prevent the rail structure from bowing.

In another aspect, a mattress includes a tub having sides defining an opening, a layer covering a portion of the opening, and a strap connecting the sides of the tub to the layer.

In some implementations, the tub includes a foam.

In some implementations, the opening defines a bottom plane of the tub.

In a further aspect, a mattress includes a first side rail, a second side rail, a core positioned between the first side rail and the second side rail, and a layer positioned under the core. The layer has multiple straps extending from the layer to at least one of the first side rail and the second side.

In some implementations, the straps include at least one first side strap extending from the layer and configured to be connected to the first side rail and at least one second side strap extending from the layer and configured to be connected to the second side rail. In some cases, at least one first side strap has (i) a first end configured to be connected to the first side rail and (ii) an opposite end fixed to the layer and at least one second side strap has (i) a first end configured to be connected to the second side rail and (ii) an opposite end fixed to the layer.

In some implementations, at least one first side strap includes a first first-side strap and a second first-side strap that are positioned in a longitudinal middle section of the mattress with the second first-side strap being spaced from the first first-side strap. In some cases, the first first-side strap extends in parallel with the second first-side strap. In some implementations, the first first-side strap extends at an angle relative to the second first-side strap.

In some implementations, at least one second side strap includes a first second-side strap and a second second-side strap that are positioned in the longitudinal middle section of the mattress with the second second-side strap being spaced from the first second-side strap. In some cases, the first second-side strap and the second second-side strap align with the first first-side strap and the second first-side strap, respectively, along a transverse direction extending between the first side rail and the second side rail.

In some cases, at least one second side strap aligns with at least one first side strap along a transverse direction extending between the first side rail and the second side rail. In some cases, at least one second side strap extends in parallel with at least one first side strap. In some cases, at least one second side strap extends at an angle relative to at least one first side strap.

In some implementations, the first side rail defines a first cutout such that the first side rail may be structurally weakened at the first cutout and the first first-side strap and the second first-side strap connect the first side rail with the layer on opposite sides of the first cutout. In some cases, the second side rail defines a second cutout such that the second side rail may be structurally weakened at the second cutout and a first second-side strap and a second second-side strap connect the second side rail with the layer on opposite sides of the second cutout.

In some implementations, the first side rail defines a first cutout such that the first side rail may be structurally weakened at the first cutout and at least one first side strap connects the first side rail with the layer proximate the first cutout. In some implementations, the second side rail defines a second cutout such that the second side rail may be structurally weakened at the second cutout and at least one second side strap connects the second side rail with the layer proximate the second cutout.

In some implementations, the first side rail, the second side rail, and the layer include one or more foam materials.

In some implementations, the core includes an inflatable air chamber that, when inflated, presses at least one of the first side rail and the second side rail outwards.

In some implementations, the mattress further includes a first air chamber hose extending through the first side rail between the first first-side strap and the second first-side strap.

In some implementations, the mattress further includes a second chamber air hose extending through the second side rail between the first second-side strap and the second second-side strap.

In some implementations, the mattress further includes multiple fastening elements to attach the straps to the first side rail and the second side rail. In some cases, each of the fastening elements includes a first fastening element to attach the end of at least one first strap or the second side strap onto the first side rail or the second side rail, respectively, and a second fastening element coupled to the first side rail or the second side rail, the second fastening element to receive and couple to the first fastening element. In some cases, the fastening elements include at least one of an adhesive tape or a hook and loop fastener.

In some implementations, the mattress further includes a first layer having a first layer top and a first layer bottom and extending from a first layer edge to a second layer edge. The first side rail is attached to the first layer bottom proximate the first layer edge and the second side rail is attached to the first layer bottom proximate the second layer edge. In some cases, the core is positioned under the first layer bottom between the first side rail and the second side rail.

In some implementations, the layer is a second layer having a second layer top and a second layer bottom and positioned under the core such that the second layer top faces the core. In some cases, the second layer extends between the first side rail and the second side rail.

In some implementations, the mattress further includes a foot rail and a head rail. The first layer, the first side rail, the second side rail, the foot rail, and a head rail define an upside-down foam tub that receives the core.

In some implementations, the mattress further includes a mattress cover enclosing the first layer, the first side rail, the second side rail, the core, at least one first strap, and at least one second strap.

In another aspect, a bed includes a mattress having a first foam layer, a second foam layer, and a bottom layer with at least one first side strap and at least one second side strap. The first foam layer has a top surface and an opposite bottom surface, an inflatable chamber arranged opposite to the top surface of the first foam layer, a foam rail structure including a top foam rail, a bottom foam rail, a first side foam rail, and a second side foam rail opposite the first side foam rail. The foam rail structure extends between the top and bottom foam rails. The foam rail structure extends from a periphery of the first foam layer and surrounds the inflatable chamber. The second foam layer is positioned under the inflatable chamber. The bottom layer is positioned under the second foam layer. The bottom layer has at least one first side strap and at least one second side strap. At least one first side strap extends from the bottom layer and under the inflatable chamber and has (i) a first end configured to be connected to the first side foam rail and (ii) an opposite end fixed to the bottom layer. At least one second side strap extends from the bottom layer opposite at least one first side strap under the inflatable chamber and has (i) a first end configured to be connected to the second side foam rail and (ii) an opposite end fixed to the bottom layer.

In some implementations, at least one first side strap and at least one second side strap may be arranged to extend across a portion of a bottom of the mattress. The portion of the bottom of the mattress being shorter than a shortest length between the first side foam rail and the second side foam rail.

In some implementations, the bed further includes a foundation to support the mattress. At least one first side strap and at least one second side strap are disposed between a bottom of the mattress and a top of the foundation.

In some implementations, the bed further includes multiple fastening elements to attach at least one first side strap and at least one second side strap onto the respective side foam rails and onto the second foam layer. In some cases, the fastening elements include adhesive tapes applied to the opposite ends of each of at least one first side strap and at least one second side strap. In some cases, the fastening elements include hook and loop fasteners.

In some implementations, the foam rail structure includes a notch and at least one of either of at least one first side strap or at least one second side strap is attached to the foam rail structure adjacent to the notch.

In yet another aspect, a mattress includes a rail structure and a layer having a strap extending from the layer. The strap connects the rail structure to the layer.

In some implementations, the rail structure includes a first side rail and a second side rail. In some cases, the strap includes a first side strap and a second side strap. The first side strap is connected to the first side rail and extends from the layer and the second side strap connected to the second side rail and extends from the layer.

In another aspect, a mattress includes a rail structure surrounding a core and a bottom layer with multiple straps extending from the bottom layer under the core. The straps connect the rail structure to the bottom layer.

In some implementations, the rail structure and the bottom layer are positioned to hold the core in place.

In some implementations, the straps are configured to prevent the rail structure from bowing.

In yet another aspect, the mattress includes a tub having sides defining an opening and a layer covering a portion of the opening. The layer has a strap connecting the sides of the tub to the layer.

In some implementations, the tub includes a foam.

In some implementations, the opening defines a bottom plane of the tub.

The devices, systems, and techniques described herein may provide one or more of the following advantages. Some embodiments described herein include reinforcement straps that are used with a bed to secure a mattress cover to other components of the mattress system, such as the top layer, the intermediate layer, the rail structure, the mattress core.

The straps can improve the structural stability of the bed. For example, in some cases, bed components such as inflatable chambers can expand and contact the rail structure, causing the rail structure to change shape or bow. When the straps are couple to the rail structure and mattress bottom, the change in shape or bowing of the rail structure can be reduced. For example, when a person sits or lays down on the mattress, the mattress core can compress and contact the rail structure, causing the rail structure to change shape or bow. When the straps are couple to the rail structure and mattress bottom, the change in shape or bowing of the rail structure can be reduced.

The straps can decrease relative motion between mattress components. For example, when a person sits or climbs on the bed, a force can be imparted onto one or more mattress components, but not other components causing bed components to move relative to mattress components. Using straps can reduce the relative motion between mattress components.

Utilizing the straps can decrease assembly time. For example, a shorter strap can be positioned from each side of the mattress without having to flip the mattress.

The straps can decrease the personnel required to assemble the mattress. For example, each shorter strap can be positioned individually without lifting or flipping the entire mattress.

With the short reinforcement straps, which do not extend all the way across the opposite sides (e.g., left and right sides) of the mattress, the mattress can be manufactured in a time efficient and cost-efficient manner. For example, at a manufacturing site (e.g., at an assembly line), a single person can grab one or more separate short straps at each side of a partially assembled mattress and attach the straps between each side of the mattress and the mattress bottom. Alternatively, two persons positioning at the opposing sides of the mattress can attach the short straps at the opposite sides of the mattress independently. This increases efficiency in attaching the straps to the mattress, compared to longer straps that are configured to be routed all the way across the opposite sides of the mattress. Further, the straps can be used for different sizes of mattresses (e.g., king, queen, twin, etc.). Therefore, the straps can be made in a single length without considering different sizes of mattresses.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example bed system for providing a quality sleep experience with an example local bed system.

FIG. 2 is a bottom perspective view of the mattress system, illustrating the mattress system upside down.

FIG. 3 is a partial exploded view of the mattress system of FIG. 2.

FIG. 4 is a partial exploded view of the mattress system of FIG. 2, illustrating an example top layer and an example intermediate layer.

FIG. 5 is a partial exploded view of the mattress system of FIG. 2, illustrating the top layer, the intermediate layer, and an example airflow layer.

FIG. 6 is a partial exploded view of the mattress system of FIG. 2, illustrating the top layer, the intermediate layer, an example rail structure, and an example airflow pad assembly.

FIG. 7 is a partial exploded view of the mattress system of FIG. 2 from a different angel.

FIG. 8A is a cross sectional view of the top layer, the intermediate layer, the rail structure, the air chamber, the airflow layer, and an example bottom layer of the mattress system, taken along line A-A in FIG. 2.

FIG. 8B is a cross sectional view of the top layer, the intermediate layer, the rail structure, and the airflow layer of the mattress system, taken along line B-B in FIG. 2.

FIG. 9 is a bottom partial view of the mattress of FIG. 2.

FIG. 10 illustrates a cutaway view of an example mattress system.

FIGS. 11A-C are perspective views of an example airflow pad assembly that is used with a mattress system.

FIG. 12 is a perspective view of the airflow pad assembly of FIG. 11.

FIG. 13 illustrates an example airflow material and an example pad cover of the airflow pad.

FIG. 14 illustrates a bottom perspective view of an example mattress with a set of reinforcement straps attached in place.

FIG. 15 illustrates a bottom perspective, exploded view of the mattress with the reinforcement straps removed and without a core illustrated.

FIGS. 16A-16C illustrate alternative configurations of the reinforcement straps.

FIGS. 17A-17D illustrate a bottom layer having reinforcement straps.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

FIG. 1 illustrates an example bed system 100 for providing a quality sleep experience with an example local bed system 101. The local bed system 101 can include a bed 102 and a bed control system 110 used in conjunction with the bed 102 and configured to control one or more user comfort features of the bed 102.

The bed 102 has a head 108 and a foot 124. The head 108 can also be referred to as a head end or head-side and the foot 124 can also be referred to as a foot end or a foot-side. The bed 102 can include a mattress 104 and a foundation 106. In some embodiments, the mattress 104 can be an air mattress having an inflatable air chamber and a controller for controlling inflation of the inflatable air chamber. In other embodiments, the mattress 104 does not include an air chamber. For example, the mattress 104 may include foam and/or springs instead of or in addition to an inflatable air chamber. The mattress 104 can be sized and shaped as a twin mattress, full mattress, queen mattress, king mattress, California king mattress, split king mattresses, partially split mattress (e.g. a mattress 104 that is split at the head 108 and/or foot 124 ends and joined in a middle 126 of the mattress 104), and/or other mattress 104 as suitable for the application. The foundation 106 is positioned under the mattress 104 to support the mattress 104. In some embodiments, the foundation 106 can be an adjustable foundation with one or more articulable sections, such as for raising the head 108 and foot 124 of the foundation 106 and the mattress 104. In other embodiments, the foundation 106 can be a stationary foundation.

The bed 102 can be configured to provide a microclimate control of the mattress 104. In some implementations, the bed 102 provides a foot warming function. For example, the bed 102 can include a foot warming device 120 which is disposed on the mattress 104 or incorporated in the mattress 104 and at a foot side of the bed 102. The foot warming device 120 can be disposed on a top of the mattress 104, included in the mattress 104, or disposed at other locations of the bed 102 and/or in other configurations. The foot warming device 120 can include an electronic heating element in some implementations. The foot warming device 120 can include an air circulation element through which heated air is circulated in other implementations. Other configurations are also possible.

Alternatively or in addition, the bed 102 can be configured to provide a body cooling/heating function. For example, the bed 102 can include an airflow insert pad 122 that can be included in the mattress 104 and configured to circulate ambient or conditioned air through the mattress under the user at rest. The airflow insert pad 122 can be arranged at various locations in the mattress 104. In the illustrated example, the airflow insert pad 122 is disposed between the head 108 and foot 124 of the mattress 104 (e.g., in the middle 126 of the mattress 104).

The bed control system 110 operates to control features available for the bed 102. In some implementations, the bed control system 110 includes a bed articulation system 112, an air chamber control system 114, a foot warming control system 116, and an airflow insert pad control system 118.

The bed articulation system 112 operates to articulate the foundation 106 and/or the mattress 104. For example, the bed articulation system 112 can adjust one or more articulable sections of the foundation 106 to raise the head 108 and foot 124 of the foundation 106 and/or the mattress 104. The bed articulation system 112 can include a controller and an actuator (e.g., a motor) operated by the controller and coupled to the articulable sections of the foundation 106 so that the sections of the foundation 106 are automatically adjusted to desired positions. Alternatively or in addition, the articulable sections of the foundation 106 can be manually adjusted.

The air chamber control system 114 operates to control the air chamber of the mattress 104. The air chamber control system 114 can include a controller and an actuator (e.g., a pump) operated by the controller and fluidly connected to the air chamber. The actuator is controlled to inflate or deflate the air chamber to provide and maintain a desired pressure in the air chamber, thereby providing a desired firmness of the air chamber.

The foot warming control system 116 operates to control the foot warming device 120 disposed in the mattress 104. The foot warming control system 116 can include a controller configured to activate a heating element of the foot warming device 120 and maintain a desired temperature of the heating element.

The airflow insert pad control system 118 operates to control the airflow insert pad 122 disposed in the mattress 104. The airflow insert pad control system 118 can include an air controller configured to cause ambient or conditioned air to flow into or out of the airflow insert pad 122 so that a top layer of the mattress above or adjacent the airflow insert pad 122 have a desired temperature and/or humidity.

In some implementations, the bed articulation system 112, the air chamber control system 114, the foot warming control system 116, and the airflow insert pad control system 118 can be independently configured and operated. In other implementations, some or all of the bed articulation system 112, the air chamber control system 114, the foot warming control system 116, and the airflow insert pad control system 118 are at least partially combined so that they share at least part of their components such as actuators (e.g., motors, pumps, etc.) and/or controllers (e.g., control circuits, processors, memory, network interfaces, etc.).

The bed control system 110 can be accessed by a user via one or more control devices 130, such as a bed-side controller 132 and a mobile computing device 134. The bed-side controller 132 is wired to, or wirelessly connected to, the bed control system 110 to enable the user to at least partially control the bed control system 110. The bed-side controller 132 includes an input device (e.g., a keypad, buttons, switches, etc.) for receiving a user input of controlling various settings of the bed control system 110, such as articulation positions, temperature settings, air chamber pressure settings, etc. The bed-side controller 132 can further include an output device (e.g., a display, a speaker, etc.) for outputting the statuses and conditions of the bed control system 110 and other information useful to the user, such as articulation positions, temperature settings, air chamber pressure settings, sleep analysis results, etc. The same or similar functionalities can be implemented with the mobile computing device 134, such as a mobile device running a dedicated software application. For example, the user can use a mobile device as an input device to control various settings of the bed control system 110, such as articulation positions, temperature settings, air chamber pressure settings, etc., and further use the mobile device as an output device to see the statuses and conditions of the bed control system 110 and other useful information, such as articulation positions, temperature settings, air chamber pressure settings, sleep analysis results, etc.

Referring still to FIG. 1, the system 100 can include a server system 140 connected to the local bed system 101 and configured to provide one or more services associated with the bed 102. The server system 140 can be connected to the local bed system 101, such as the bed 102, the bed control system 110, and/or the control devices 130, via a network 142. The server system 140 can be of various forms, such as a local server system with one or more computing devices dedicated to one or more beds, or a cloud server. The network 142 is an electronic communication network that facilitates communication between the local bed system 101 and the server system 140. An electronic communication network is a set of computing devices and links between the computing devices. The computing devices in the network use the links to enable communication among the computing devices in the network. The network 142 can include routers, switches, mobile access points, bridges, hubs, intrusion detection devices, storage devices, standalone server devices, blade server devices, sensors, desktop computers, firewall devices, laptop computers, handheld computers, mobile telephones, and other types of computing devices. In various embodiments, the network 142 includes various types of links. For example, the network 142 includes wired and/or wireless links. Furthermore, in various embodiments, the network 142 is implemented at various scales. For example, the network 142 can be implemented as one or more local area networks (LANs), metropolitan area networks, subnets, wide area networks (such as the Internet), or can be implemented at another scale.

In some implementations, the server system 140 can provide a bed data service that can be used in a data processing system associated with the local bed system 101. The server system 140 can be configured to collect sensor data and sleep data from a particular bed and match the sensor and sleep data with one or more users that use the bed when the sensor and sleep data were generated. The sensor and sleep data, and the matching data, can be stored as bed data 150 in a database. The bed data 150 can include user identification data usable to identify users of beds. The users can include customers, owners, or other users registered with the server system 140 or another service. Each user can have, for example, a unique identifier, user credentials, contact information, billing information, demographic information, or any other technologically appropriate information. The bed data 150 can include management data usable to identify data related to beds or other products associated with data processing systems. For example, the beds can include products sold or registered with a system associated with the server system 140. Each bed can have, for example, a unique identifier, model and/or serial number, sales information, geographic information, delivery information, a listing of associated sensors and control peripherals, etc. Additionally, an index or indexes stored in the bed data 150 can identify users that are associated with beds. For example, this index can record sales of a bed to a user, users that sleep in a bed, etc. The bed data 150 can include sensor data that record raw or condensed sensor data recorded by beds with associated data processing systems. For example, a bed's data processing system can have a temperature sensor, pressure sensor, and light sensor. Readings from these sensors, either in raw form or in a format generated from the raw data (e.g., sleep metrics) of the sensors, can be communicated by the bed's data processing system to the server system 140 for storage in the bed data 150. Additionally, an index or indexes stored by the server system 140 can identify users and/or beds that are associated with the sensor data. In some implementations, the server system 140 can use any of its available data to generate advanced sleep data. The advanced sleep data includes sleep metrics and other data generated from sensor readings. Some of these calculations can be performed in the server system 140 instead of locally on the bed's data processing system, for example, because the calculations are computationally complex or require a large amount of memory space or processor power that is not available on the bed's data processing system. This can help allow a bed system to operate with a relatively simple controller and still be part of a system that performs relatively complex tasks and computations.

Alternatively or in addition, the server system 140 can provide a sleep data service that can be used in a data processing system that can be associated with the local bed system 101. In this example, the server system 140 is configured to record data related to users' sleep experience and store the data as sleep data 152. The sleep data 152 can include pressure sensor data related to the configuration and operation of pressure sensors in beds. For example, the pressure sensor data can include an identifier of the types of sensors in a particular bed, their settings and calibration data, etc. The sleep data 152 can include pressure-based sleep data which can be calculated based on raw pressure sensor data and represent sleep metrics specifically tied to the pressure sensor data. For example, user presence, movements, weight change, heart rate, and breathing rate can be determined from raw pressure sensor data. Additionally, an index or indexes stored by the server system 140 can identify users that are associated with pressure sensors, raw pressure sensor data, and/or pressure-based sleep data. The sleep data 152 can include non-pressure sleep data which can be calculated based on other sources of data and represent sleep metrics obtained from such other sources of data. For example, user entered preferences, light sensor readings, and sound sensor readings can all be used to track sleep data 152. Additionally, an index or indexes stored by the server system 140 can identify users that are associated with other sensors and/or non-pressure sleep data 152.

Alternatively or in addition, the server system 140 can provide a user account service that can be used in a data processing system associated with the local bed system 101. For example, the server system 140 can record a list of users and to identify other data related to those users and store such data as user account data 154. The user account data 154 are related to users of beds with associated data processing systems. For example, the users can include customers, owners, or other users registered with the server system 140 or another service. Each user can have, for example, a unique identifier, user credentials, demographic information, or any other technologically appropriate information. The user account data 154 can include engagement data usable to track user interactions with the manufacturer, vendor, and/or manager of the bed and/or cloud services. This engagement data can include communications (e.g., emails, service calls), data from sales (e.g., sales receipts, configuration logs), and social network interactions. The user account data 154 can include usage history data related to user interactions with one or more applications and/or remote controls of a bed. For example, a monitoring and configuration application can be distributed to run on, for example, the control devices 130. This application can log and report user interactions for storage. Additionally, an index or indexes stored by the server system 140 can identify users that are associated with each log entry.

Alternatively or in addition, the server system 140 can provide an environment service that can be used in a data processing system associated with the local bed system 101. For example, the server system 140 can record data related to users' home environment and store such data as environment data 156. The environment data 156 can be obtained using one or more sensors installed in or around the bed. Such sensors can be of various types that can detect environmental variables, such as light sensors, noise sensors, vibration sensors, thermostats, etc. The environment data 156 can include historical readings or reports from those sensors. By way of example, a light sensor is used to collect data indicative of the frequency and duration of instances of increased lighting when the user is asleep.

Referring to FIGS. 2-10, an example mattress system 200 is described. The mattress system 200 can be used to implement the mattress 104 of FIG. 1.

FIG. 2 is a bottom perspective view of the mattress system 200, illustrating the mattress system 200 upside down. The mattress system 200 can include a top layer (e.g., a first layer) 202, an intermediate layer (e.g., a second layer) 204, a rail structure 206, and a bottom layer (e.g., a third layer) 208. In some implementations, the top layer 202, the intermediate layer 204 and the bottom layer 208 are arranged in order from the top to the bottom of the mattress system 200. The rail structure 206 is arranged around a periphery of the mattress system 200 and configured to at least partially surround an air chamber assembly 220 (FIG. 3). As illustrated in FIG. 2, the bottom layer 208 can be disposed to be at least partially surrounded by the rail structure 206. The bottom layer 208 can be configured to close a space 210 (FIG. 3) defined by the rail structure 206. In other implementations, the bottom layer 208 can be configured and disposed above the rail structure 206. The mattress system 200 includes multiple straps 550A-550D extending from the rail structure 206 and connected to the bottom layer 208. The straps 550A-550D are described in more detail in reference to FIGS. 9, and 14-16C.

FIG. 3 is a partial exploded view of the mattress system 200 of FIG. 2 (disposed upside down). The mattress system 200 can include the air chamber assembly 220. In the illustrated example, the air chamber assembly 220 includes a pair of air chambers 222 disposed between the top layer 202 and the bottom layer 208. The air chambers 222 can be arranged to be surrounded by the rail structure 206. The air chamber assembly 220 can further include a pump system 224 (FIG. 10) configured to inflate and/or deflate the air chambers 222.

The mattress system 200 further includes an airflow layer 230 configured to distribute ambient or conditioned air therethrough and into the top layer 202, and/or draw ambient or conditioned air therethrough and from the top layer 202. The airflow layer 230 can include one or more airflow pad assemblies 232. An example of the airflow pad assembly 232 is described in more detail herein, for example with reference to FIGS. 11-13. The airflow layer 230 can also be referred to herein as the airflow distribution layer, air distribution layer, or other similar terms. The airflow pad assembly 232 can also be referred to herein as the airflow pad, the airflow insert, or other similar terms.

As depicted in FIG. 3, the rail structure 206 can be disposed on the intermediate layer 204 to define the space 210 for at least partially receiving the air chamber assembly 220. The bottom layer 208 can be disposed at least partially within the space 210 to at least partially cover the space 210 and the air chamber assembly 220 within the space 210.

The top layer 202, the intermediate layer 204, the rail structure 206, and the bottom layer 208 can be made of various materials. For example, at least one of the top layer 202, the intermediate layer 204, the rail structure 206, and the bottom layer 208 can be made of foam, which may be closed-cell, open-cell, or a combination thereof. Other materials, such as one or more coil springs, air chambers, spacer materials, and/or other suitable materials, can be used for at least one of the top layer 202, the intermediate layer 204, the rail structure 206, and the bottom layer 208.

FIG. 4 is a partial exploded view of the mattress system 200 of FIG. 2 (disposed upside down), illustrating the top layer 202 and the intermediate layer 204. The top layer 202 has a top surface 212 (opposite to a bottom surface 214) on which a user's body can be rested either directly, or indirectly through a mattress cover and/or one or more additional layers disposed on the top surface. The top layer 202 (the first layer) extends from a first layer edge 228 to a second layer edge 236, that is, opposite side edges of the layer 202.

The intermediate layer 204 can be disposed opposite to the top surface 212 of the top layer 202. For example, the top layer 202 has the bottom surface 214 opposite to the top surface 212, and the intermediate layer 204 is disposed on the bottom surface 214 of the top layer 202. The second layer 204 (the intermediate layer or additionally the bottom layer 208) has a second layer top 238 and a second layer bottom 244. The second layer bottom 244 is opposite the second layer top 238. The second layer 204 extends between a first side rail 566 and a second side rail 568 (described in more detail in reference to FIGS. 14-15. The intermediate layer 204 can be attached to the top layer 202 in various ways. For example, the intermediate layer 204 can be glued to the top layer 202, or attached to the top layer 202 using fasteners, such as hook-and-loop fasteners (e.g., VELCRO®), zippers, clips, pins, buttons, straps, ties, snap fasteners, and other suitable types of fasteners. In some cases, the intermediate layer 204 replaces the bottom layer 208.

In some implementations, the intermediate layer 204 provides a cutout section 240 configured to receive the airflow layer 230. The cutout section 240 is described in further detail with reference to FIGS. 5-7.

FIG. 5 is a partial exploded view of the mattress system 200 of FIG. 2 (disposed upside down), illustrating the top layer 202, the intermediate layer 204, and the airflow layer 230. The airflow pad assemblies 232 can be disposed in the cutout section 240 of the intermediate layer 204. The airflow pad assemblies 232 can be enclosed in the cutout section 240 and surrounded by the intermediate layer 204 such that the airflow pad assemblies 232 are not exposed on the lateral sides of the mattress system 200. In other words, the airflow pad assemblies 232 are not visible from any lateral side of the mattress system 200, and the intermediate layer 204 is instead visible from the lateral sides of the mattress system 200, as shown in FIGS. 2 and 3. The airflow pad assemblies 232 can be attached to the bottom surface 214 of the top layer 202 through the cutout section 240 of the intermediate layer 204. The airflow pad assemblies 232 can be attached to the bottom surface 214 the top layer 202 in various ways. For example, the airflow pad assemblies 232 can be glued to the bottom surface 214 of the top layer 202 or attached to the bottom surface 214 of the top layer 202 using fasteners, such as hook-and-loop fasteners (e.g., VELCRO®), zippers, clips, pins, buttons, straps, ties, snap fasteners, and other suitable types of fasteners.

FIGS. 6 and 7 are partial exploded views of the mattress system 200 of FIG. 2 (disposed upside down), illustrating the top layer 202, the intermediate layer 204, the rail structure 206, and one of the airflow pad assemblies 232. As illustrated, the rail structure 206 includes one or more notches 242, each configured to receive an air duct 234 of the airflow pad assembly 232. The notches 242 can be sized to fully receive the air duct 234 so that the air duct 234 does not protrude from the interior surface of the rail structure 206. For example, the notches 242 can be dimensioned to receive the air duct 234 such that the air duct 234 is flushed with the interior surface of the rail structure 206 or disposed below the level of the interior surface of the rail structure 206. As such, the air duct 234 being received within the notch 242 does not interfere with other components of the mattress system 200, such as the air chambers 222 being received within the space 210 of the rail structure 206. The notches 242 can be arranged in locations of the rail structure 206 which correspond to the positions of the air ducts 234 of the airflow pad assemblies 232. In the illustrated example, the notches 242 are arranged in the rail structure 206 between the head 108 and the foot 124 of the mattress system 200, such as in the middle 126 of the length of the mattress system 200.

In alternative embodiments, the mattress system 200 does not include the top layer 202. In this configuration, the bottom layer 208 can function as a top layer of the mattress. Alternatively, the top layer 202 can have different sizes (e.g., thickness) to provide different comfort levels or for other purposes.

In some implementations, the intermediate layer 204 can be arranged in parallel to the airflow layer 230 (e.g., air distribution layer). For example, the intermediate layer 204 can be configured to be parallel with the airflow pad assemblies 232 when assembled.

Referring to FIGS. 8A, 8B, and 9, an example arrangement of components of the mattress 200 is described. FIG. 8A is a cross sectional view of the top layer 202, the intermediate layer 204, the rail structure 206, the air chamber 222, the airflow layer 230, and the bottom layer 208 of the mattress system 200, taken along line A-A in FIG. 2. In FIG. 8A, an example mattress cover 209 is illustrated. FIG. 8B is a cross sectional view of the top layer 202, the intermediate layer 204, the rail structure 206, and the airflow layer 230 of the mattress system 200, taken along line B-B in FIG. 2. In FIG. 8B, the air chamber 222 is schematically illustrated with dotted lines. FIG. 9 is a bottom partial view of the mattress of FIG. 2.

As described, the mattress 200 includes the inflatable air chamber 222, the airflow layer 230 (e.g., an air distribution layer), and a foam layer 203. The foam layer 203 can include the top layer 202. The foam layer 203 can further include the intermediate layer 204. The air distribution layer is positioned above the inflatable air chamber 222. The foam layer 203 is positioned above the air distribution layer and proximate a top of the mattress. As described herein, the foam layer 203 and the air distribution layer (e.g., the airflow layer 230) can permit airflow therethrough. The air distribution layer resists air flow less than the foam layer. For example, the air distribution layer can allow a higher airflow rate than the foam layer above the air distribution layer. The mattress 200 further includes a first air chamber hose 226A and a second air chamber hose 226B (shown in FIG. 8B) connected to the inflatable air chamber for inflating or deflating the inflatable air chamber 222. For example, one end of each of the air chamber hoses 226A, 226B is connected to the respective air chamber 222A, 222B to be in fluid communication with the interior of the air chamber 222, and the other end of the air chamber hose is fluidly connected to the pump system (e.g., the pump system 224 as shown in FIG. 10). The mattress 200 further includes an air distribution hose (e.g., the air duct 234) fluidly connected to the air distribution layer (e.g., the airflow layer 230) for moving air into, from, and through the air distribution layer. In some implementations, in a direction from the bottom to the top, the air distribution hose extends from a location below the inflatable air chamber and is routed around a side of the inflatable air chamber and to the air distribution layer above the inflatable air chamber. In other words, in the reverse direction (from the top to the bottom), the air distribution hose is connected to the air distribution layer above the inflatable air chamber, and routed around the side of the inflatable air chamber and extends to a location below the lowest level of the inflatable air chamber so that the air distribution layer extends over the lowest level of the inflatable air chamber. For example, as illustrated in FIG. 8A, the air distribution hose (e.g., the air duct 234) is connected to the air distribution layer (e.g., the airflow layer 230) above the inflatable air chamber 222, and then routed along a side of the air chamber 222, extending up to a location lower than the inflatable air chamber 222.

In some implementations, the mattress 200 includes the mattress cover 209 that at least partially encloses the components of the mattress 200, such as the top layer 202, the intermediate layer 204, the rail structure 206, the air chamber 222, the airflow layer 230, and the bottom layer 208. The mattress cover 209 includes a common hole 211 through which the air distribution hose and the air chamber hose can extend out together.

In some implementations, the mattress 200 includes a plurality of inflatable air chambers, and the air distribution layer includes a plurality of air distribution zones or pads corresponding to the plurality of inflatable air chambers. In the illustrated examples, the mattress 200 includes first and second air chambers 222A and 222B, and the air distribution layer includes two air distribution pads 232A and 232B (defining two air distribution zones) that are positioned under the first and second air chambers 222A and 222B, respectively, from the view of FIG. 8A. The air chamber hose and the air distribution hose described above are similarly provided to each set of the inflatable air chamber and the air distribution pad.

In some implementations, the mattress 200 includes a chamber insulator 250 positioned between the first and second air chambers 222A and 222B and configured to reduce heat transfer between the first and second air chambers 222A and 222B. In addition or alternatively, the mattress 200 includes an air distribution insulator 260 positioned between the first and second air distribution pads 232A and 232B and configured to reduce heat transfer between the first and second air distribution pads 232A and 232B. The chamber insulator 250 and the air distribution insulator 260 can reduce heat transfer between two different areas (e.g., left and right sides) of the mattress 200, thereby improving independent temperature controls for different users resting on such different areas of the mattress top.

As shown in FIGS. 8A, 8B, and 9 (the bottom partial view of the mattress 200), as described herein, the rail structure 206 includes the notches 242 (e.g., hose passages) configured to receive and route the air distribution hoses (e.g., the air ducts 234). For example, the notches 242 are provided on the side rails of the rail structure 206. In some implementations, the air chamber hoses 226A, 226B can be routed within or adjacent the notches 242 along with the air distribution hoses.

In some implementations, a foundation (e.g., the foundation 106) can be provided to support the mattress 200. For example, the foundation provides a support platform configured for supporting the mattress 200. The support platform can include a first foundation opening extending through the support platform and configured to receive the air chamber hose and/or the air distribution hose. A pump assembly (e.g., the pump assembly 224 as shown in FIG. 10) can be fluidly connected to an end hose end of the chamber air hose and configured to supply fluid (e.g., air) to the inflatable air chamber 222. The pump assembly can be positioned in the foundation. Further, an air controller (e.g., the air controller 338 as shown in FIG. 10) can be fluidly connected to the air distribution hose and configured to move air into or from the air distribution layer through the air distribution hose. The air controller can be positioned in the foundation.

Referring to FIG. 9, the mattress 200 can include reinforcement straps 550. Two reinforcement straps 550 can be used, including a first strap 550A and a second strap 550B, which can be attached to a same side of the rail structure 206 and extend partially over the bottom layer 208. Examples of the reinforcement straps 550A, 550B are described in more detail in reference to FIGS. 14-16B.

FIG. 10 illustrates a cutaway view of an example mattress system 300. The mattress system 300 can be used to implement the mattress system 200 of FIGS. 2-9 or the mattress 104 of FIG. 1. Similarly to the mattress system 200, the mattress system 300 includes a top layer 302, an intermediate layer 304, a rail structure 306, an air chamber assembly 320, an airflow layer 330, and a bottom layer 308, which can be configured similarly to the top layer 202, the intermediate layer 204, the rail structure 206, the air chamber assembly 220, the airflow layer 230, and the bottom layer 208, respectively.

Similar to the airflow layer 230 described herein, the airflow layer 330 can include an airflow pad assembly 332. The airflow pad assembly 332 can include one or more airflow pads 334 and an air duct 336 extending from the airflow pad 334 and fluidly connecting the airflow pad 334 with an air controller 338. The air controller 338 is configured to move ambient or conditioned air through the airflow pad 334 and further through the top layer 302 to control a temperature at a top surface 312 of the top layer 302. For example, the air controller 338 can operate to draw air from the airflow pad 334 and the top layer 302 through the air duct 336, thereby decreasing a temperature at the top surface 312 of the top layer 302. Alternatively, the air controller 338 can operate to supply ambient or cooling air to the airflow pad 334 through the air duct 336, thereby enabling such ambient or cooling air to be distributed through the top layer 302 and decreasing a temperature at the top surface 312 of the top layer 302. Alternatively, the air controller 338 can operate to supply heating air to the airflow pad 334 through the air duct 336, thereby enabling such heating air to be distributed through the top layer 302 and increasing a temperature at the top surface 312 of the top layer 302.

In the illustrated implementations, the air chamber hoses 226A, 226B are routed at the side locations of the mattress. In alternative implementations, the air chamber hoses 226A, 226B can be routed at different locations of the mattress, such as the head 108 or foot 124 of the mattress 104, or other suitable locations of the mattress 104.

In the illustrated implementations, the air ducts 234 are positioned at the side locations of the mattress 104. In alternative implementations, the air ducts 234 can be routed at other locations of the mattress 104. For example, at least one of the air ducts 234 can be arranged in the middle 126 of the mattress 104 and travel between the air chambers 222 of the mattress 104.

Referring to FIGS. 11A-C, 12, and 13, an example airflow pad assembly 400 is illustrated. FIGS. 11A-C are perspective views of an example airflow pad assembly 400 that is used with a mattress system, such as the mattress 104, the mattress system 200, or the mattress system 300. The airflow pad assembly 400 can be used to implement the airflow pad assembly 232, 332 described above.

Similar to the airflow pad assembly 232, 332, the airflow pad assembly 400 includes an airflow pad 402 and an air duct 404. The airflow pad 402 is arranged under a top layer of a mattress system, such as the top layer 202, 302 of the mattress system 200, 300. The airflow pad 402 is configured to permit air to flow therethrough and further through the top layer above the airflow pad 402. In this example, the top layer of the mattress system can be made of foam, which may be closed-cell, open-cell, or a combination thereof, so that air can be distributed through the top layer. In some implementations, the airflow pad 402 is configured to permit an airflow rate that is higher than an airflow rate of the top layer above the airflow pad 402.

The airflow pad 402 can permit ambient or conditioned air to flow therethrough and further through the top layer above the airflow pad 402 to control a temperature at a top surface (e.g., a surface opposite to the airflow pad 402) of the top layer. In some implementations, air can be drawn from the airflow pad 402 and thus from the top layer above the airflow pad 402, thereby decreasing a temperature at the top surface of the top layer above the airflow pad 402. For example, when a user rests on the top surface of the top layer in the mattress system, drawing air from the airflow pad 402 causes air to be further drawn from the top layer, and thus cools both the top layer and the user's body contacting the top layer. In other implementations, ambient or cooling air can be supplied to the airflow pad 402 and thus distributed through the top layer above the airflow pad 402, thereby decreasing a temperature at the top surface of the top layer above the airflow pad 402. In a similar example where a user rests on the top surface of the top layer in the mattress system, supplying ambient or cooling air to the airflow pad 402 causes air to be further distributed into and throughout the top layer, and thus cools the user's body contacting the top layer. In yet other implementations, heating air can be supplied to the airflow pad 402 and thus distributed through the top layer above the airflow pad 402, thereby increasing a temperature at the top surface of the top layer above the airflow pad 402. In a similar example where a user rests on the top surface of the top layer in the mattress system, supplying heating air to the airflow pad 402 causes air to be further distributed into and throughout the top layer, and thus warms the user's body contacting the top layer.

Referring to FIG. 13, the airflow pad 402 can include an airflow material 410 and a pad cover 412 that at least partially wraps the airflow material 410. The airflow material 410 can be a material that is different from the material of the top layer above the airflow pad 402. As described herein, the airflow material 410 is configured to provide an airflow rate that is higher than an airflow rate of the top layer above the airflow pad 402. In addition, the airflow material 410 can be made of a water-resistant material so that the airflow pad 402 can avoid water intrusion while permitting for air distribution. Further, the airflow pad 402 is made to be breathable. In addition, the airflow material 410 is made to be resilient enough to provide desired support for a user resting on the mattress system, along with other layers of the mattress system.

In some implementations, the airflow material 410 can have three-dimensional structures with elastic polyolefin fibers. Alternatively or in addition, the airflow material 410 is made of 100% polyolefin. Alternatively or in addition, the airflow material 410 is configured to provide a resilience rate of thickness no less than 95% after 80,000 times of repeated compressions. In addition or alternatively, the airflow material 410 includes Qshion™ material, which is available from Qshion 4D, Taiwan, R.O.C. The Qshion™ material provides complex three-dimensional structures with elastic polyolefin fibers which provide desired ventilation and sleeping environment. Further, the Qshion™ material includes a breathable, non-toxic, recyclable POE material which can provide full support and comfort. The Qshion™ material is washable and dries quickly. The Qshion™ material allows airflow to keep a user cool and comfortable for an extended period of time (e.g., overnight). Further, the Qshion™ material is configured to help relieve joint and muscle pressure of a user. The Qshion™ material is a nontoxic, recyclable material which allows a user to sleep in a safe and healthy environment. The Qshion™ material is more breathable than foam materials. Further, the Qshion™ material has a resilience rate of thickness no less than 95% after 80,000 times of repeated compressions, while foam materials typically have resilience rates of thickness of 90% or less after the same repeated compressions. The Qshion™ material does not absorb moisture and free of dust mites, while foam materials keep humidity and lead to mold. In other embodiments, the airflow material 410 can be different than Qshion™ material in some ways and yet include one, more than one, or all of the above-identified properties of Qshion™ material.

In some implementations, the airflow material 410 may have one or more of an anti-microbial property or an anti-fungal property. For example, the airflow material 410 can include silver or copper.

The pad cover 412 is configured to cover the airflow material 410. For example, the pad cover 412 is configured to at least partially enclose the airflow material 410. In some implementations, the pad cover 412 can include a zip fastener 414 (FIG. 13) configured to open the pad cover 412 to receive or remove the airflow material 410. In other implementations, the pad cover 412 does not include the zip fastener 414 or other fastener for reopening the pad cover.

As illustrated in FIGS. 11A and 12, the pad cover 412 can include a vent 416 configured to permit for air to pass through. The vent 416 can be provided in a top of the pad cover 412 so that the vent 416 faces a bottom surface of the top layer (e.g., the bottom surface 214, 314 of the top layer 202, 302) above the airflow pad 402. The pad cover 412 can be made of an air restrictive material so that air can flow at least substantially through the vent 416. The pad cover 412 can be free of holes that would significantly direct airflow therethrough, except for the vent 416. Alternatively, the pad cover 412 is made of a material that permits for air flow, but at a slower rate than the vent 416. In some implementations, the vent 416 is configured in the form of a window provided in the pad cover 412. In some implementations, the vent 416 is an opening covered by a meshed material. In other implementations, the vent 416 is an opening with or without any material covering the opening. The vent 416 can be of various shapes, such as a square window, a rectangular window, a circular or oval window, and other suitable polygonal shapes. Alternatively or in addition, the vent 416 can be made in a plurality of holes and/or slits that are arranged in one or more groups.

In some implementations, the edges of the vent 416 can be spaced inward of the perimeter of the airflow pad 402 to form a border around the vent 416. The border around the vent 416 can ensure that the surface (e.g., the top surface) of the airflow pad 402 is not entirely the vent 416. For example, the vent 416 is sized to have edges spaced at widths D1-D4 from the perimeter of the pad cover 412. The widths D1-D4 can be determined such that the border around the vent 416 is wider on the side so as to have less or no flow near the outer side of the airflow pad 402, and more flow in the middle and near the inner side of the airflow pad 402. In some implementations, the inlet/outlet (e.g., the pad-side end 430) of the air duct 404 are arranged in a portion of the airflow pad 402 that corresponds with (e.g., aligned with) the border around the vent 416. For example, the pad-side end 430 of the air duct 404 is arranged opposite side of a border (the portion having the width D3) of the airflow pad 402. Such arrangement of the inlet/outlet of the air duct 404 can prevent airflow from just blasting upwards from the air duct 404 directly through the vent 416 in an air supply mode, or from suctioning downwards into the air inlet/outlet of the air duct 404 directly through the vent 416 in an air draw mode. Rather, the arrangement of the inlet/outlet of the air duct 404 can allow air to evenly distributed through the entire airflow material 410 (or a majority thereof) as it flows between the inlet/outlet of the air duct 404 and the vent 416.

The pad cover 412 can be configured to provide a plenum chamber that substantially surround a core of the airflow material 410. For example, the pad cover 412 is made of a material that limits airflow while permitting for air to flow through the vent 416. As illustrated, the airflow material 410 can be configured as a layer generally having a top, a bottom, and sides. The pad cover 412 is positioned on at least part of the top, the bottom, and the sides of the airflow material 410, and provides an opening through the vent 416 arranged on the pad cover 412 abutted with the top of the airflow material 410. The vent 416 can be covered by a meshed material or other materials that permit airflow, so that air can flow through the vent 416 and out of or into the airflow material 410 surrounded by the pad cover 412.

The airflow pad 402 is fluidly connected to the air duct 404 at one end. The other end of the air duct 404 can be fluidly connected to an air controller (e.g., the air controller 338) configured to supply ambient or conditioned air into the airflow pad 402 through the air duct 404 and/or draw air from the airflow pad 402 through the air duct 404.

Referring to FIGS. 11A-C, the air duct 404 includes a pad-side end 430 connected to the airflow pad 402 and fluidly communicating with the airflow material 410 within the airflow pad 402. The air duct 404 has a fan-side end 432 configured to be fluidly connected to a fan assembly (e.g., the air controller 338), or mate with a connection point of the mattress foundation 106. In some implementations, the air duct 404 can be a bellows-style hose with a repeating series of alternating flex points along the duct. This can allow the air duct to expand and contract as well as to bend to accommodate an air controller being used in different applications.

As described herein, the airflow pad 402 can be configured to include various features that permit for the airflow pad 402 to have a small form factor. For example, the airflow material 410 and the pad cover 412 are configured to provide a smaller thickness of the airflow pad 402 than a layer (e.g., the top layer 202) above the airflow pad 402. For example, the intermediate layer 204 that incorporates the airflow pad assembly 400 (including one or more airflow pads 402) can be configured to have a smaller thickness than the top layer 202 so that the comfort that the top layer 202 can provide is not reduced or otherwise compromised by the inclusion of the intermediate layer 204 and/or the airflow pad assembly 400 (including the airflow pads 402). In some implementations, a ratio in thickness of the top layer 202 over the intermediate layer 204 can range between about 1.2 to about 10. By way of example, the top layer 202 can be made to be 4 inches thick while the intermediate layer 204 (including the airflow pad assembly 400) can be made to be 1 inch thick. As may be appreciated, however, any suitable ratio in thickness may be used.

FIG. 14 illustrates a bottom perspective view of an example mattress with a set of reinforcement straps attached in place. FIG. 15 illustrates a bottom perspective, exploded view of the mattress with the reinforcement straps removed. In FIG. 15, a core of the mattress and a bottom layer are removed to better illustrate components of the mattress.

Referring to FIGS. 14 and 15, example reinforcement strap sets 550 extend from the rail structure 206 and terminate at a longitudinal middle section 518 at a bottom surface 516 of the bottom layer 208. The reinforcement strap sets 550 extend into the longitudinal middle section 518 but do not contact to opposite side rail. That is, each opposing reinforcement strap set 550 extending from one side rail (such as the first side rail 566) ends are coupled to the bottom surface 516 and do not contact the opposite side rail (such as the second side rail 568). In this document, the reinforcement strap sets 550 can also be referred to as straps, mattress straps, or side straps.

One or more reinforcement straps 550A-550D can be used to hold the mattress 500 in place and keep it from bowing outwards when used. In some examples, a core (e.g., the inflatable air chambers 222 in FIG. 3) is configured to be inflated or deflated to adjust its firmness. When inflated, the core may press against adjacent mattress structures (e.g., layers above and/or below the core, and the sides surrounding the core) outwardly, causing the adjacent mattress structures to bulge or bow outwards. The reinforcement straps 550A-550D are configured and arranged to restrict or prevent this by attaching the rail structure 206 to the bottom surface 516 of the bottom layer 208.

The reinforcement straps 550A-550D can be a fabric such as cotton, polyester, canvas, vinyl, tweed, suede, or corduroy. In some cases, the fabric is semi-rigid. In other cases, the fabric has minimal stretch. In some implementations, the fabric is a blend of inherent flame-retardant rayon, polyester, and para-aramid. For example, the fabric can be 50% flame retardant rayon, 45% polyester, and 5% para-aramid. Any suitable material or combination of materials may be used.

Referring to FIGS. 14-15, the mattress 500 can include a layer and a rail structure attached to the layer. The layer can have a layer top and a layer bottom opposite to the layer top. The layer can extend between a first layer edge and a second layer edge. Examples of the first and second layer edges are opposite side edges of the layer. In addition, the layer can extend between a third layer edge and a fourth layer edge, examples of which are head-side and foot-side edges. The rail structure can include a first side rail attached to the layer bottom proximate the first layer edge, and a second side rail attached to the layer bottom proximate the second layer edge. For example, the first and second side rails can be rails arranged at opposite sides along the length of the mattress. In addition, the rail structure can include a third side rail attached to the layer bottom proximate the third layer edge, and a fourth side rail attached to the layer bottom proximate the fourth layer edge. For example, the third and fourth side rails can be rails arranged at the head-side edge and the foot-side edge. A core of the mattress, such as one or more air chambers, foams, and/or spring assemblies, can be positioned under the layer bottom between the first side rails and the second side rails. In addition, the core can be positioned under the layer bottom between the third side rails and the fourth side rails. Multiple straps extend from at least one of the first side rail and the second side rail and are connected to the layer. The straps couple the side rails to the bottom layer.

As illustrated in FIGS. 14 and 15, the mattress 500 can be configured similarly to the mattress 104 or the mattress system 200, 300. For example, the mattress 500 includes a top layer 502, an intermediate layer 504, a rail structure 506, and an airflow layer 530, which are configured similarly to the top layer 202, 302, the intermediate layer 204, 304, the rail structure 206, 306, and the airflow layer 230, 330, respectively. The mattress 500 can be configured to include a core of various types, such as one or more inflatable air chambers, air hoses, foams, and/or spring assemblies, that can be received in a space defined by the rail structure 506 in the same or similar manner as described herein.

The rail structure 506 can include a head rail 562, a foot rail 564, and first side rail 566 and second side rail 568 extending between the head rail 562 and the foot rail 564 opposite the first side rail 566. The first side rail 566 is attached to the bottom 214 of the top layer 202 proximate to the first layer edge 228. The second side rail 568 is attached to the bottom 214 of the top layer 202 proximate to the second layer edge 236.

In some implementations, the rail structure 506 can be made of one or more foam materials. In this example, the rail structure 506 is attached to the intermediate layer 504. When attached to the intermediate layer 504, the rail structure 506 may be also engaged with, or attached to, the airflow layer 530 that is positioned in a cutout section of the intermediate layer 504 (e.g., to be flushed with the intermediate layer 504). For example, the head rail 562 is attached to a bottom of the intermediate layer 504 at (or proximate) a head edge of the intermediate layer 504, and the foot rail 565 is attached to the bottom of the intermediate layer 504 at (or proximate) a foot edge of the intermediate layer 504 (opposite to the head edge of the intermediate layer 504). The first and second side rails 566, 568 are attached to the bottom of the intermediate layer 504 at (or proximate) opposite sides of the intermediate layer 504. Similar to the rail structure 206, 306, the rail structure 506 forms an upside-down foam tub, along with the layers (e.g., the intermediate layer 504, the airflow layer 530, and/or the top layer 502). For example, the rail structure 506 defines a space for receiving a mattress core, such as one or more inflatable air chambers (e.g., the air chambers 222 in FIG. 3), foams, and/or spring assemblies. The mattress core is positioned under the bottom surface 214 of the top layer 202 (the first layer) between the first side rail 566 and the second side rail 568. In this document, the mattress core can also be referred to as a core.

In the illustrated examples, four reinforcement straps 550A-550D are used. The first reinforcement strap 550A can also be referred to as first first-side strap 550A. The second reinforcement strap 550B can be referred to as a second first-side strap 550B. The third reinforcement strap 550C can be referred to as a first second-side strap 550C. The fourth reinforcement strap 550D can be referred to as a second second-side strap 550D. The illustrated examples of FIGS. 14-15 show four reinforcement straps 550A-550D used to secure the mattress 104. Alternatively, two, three, five, six (e.g., as shown in FIG. 16C including a third first-side strap 550E and a third second-side strap 550F as described in more detail later), seven, or more reinforcement straps 550 can be used.

Referring to FIGS. 14-15, the first first-side strap 550A and the second first-side strap 550B are connected to the first side rail 566 and extend under the core or the bottom surface 516 of the bottom layer 208 from the first side rail 566. The first second-side strap 550C and the second second-side strap 550D can be connected to second side rail 568 and extend under the core from the second side rail 568.

One end 508A of the first first-side strap 550A can be connected to a first connection location 570A located on a bottom 510 of the first side rail 566, and another end 512A of the first first-side strap 550A can be connected to a second connection location 514A located on the bottom surface 516 of the bottom layer 208. Similarly, the second first-side strap 550B can be connected to the first side rail 566 and extend under the core or the bottom surface 516 of the bottom layer 208 from the first side rail 566 to bottom surface 516. One end 508B of the second first-side strap 550B can be connected to a third connection location 570B located on the bottom 510 of the first side rail 566, and another end 512B of the second first-side strap 550B can be connected to a fourth connection location 514B located on the bottom surface 516 of the bottom layer 208. The first first-side strap 550A and the second first-side strap 550B can be arranged relative to one another in various configurations. For example, the first first-side strap 550A is arranged close to the second first-side strap 550B and extends to be parallel with the second first-side strap 550B. The first first-side strap 550A can be arranged at a distance 522 from the second first-side strap 550B. An example of the distance 522 can range from about 5 inches to about 70 inches. In some cases, as shown in FIGS. 2, 9, and 14-15, the first first-side strap 550A is arranged at a distance 522 from the second first-side strap 550B extending parallel with the first first-side strap 550A.

Similar to the first and second first-side straps 550A and 550B, the first second-side strap 550C and the second second-side strap 550D are connected to the second side rail 568 and extend under the core from the second side rail 568. One end 508C of the first second-side strap 550C can be connected to a fifth connection location 572B located on the bottom 510 of the second side rail 568, and another end 512C of the first second-side strap 550C can be connected to a sixth connection location 514C located on the bottom surface 516 of the bottom layer 208. Similarly, the second second-side strap 550D can be connected to the second side rail 568 and extend under the core from the second side rail 568 to bottom surface 516. One end 508D of the second second-side strap 550D can be connected to a seventh connection location 572A located on the bottom 510 of the second side rail 568, and another end 512D of the second second-side strap 550D can be connected to an eighth connection location 514D located on the bottom surface 516 of the bottom layer 208. The first second-side strap 550C and the second second-side strap 550D can be arranged relative to one another in various configurations. For example, the first second-side strap 550C is arranged close to the second second-side strap 550D and extends to be parallel with the second second-side strap 550D. The first second-side strap 550C can be arranged at a distance 522 from the second second-side strap 550D. An example of the distance 522 can range from about 5 inches to about 70 inches. In some cases, as shown in FIGS. 2, 9, and 14-15, the first second-side strap 550C is arranged at a distance 522 from the second second-side strap 550D extending parallel with the first second-side strap 550C.

Referring to FIG. 15, the mattress 500 has a transverse axis 526 extending between the first side rail 566 and the second side rail 568. The transverse axis 526 defines a transverse direction shown by arrow 528. As shown in FIG. 15, the transverse axis 526 is perpendicular to the first side rail 566 and the second side rail 568. Alternatively, the transverse axis 526 can be at an angle other than perpendicular to the first side rail 566 and the second side rail 568. The first second-side strap 550C and the second second-side strap 550D can align with the first first-side strap 550A and the second first-side strap 550B, respectively, along the transverse direction 528. In some cases, when only one first side strap (for example, first first-side strap 550A) and only one second side strap (for example, first second-side strap 550C) are used, the first second-side strap 550C can align with the first first-side strap 550A along the transverse axis 526, that is the transverse direction 528 extending between the first side rail 566 and the second side rail 568. In some arrangements, the first second-side strap 550C extends parallel and is aligned with the first first-side strap 550A along the transverse axis 526.

Referring to FIG. 15, the reinforcement straps 550A-550D have a length 532 that can vary according to the size of a mattress. For example, the lengths 532 can be at least 3 inches and up to half of the width of the mattress (e.g., 76 inches for a standard king bed). Generally, the lengths 532 of the reinforcement straps 550A-550D can be between 1 inch and 54 inches. In other examples, the lengths 532 can be between 3 inches and 115 inches. The lengths 532 of each of the first first-side strap 550A, the second first-side strap 550B, first second-side strap 550C, the second second-side strap 550D can be the same or differ. The reinforcement straps 550 extend from the first and second side rails 566, 568 for the respective length 532 to attach to the bottom layer 208. The shortest distance 534 between the first side rail 566 and the second side rail 568 can be greater than a total of each of the respective lengths 532 of a pair of opposing reinforcement straps 550A-550D. For example, the first first-side strap 550A and the aligned opposite first second-side strap 550C can each have the length 532 of twelve inches for a total of twenty-four inches and the distance 534 between the first side rail 566 and the second side rail 568 is six feet. For example, the first first-side strap 550A and the aligned opposite first second-side strap 550C can each have a length 532 of twenty-nine inches for a total of fifty-eight inches and the distance 534 between the first side rail 566 and the second side rail 568 is sixty inches. In some implementations, the arrangement can vary depending on the size of the notch in the foam. It can also vary depending on the size of the base pad and its location. The measurements can also depend on whether the straps are perpendicular to the rails or not, whether the straps are perpendicular to one another, etc.

The reinforcement straps 550A-550D have a width 536. For example, the widths 536 of the reinforcement straps 550A-550D can be between 0.5 inches and 115 inches. The widths 536 of each of the first first-side strap 550A, the second first-side strap 550B, first second-side strap 550C, the second second-side strap 550D can be the same or differ. The reinforcement straps 550 extend along the first and second side rails 566, 568 for the respective width 536 to attach to the bottom layer 208. For example, the shortest width 536 that the reinforcement straps 500 can each extend along first and second side rails 566, 568 for 0.5 inches. For example, the reinforcement straps 550 can extend along the first and second side rails 566, 568 for a distance of 115 inches, that is, the width 536 is 115 inches. In some cases, the reinforcement straps 550 can extend along the first and second side rails 566, 568 from the top rail to the bottom rail. In some cases, the first first-side strap 550A and the second first-side strap 550B can each have the width 536 of 57.5 inches for a total of 115 inches. For example, the first first-side strap 550A and the second first-side strap 550B can each have a width 536 of 0.5 inches for a total of one inch. In some implementations, the arrangement can vary depending on the size of the notch in the foam. It can also vary depending on the size of the base pad and its location. The measurements can also depend on whether the straps are perpendicular to the rails or not, whether the straps are perpendicular to one another, etc.

FIGS. 16A-16C illustrate alternative configurations of the reinforcement straps. Referring to FIGS. 16A-16C, although four reinforcement straps 550 are primarily illustrated in the illustrated examples, more than two reinforcement straps 550 can be used in similar manners in other implementations. In yet alternative implementations, a single reinforcement strap 550 can be used in a desired configuration.

Referring to FIG. 16A, four reinforcement straps 550 are shown in a different configuration. The reinforcement straps 550 can include the first first-side strap 550A. The first first-side strap 550A can be connected to one of the opposite side rails 566 so as to extend under the mattress core and the bottom layer 208 between bottoms of the side rails 566, 568. The opposite side rails 566, 568 are spaced apart by a distance 534. The first first-side strap 550A can be attached to the first side rail 566 at predetermined connection location 570A. Further, the reinforcement straps 550 can include the second first-side strap 550B. Similar to the first first-side strap 550A, the second first-side strap 550B can be connected to the first side rail 566 so as to extend under the mattress core between bottoms 510 of the side rails 566, 568. The second first-side strap 550B can be attached to the first side rails 566 at predetermined connection locations 570B. In some implementations, the first first-side strap 550A and the second first-side strap 550B are positioned at the longitudinal middle section 518 of the bottom surface 516. The first first-side strap 550A can extend to be other than parallel with the second first-side strap 550B and spaced at a predetermined distance from the second first-side strap 550B.

In addition, the reinforcement straps 550 can include the first second-side strap 550C. The first second-side strap 550C can be connected to the other opposite side rail, that is, the second side rail 568 so as to extend under the mattress core and the bottom layer 208 between bottoms of the side rails 566, 568. The first second-side strap 550C can be attached to the second side rail 568 at predetermined connection location 572A. Further, the reinforcement straps 550 can include the second second-side strap 550D. Similar to the first second-side strap 550C, the second second-side strap 550D can be connected to the second side rail 568 so as to extend under the mattress core between bottoms 510 of the side rails 566, 568. The second second-side strap 550D can be attached to the second side rails 568 at predetermined connection locations 572B. In some implementations, the first second-side strap 550C and the second second-side strap 550D are positioned at the longitudinal middle section 518 of the bottom surface 516. The first second-side strap 550C can extend to be other than parallel with the second second-side strap 550D and spaced at a predetermined distance from the second second-side strap 550D.

The first first-side strap 550A and the second first-side strap 550B are connected to the first side rail 566 and extend under the core from the first side rail 566. The first second-side strap 550C and the second second-side strap 550D can be connected to second side rail 568 and extend under the core from the second side rail 568. One end 508A of the first first-side-strap 550A can be connected to a first connection location 570A located on a bottom 510 of the first side rail 566, and another end 512A of the first first-side strap 550A can be connected to a second connection location 514A located on a bottom surface 516 of the bottom layer 208. Similarly, the second first-side strap 550B can be connected to the first side rail 566 and extend under the core from the first side rail 566 to bottom surface 516. One end 508B of the second first-side strap 550B can be connected to a third connection location 570B located on the bottom 510 of the first side rail 566, and another end 512B of the second first-side strap 550B can be connected to a fourth connection location 514B located on the bottom surface 516 of the bottom layer 208.

The first second-side strap 550C and the second second-side strap 550D can be connected to second side rail 568 and extend under the core from the second side rail 568. One end 508C of the first second-side strap 550C can be connected to a fifth connection location 572B located on a bottom 510 of the second side rail 568, and another end 512C of the second second-side strap 550C can be connected to a sixth connection location 514C located on the bottom surface 516 of the bottom layer 208. Similarly, the second second-side strap 550D can be connected to the second side rail 568 and extend under the core from the second side rail 568 to bottom surface 516. One end 508D of the second second-side strap 550D can be connected to a seventh connection location 572A located on the bottom 510 of the second side rail 568 and another end 512D of the second second-side strap 550D can be connected to an eighth connection location 514D located on the bottom surface 516 of the bottom layer 208.

Other configurations of the straps 550 can be possible. In some implementations, the straps 550 can be routed to cross each other as described in more detail in reference to FIG. 16B. For example, two straps can be used, such as a first strap 550A and a second strap 550C that are connected to the opposite side rails 566, 568 to extend under the mattress core between the bottoms 510 of the side rails 566, 568. The first strap 550A can be routed to cross the second strap 550C by connecting one end 508A of the first strap 550A to one of the side rails 566 between the head rail 562 and the foot rail 564 and connecting the other end 512A of the first strap 550A to the second connection location 514A between the foot rail 562 and the second strap 550C. The second strap 550C can be routed to cross the first strap 550A by connecting one end 508C of the second strap 550C to one of the side rails 568 between the head rail 562 and the foot rail 564 and connecting the other end 512C of the second strap 550C to the fourth connection location 514C between the foot rail 562 and the first strap 550A. The first and second straps 550A and 550C may contact, touch, or cross one another, but are not fastened to each other.

Referring to FIG. 16B, the mattress 500 includes a first first-side strap 550A coupled to and extending from a first side rail 566 and a first second-side strap 550C coupled to and extending from a second side rail 568. A first end 508A of the first first-side strap 550A is attached to the first side rail 566 at the first connection location 570A. The first first-side strap 550A extends at an angle 524 relative to the first side rail 566. The angle 524 can be between 0 and 180 degrees. A second end 512A of the first first-side strap 550A is attached at the middle longitudinal portion 518 of the bottom surface 516 at a second connection location 514A. A first end 508C of the first second-side strap 550C is attached to the second side rail 568 at a third connection location 572A. The first second-side strap 550C extends at an angle 524 relative to the second side rail 568. The angle 524 can be between 0 and 180 degrees. A second end 512B of the first second-side strap 550C is attached in the middle longitudinal portion 518 of the bottom surface 516 at a fourth connection location 514B. The first first-side strap 550A and the first second-side strap 550C cross in the middle longitudinal portion 518 of the bottom surface 516. The angles 524 of the two straps 550A and 550C can be the same or different. Alternatively, the first and second straps 550A and 550C can be connected to each other at a cross point.

Referring to FIG. 16C, in a different configuration, the reinforcement straps 550 are positioned at one or more angles 524 relative to the respective first and second side rails 566,568. For example, each of the first first-side strap 550A, the second first-side strap 550B, first second-side strap 550C, the second second-side strap 550D can be positioned between 0 and 180 degrees relative to the first and second side rails 566,568. As shown in FIG. 16C, the first first-side strap 550A is positioned approximately 45 degrees relative to the first side rail 566. The first first-side strap 550 is positioned approximately 90 degrees relative to the second first-side strap 550B. The fourth reinforcement strap, that is the second second-side strap 550D, is positioned approximately parallel to the first first-side strap 550A.

As shown in FIG. 16C, alternatively or in addition, the reinforcement straps 550 can include an additional third first-side strap 550E coupled to the first side rail 566 and a third second-side strap 550F coupled to the second side rail 568. The angle 524 of the third first-side strap 550E relative to the first side rail 566 is approximately 165 degrees. The angle 524 of the third second-side strap 550F relative to the second side rail 568 is approximately 20 degrees.

In some implementations, referring to FIGS. 14 and 15, the rail structure 506 can include one or more cutouts 542 for various purposes. For example, the rail structure 506 includes cutouts 542 configured to receive air ducts of the airflow layer 530 and/or other components (e.g., air passages, electronic wires, etc.) of the mattress system. The cutouts 542 can be configured similarly to the notches 242 described herein. The cutouts 542 of the rail structure 506 can structurally weaken the rail structure 506 at or around the cutouts. The straps 550 can be attached to the rail structure 506 on opposite side of the cutouts 542, thereby reinforcing or maintaining the rail structure 506 at or around the cutouts 542. For example, in the illustrated example, the cutouts 542 are provided in the opposite side rails 566, 568, the first first-side strap 550A and/or the second first-side strap 550B are connected to the opposite side rail 566 proximate the cutouts 542, and the first second-side strap 550C and/or the second second-side strap 550D are connected to the opposite side rail 568 proximate the cutouts 542, as illustrated in FIGS. 14 and 15.

Referring to FIG. 15, the straps 550 can be attached to the rail structure 506 using one or more fastening elements 574. The fastening elements 574 can be of various types. For example, the fastening elements 574 include adhesive tapes. Alternatively or in addition, the fastening elements 574 can be hook-and-loop fasteners, zippers, clips, pins, buttons, straps, ties, snap fasteners, and other suitable types of fasteners.

In one example, the fastener elements 574 of each of the straps 550 are microhooks attached at its both ends (for example, ends 508A and 512A) and the person can simply peel off the protection films from the microhooks and attach them to the side rail 566 and the bottom layer 516. In a similar manner, one or more of the straps 550B-550D can be attached to the respective side rail 566, 568.

In an alternative example, one end 508A of the strap 550A can be permanently attached to the side rail 566 (for example, by an adhesive) and the other end 512A of the strap 550A can be detachable (for example, with the microhooks). However, any suitable attachment components or methods may be used. In some cases, this can be more beneficial because the strap 550A is integrated into the bed rail 556. In a similar manner, one or more of the straps 550B-550D can be attached to the respective side rail 566, 568.

The fastening elements 574 can be applied at the connection locations 570A-B, 572A-B, 514A-D, or at desired locations (e.g., the ends 508A-508D and 512A-512D) of the straps 550, so that such desired location of the straps 550 are attached to the connection points of the rail structure 506. For example, adhesive tapes can be applied between the connection locations 570A-B, 572A-B of the rail structure and the ends 512A-D of the straps 550. The fastening elements 574 couple the reinforcement straps 550 to the first and second side rails 566, 568 and the bottom surface 516. The ends 508A-508B of the reinforcement straps 550A-550B are coupled to the first side rail 566 and the ends 508C-508D are coupled to the second side rail 568 by fastening elements 574. The ends 512A-512D of the reinforcement straps 550A-550D terminate at different locations 514A-D, respectively on the bottom surface 516. The reinforcement straps 550A-550D are not fastened to each other but may contact or touch each other as described in reference to FIG. 16B.

As illustrated in FIG. 14, the mattress 500 can further include a mattress cover 580 configured to cover components of the mattress 500, such as the top layer 502, the intermediate layer 504, the rail structure 506, an airflow layer 530, and the straps 550. In FIG. 15, the mattress core and the mattress cover 580 have been removed. In some implementations, the mattress cover 580 can cover the reinforcement straps so they are not visible from the bottom of the bed or able to get snagged on anything and come loose during manufacturing.

As such, the reinforcement straps that extend between rails and run across the bottom of the mattress can help hold the mattress core and other mattress components in place and keep them from bowing outwards after repeated edge of bed stress from a user entering and exiting. The reinforcement straps can be used with pieces of hook materials (e.g., 3M hook materials) with adhesive backing. The hook materials can be placed along the bottom side of the perimeter side rails. In some implementations, the reinforcement straps can include a scrim material and attach to the hook materials and extend from one side of the bed to the other side. The straps are removable to allow other components (e.g., the air chambers, layers, etc.) to be assembled without interference. The straps can be adjustable to accommodate for stretch or changes over time, varying tolerances of the foam tub and its cover, or general aesthetic preference impact. The straps can have a width of varying sizes, such as a width ranging between about 0.5 inches and about 115 inches.

In some embodiments, the straps 550A-550B can each extend from one side rail 566, across the longitudinal middle section 518, to the second side rail 568 and the straps 550C-550D can each extend from the other side rail 568, across the longitudinal middle section 518, to the first side rail 566. This can use relatively long straps 550A-550D that extend across all or most of the mattress 500. According to implementations of the present disclosure, the straps 550A-550B and 550C-550D can be shorter than other types of straps that extend across all or most of the width of the mattress 500. Again, the shorter straps 550A-D extend from each of the first side rail 566 and the second side rail 568, respectively, across the longitudinal middle section 518, toward the other rail, respectively, without extending across the entire mattress 500. As described above, the mattress 500 with shorter straps 550A-550D can have a number of advantages over systems of longer straps 550A-550D. For example, some systems with shorter straps 550A-550D can be easier to use because a user or person installing the straps (the installer) can reach both ends 508A, 512A of the strap 550A from a single side of the mattress 500. Additionally, some mattress 500 with shorter straps 550A-550D can use less strap material, and therefore, be less expensive and lower weight. Moreover, in those embodiments where the straps 550 are angled in a manner as described in reference to FIGS. 16B-16C, the position of the mattress can be beneficially maintained relative to a force being exerted on the mattress or mattress system at an angle generally corresponding to the angle 524, for example, when a person enters or exits, that is climbs onto, off of, sits on, or stands up from, the mattress 500.

FIGS. 17A-17D illustrate a bottom layer having reinforcement straps. FIG. 17A shows a mattress 1700 generally similar to the mattress 500 described in reference to FIGS. 14-16C. Referring to FIGS. 3 and 17A-17D, the mattress 1700 includes the rail structure 206 arranged around a periphery of the mattress system 1700 and configured to at least partially surround an air chamber assembly as described in reference to FIG. 3. The rail structure 206 partially defines the space 210 for at least partially receiving the air chamber assembly 220 (shown in FIG. 3). The rail structure 206 includes the first side rail 566 and the second side rail 568. The rail structure 206 includes one or more notches 242, each configured to receive the air duct 234 of the airflow pad assembly 232. The notches 242 can be sized to fully receive the air duct 234 so that the air duct 234 does not protrude from the interior surface of the rail structure 206.

As illustrated in FIGS. 17A-17D, similar to the bottom layer 208, previously described, the bottom layer 1702 can be disposed to be at least partially surrounded by the rail structure 206. The bottom layer 1702 can be configured to close the space 210 (FIG. 3) defined by the rail structure 206. The bottom layer 1702 can partially, mostly, or entirely enclose the space 210.

In this example, the bottom layer 1702 includes reinforcement straps 1704a-d coupled to the bottom layer. The reinforcement straps 1704a-d each have a first end 1706a-d, respectively, coupled to the bottom layer 1702. The reinforcement straps 1704a-d each have a second end 1708a-d, respectively, extending from the bottom layer 1702. As illustrated, the first end 1706a-d is an end fixed to the bottom layer 1702, and the second end 1708a-d is a first end which may be free to be detached and reattached to the rail structure.

In some cases, as shown in FIGS. 17A-17C, the reinforcement straps 1704a-d and the bottom layer 1702 are formed from a single piece of fabric. Therefore, the reinforcement straps 1704a-d are integral with (and thus part of) the bottom layer 1702. In other cases, as shown in FIG. 17D, the reinforcement straps 1704a-d are coupled to the bottom layer 1702 by fastening elements 1710. The fastening elements 1710 can be of various types. For example, the fastening elements 1710 may include thread in which the reinforcement straps 1704a-d are sewn to the bottom layer 1702 (thus the reinforcement straps 1704a-d are stitched to the bottom layer 1702). Alternatively or in addition, the fastening elements 1710 can include adhesive tapes, hook-and-loop fasteners, zippers, clips, pins, buttons, straps, ties, or snap fasteners. Any suitable fastening elements may be used.

The reinforcement straps 1704a-d have fastening elements 574 to couple the second ends 1708a-d to the side rails 566, 568. The same or similar fastening elements described with reference to FIG. 15 can be used for the fastening elements 574 in this example.

The bottom layer 1702 can include recessed portions 1712 where the reinforcement straps 1704a-d extend. For example, the bottom layer 1702 has head and foot edges 1714 and 1716 and opposite side edges 1718, 1720 extending between the head and foot edges 1714 and 1716. The side edges 1718,1720 can be curved toward an inner portion 1722 of the bottom layer 1702. In some implementations, the side edges 1718,1720 can be curved away from the first and second side rails 566 and 568 when the bottom layer 1702 is attached to the rail structure 206. Therefore, when the bottom layer 1702 is attached to the rail structure 206, the curved side edges 178, 1720 and the respective first and second side rails 566 and 568 define the recessed portions 1712 (with respect to the dotted lines in FIG. 17A), and the reinforcement straps 1704a-d run across the recessed portions 1712 between the curved side edges 1718, 1720 and the first and second side rails 566 and 568, respectively.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub-combination. Accordingly, various features have been described above in the feature groups for clarity and organization purposes, however, it will be understood that features from the various feature groups can be beneficially combined together in a common system. Accordingly, various embodiments are specifically intended to include features of more than one, and sometimes many, feature groups. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. As used herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

As used herein, the term “approximately” refers to a condition or parameter which can have a value or threshold value generally within acceptable engineering, machining, measurement, or manufacturing tolerances. For example, the parameter value or threshold value can be considered approximately met when the value is within 5% of the actual parameter value or threshold value. For example, the parameter value can be considered to be equal to the threshold value when the parameter value is within 5% of the threshold value. However, different approximations for different parameter values or threshold values may be used in different embodiments.

Claims

1. A mattress comprising:

a first side rail;

a second side rail;

a core positioned between the first side rail and the second side rail;

a layer positioned under the core; and

a plurality of straps extending from the layer and connected to at least one of the first side rail and the second side rail.

2. The mattress of claim 1, wherein the plurality of straps comprises:

at least one first side strap connected to the first side rail and the layer; and

at least one second side strap connected to the second side rail and the layer.

3. The mattress of claim 2, wherein:

the at least one first side strap extends from the layer and has (i) an end connected to the first side rail and (ii) an opposite end connected to the layer; and

the at least one second side strap extends from the layer and has (i) an end connected to the second side rail and (ii) an opposite end connected to the layer.

4. The mattress of claim 3, wherein the at least one first side strap includes a first first-side strap and a second first-side strap that are positioned in a longitudinal middle section of the mattress with the second first-side strap being spaced from the first first-side strap.

5. The mattress of claim 4, wherein the first first-side strap extends in parallel with the second first-side strap.

6. The mattress of claim 4, wherein the at least one second side strap includes a first second-side strap and a second second-side strap that are positioned in the longitudinal middle section of the mattress with the second second-side strap being spaced from the first second-side strap.

7. The mattress of claim 6, wherein the first second-side strap and the second second-side strap align with the first first-side strap and the second first-side strap, respectively, along a transverse direction extending between the first side rail and the second side rail.

8. The mattress of claim 2, wherein the at least one second side strap aligns with the at least one first side strap along a transverse direction extending between the first side rail and the second side rail.

9. The mattress of claim 2, wherein the at least one second side strap extends in parallel with the at least one first side strap.

10. The mattress of claim 2, wherein a shortest length between the first side rail and the second side rail is longer than a total of a length of each of the at least one first side strap and a length of each of the at least one second side strap.

11. The mattress of claim 4, wherein:

the first side rail defines a first cutout;

the first first-side strap and the second first-side strap connect the first side rail with the layer on opposite sides of the first cutout;

the second side rail defines a second cutout; and

a first second-side strap and a second second-side strap connect the second side rail with the layer on opposite sides of the second cutout.

12. The mattress of claim 3, further comprising a plurality of fastening elements configured to attach the plurality of straps to the first side rail, the second side rail, and the layer.

13. The mattress of claim 12, wherein the plurality of fastening elements comprises:

a first fastening element configured to attach the end of the at least one first side strap onto the first side rail; and

a second fastening element configured to attach the opposite end of the at least one first side strap onto the layer.

14. The mattress of claim 12, wherein the plurality of fastening elements comprise at least one of an adhesive tape or a hook and loop fastener.

15. A bed comprising:

a mattress including: a first foam layer having a top surface and an opposite bottom surface; an inflatable chamber arranged opposite to the top surface of the first foam layer; a foam rail structure including a top foam rail, a bottom foam rail, a first side foam rail, and a second side foam rail opposite the first side foam rail, the foam rail structure extending between the top and bottom foam rails, the foam rail structure extending from a periphery of the first foam layer and configured to surround the inflatable chamber; and a second foam layer positioned under the inflatable chamber;

at least one first side strap extending under the inflatable chamber and having (i) an end connected to the first side foam rail and (ii) an opposite end connected to the second foam layer; and

at least one second side strap extending under the inflatable chamber and having (i) an end connected to the second side foam rail and (ii) an opposite end connected to the second foam layer, wherein the at least one first side strap and the at least one second side strap are arranged to extend across a portion of a bottom of the mattress, the portion of the bottom of the mattress being shorter than a shortest length between the first side foam rail and the second side foam rail.

16. The mattress of claim 15, wherein the at least one first side strap and the at least one second side strap are configured to prevent the foam rail structure from substantially bowing.

17. A bed comprising:

a mattress including: a first foam layer having a top surface and an opposite bottom surface; an inflatable chamber arranged opposite to the top surface of the first foam layer; a foam rail structure including a top foam rail, a bottom foam rail, a first side foam rail, and a second side foam rail opposite the first side foam rail, the foam rail structure extending between the top and bottom foam rails, the foam rail structure extending from a periphery of the first foam layer and configured to surround the inflatable chamber, the foam rail structure defining an upside-down foam tub configured to receive a core; the core; and a second foam layer positioned under the inflatable chamber;

a bottom layer positioned under the second foam layer, the bottom layer comprising: at least one first side strap extending from the bottom layer and under the inflatable chamber and having (i) a first end configured to be connected to the first side foam rail and (ii) an opposite end fixed to the bottom layer; and at least one second side strap extending from the bottom layer opposite the at least one first side strap under the inflatable chamber and having (i) a second end configured to be connected to the second side foam rail and (ii) an opposite end fixed to the bottom layer.

18. The bed of claim 17, further comprising a foundation configured to support the mattress, wherein the at least one first side strap and the at least one second side strap are disposed between a bottom of the mattress and a top of the foundation.

19. The bed of claim 17, wherein the foam rail structure includes a notch, and at least one of the at least one first side strap or the at least one second side strap is attached to the foam rail structure adjacent the notch.

20. The bed of claim 17, further comprising a mattress cover enclosing the first foam layer, the first side foam rail, the second side foam rail, the core, the at least one first strap, and the at least one second strap.