MULILAYERED, ADJUSTABLE MATTRESS SYSTEM WITH ORBITAL SPRINGS

Abstract

A multilayered, adjustable mattress system with orbital springs comprised of a removeable, fire resistant cover for enclosing the top of the mattress, a zipper having a predetermined zipper track along the bottom of the mattress, wherein the zipper can unzip the removable cover in both directions, a top foam cover, and an open box, rectangular, mattress encasement divided into two head sections, two body sections, and two feet sections. The layers of the mattress include multiple foam layers of varying compressibility, and a rubber spring deck, where the orbital springs are arranged in a honeycomb pattern. Additionally, the layers of the mattress can be interchanged vertically and horizontally within the mattress sections.

Description

BACKGROUND

Technical Field

The present invention relates to a multilayered, adjustable mattress system with orbital springs. More particularly, the invention relates to a mattress composed of multiple layers of foam and a newly designed orbital spring with 360-degrees of movement.

Background Art

Mattress springs have not been redesigned since the 1800s. Typical mattress springs tend to be unsupportive and uncomfortable, especially for people who are overweight. Pressure points, even in a new mattress, are common. These mattress springs are typically permanently installed at the bottom of the mattress, under the foam. Thus, people who are overweight, or those who prefer a firm mattress, do not receive the resistance they need from the mattress springs. Additionally, as mattress springs age, they tend to creak upon weight bearing. Thus, they can be loud or noisy if one sleeper is in bed and another lays down later on.

Furthermore, it is recommended that a person replace their mattress every 7 to 10 years. However, most mattress on the market are costly, and it is often a challenge to find a mattress that suits your every need. If those needs change for a period of time, or even permanently, one is stuck with the choice between restless and uncomfortable sleep, or the cost of replacing their mattress. For example, pregnant woman often struggle to get restful sleep because they are uncomfortable and are limited in what positions they are able to lay in. If, however, a pregnant woman had the option of removing a layer of the foam or the mattress springs from the mattress, she would have the space she needs to lay comfortably on her stomach or side, for the duration of her pregnancy. Additionally, once she has given birth, the mattress layer could be replaced and converted back to its original form, without the hassle of having to buy a new mattress. Furthermore, since most mattresses are a single unit, and are unable to be rearranged, when it comes time to replace the mattress, the entire mattress needs to be replaced. If, however, all the components could be separated and bought individually, one could maintain their mattress for far longer than a standard mattress.

The above-described deficiencies of today's systems are merely intended to provide an overview of some of the problems of conventional systems, and are not intended to be exhaustive. Other problems with the state of the art and corresponding benefits of some of the various non-limiting embodiments may become further apparent upon review of the following detailed description.

In view of the foregoing, it is desirable to provide a multilayered, adjustable mattress system that can be fully customizable to the user and can be upgraded and maintained for long after the life of a typical mattress.

SUMMARY OF THE INVENTION

Disclosed is a multilayered, adjustable mattress system with orbital springs comprised of a removeable, fire resistant cover for enclosing the top of the mattress, a zipper having a predetermined zipper track along bottom of the mattress, wherein the zipper can unzip the removable cover in both directions, a top foam cover, and an open box, rectangular, mattress encasement divided into two head sections, two body sections, and two feet sections. The layers of the mattress include multiple foam layers of varying compressibility, and a rubber spring deck, where the orbital springs are arranged in a honeycomb pattern.

In one embodiment, wherein the first layer of the mattress is soft foam, the second layer of the mattress is medium foam, the third layer of the mattress is firm foam, and the fourth layer of the mattress is the rubber spring deck comprised of orbital springs.

In another embodiment, the first layer of the mattress is soft foam, the second layer of the mattress is medium foam, the third layer of the mattress is firm foam, and the fourth layer of the mattress is the rubber spring deck comprised of orbital springs.

In another embodiment, the first three foam layers of the mattress are composed solely of soft foam, medium foam, firm foam, or a combination of all.

In another embodiment, the layers of the mattress are interchangeable vertically within the section of the mattress. In another embodiment, the layers of the mattress are interchangeable horizontally between the sections of the mattress.

It is therefore an object of the present invention to provide a multilayered, adjustable mattress system with orbital springs. These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view of a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 2 is a perspective view of the multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 3 is a top plan view of the multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 4 is a side cross-sectional view of one section of the multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 5 is another side cross-sectional view of the section of the multilayered, adjustable mattress system with orbital springs having the layers in a different configuration in accordance with the principles of the invention;

FIG. 6 is another side cross-sectional view of the section of the multilayered, adjustable mattress system having layers of different thicknesses in accordance with the principles of the invention;

FIG. 7 is another side cross-sectional view the section of the multilayered, adjustable mattress system having layers of the same thicknesses and orbital springs in accordance with the principles of the invention;

FIG. 8 is a top plan view of an orbital spring deck fora multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 9 is a top plan view of an intercalating foam insert for an orbital spring deck for a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 10 is a perspective view of an intercalating foam insert for a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 11 is a perspective cross-sectional view of an alternative embodiment of an orbital spring deck for a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 12 is a perspective view of another alternative embodiment of an orbital spring deck for a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 13 is a top view of an orbital spring for a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 14 is a perspective view of an orbital spring for a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 15 is a side view of an alternative embodiment of a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 16 is a side view of an alternative embodiment of a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 17 is a side view of an alternative embodiment of a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 18 is a side view of an alternative embodiment of a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention;

FIG. 19 illustrates a graph of the data shown in FIGS. 16 and 17 of a multilayered, adjustable mattress system with orbital springs in accordance with the principles of the invention.

DETAILED DESCRIPTION

The invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

The disclosed subject matter is described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments of the subject disclosure. It may be evident, however, that the disclosed subject matter may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the various embodiments herein.

Unless otherwise indicated, all numbers expressing quantities of ingredients, dimensions reaction conditions and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. The term “a” or “an” as used herein means “at least one” unless specified otherwise. In this specification and the claims, the use of the singular includes the plural unless specifically stated otherwise. In addition, use of “or” means “and/or” unless stated otherwise. Moreover, the use of the term “including”, as well as other forms, such as “includes” and “included”, is not limiting. Also, terms such as “element” or “component” encompass both elements and components comprising one unit and elements and components that comprise more than one unit unless specifically stated otherwise.

For ease of understanding, the following definitions will apply throughout this description; however, no definition should be regarded as being superceding any art-accepted understanding of the listed terms. “Foam” refers to any compressible material suitable for use in padding in a mattress, pillow or other cushioning device. “Orbital spring” refers to a spring having the shape of an inverted spherical cap which may be larger than, smaller than, or equal to a hemisphere. In most cases, an orbital spring includes an outer and an inner shell.

Various embodiments of the disclosure could also include permutations of the various elements recited in the claims as if each dependent claim was a multiple dependent claim incorporating the limitations of each of the preceding dependent claims as well as the independent claims. Such permutations are expressly within the scope of this disclosure.

Disclosed is a multilayered, adjustable mattress system with orbital springs comprised of a removeable, fire resistant cover for enclosing the top of the mattress, a zipper having a predetermined zipper track along the edge of the mattress, wherein the zipper can unzip the removable cover in both directions, a top foam cover, and an open box, rectangular, mattress encasement divided into two head sections, two body sections, and two feet sections. The layers of the mattress include multiple foam layers of varying compressibility, and a rubber spring deck, where the orbital springs are arranged in a honeycomb pattern. Additionally, the layers of the mattress can be interchanged vertically and horizontally within the mattress sections. While the invention is disclosed below in reference to a bed mattress system, those skilled in the art will appreciate that the orbital springs of the invention may be used for a variety of other purposes, where a cushioning layer is desirable, such as for example, smaller mattress, chairs, sofas, dog beds, padding used in shipping and transport, and the like.

FIG. 1 shows a perspective view of a multilayered, adjustable mattress system with orbital springs 10, in accordance with the principles of the invention. As shown, the mattress 10 consists of a rectangular prism/rectanguloid mattress encasement 20, a padded cover 16, a foam top cover 18, and two zippers 12 along a zipper track 14. The mattress encasement 20 is a rigid, rectangular prism, with a defined width, length, and height. The custom-made padded cover 16 in this embodiment unzips starting at the middle of the foot of the mattress 15. The zippers 12 unzip in opposite directions, and slides along the zipper track 14 which, in this example, runs along the bottom edge of the mattress. Those skilled in the art will appreciate the zipper track may optionally run along the top edge of the mattress. The zipper track may optionally be placed in any desirable location on the padded cover 16 and may optionally have only a single zipper. For example, the zipper track may run along the top periphery of the padded cover 16. However, the use of two zippers is beneficial because it allows for the user to open and adjust only one side if the mattress is made up with sheets and a bedspread. This is unlike other padded covers since most covers only unzip in one place and the whole bed must be taken apart to access one side. The padded cover 16 should be made from a material such as natural wool, cotton, silk, or the like. These materials have high keratin protein and moisture content and are chemical free. This ensures that the mattress is resistant to burning and benefits the customer to sleep without the concerns of breathing in and sleeping on any chemicals/toxins. Optionally, the padded cover may be made of materials commonly used to form mattress covers and other bedding components. Finally, the foam cover 18 is preferably about 5 cm thick and is coextensive with the top of the mattress encasement 20 for a smooth look and feel. The foam cover may be composed of typical mattress foam, memory foam, latex foam, or the like.

FIG. 2 shows a multilayered, adjustable mattress system with orbital springs 20 having an optional divider grid system 27, in accordance with the principles of the invention. In this embodiment, the open box, rectangular mattress encasement 23 is shown without the padded cover 16 or foam cover 18 shown in FIG. 1. The open box, rectangular mattress encasement 23 is a rigid rectanguloid, i.e. a rectangular prism, with six hollowed out sections: two head sections 34, two body sections 36, and two leg sections 38, that are each about 30-35 cm deep, but may optionally have a greater or lesser depth. Optionally, the mattress may have more or fewer sections. The sections 34, 36, 38 are separated by the divider grid system 27, built into the open box, rectangular mattress encasement 23. The divider grid system 27 has two transverse dividers 28 that run from the left side of the mattress to the right side and one longitudinal divider 26 that runs from the top of the mattress to the bottom.

Additionally, the open box, rectangular mattress encasement 23 has a rigid edge support 24, which in this embodiment is approximately 9 cm wide, that runs around the upper periphery of the entire open box, rectangular mattress encasement 23. Not only is the edge support 24 sturdy enough to support a user who wishes to sit on the side of the bed without it collapsing under their weight, it also provides side sleepers with the security that they will not roll off their mattress while asleep. Furthermore, the open box, rectangular mattress encasement 23 has a defined length 31, width 32, and height 30. The entire system may be about 30-32 cm deep. The mattress may be of any size, including queen, king and California king, or other desirable dimensions.

There are two pillow sections 34 at the top of the mattress encasement 23 equivalent in size and volume, and which may be about 38 cm wide. The two body sections 36 in the middle of the mattress also have equivalent sizes and volumes, and may be for example about 90 cm wide. The two feet sections 38 at the bottom of the mattress are also equivalent in size and volume, and may be about 58 cm wide. Therefore, the sections are not necessarily interchangeable. Additionally, the bottom left foot section 38 of FIG. 2 shows an exemplary arrangement of a plurality of layers in one of the sections 38. As shown, there is a top layer 40, a second layer 42, a third layer 44, and a bottom layer 46. Three of these layers are made up of foam with varying compressibility, and the fourth layer is made up of orbital springs, as shown in FIG. 4 below. The foam layers may be composed of any suitable mattress or cushioning material, such as for example typical mattress foam, memory foam, latex foam, or the like. FIG. 3 shows the mattress encasement 22 with the optional divider system 27 removed.

FIG. 4 shows a side cross-sectional view of a section 36 of the multilayered, adjustable mattress system with orbital springs 22, in accordance with the principles of the invention. In this embodiment, there are four layers stacked vertically one on top of the other, inside the section 36. In this embodiment, all four layers have the same width and length but vary in thickness. In this embodiment, the top layer 40 of the mattress is comprised of the softest material having the highest compressibility and the least thickness. The second layer 42 of the mattress is of medium firmness, compressibility, and thickness. The third layer 44 of the mattress is comprised of the firmest material and compressibility, and it has the largest thickness.

The fourth layer 46 is an orbital spring layer, or spring deck, comprised of orbital springs 62 which have been secured to a base 64, which in this embodiment is a rubber mat. The orbital springs 62 are affixed to the base 64 by bolts 60 and include washers 58. As displayed in this embodiment, all four layers of the mattress are interchangeable vertically, and optionally horizontally. Additionally, all foam layers may be composed of typical mattress foam, memory foam, latex foam, or other materials as the customer desires. Those skilled in the art would appreciate that these features allow the mattress to be fully customizable. For example, the user may wish to have a spring deck in each of the six sections of the mattress, or only in the body sections 36 of the mattress. Since the midline is the heaviest part of the body, it may be desirable to only include a spring deck in the body section 36 only. Additionally, a customer with a larger budget may choose to have all layers composed of latex foam, as an upgrade from the typical mattress foam.

FIG. 5 shows the same section 36 shown in FIG. 4, with the layers vertically rearranged, and with the spring deck 46 replaced with an alternative embodiment of an orbital deck 47. As shown in this embodiment, there are four layers stacked vertically one on top of the other, inside the section 36. In FIG. 5, the first, third, and bottom layers 42 of the mattress are of medium firmness, compressibility, and thickness. The second layer 47 is a spring deck, comprised of orbital springs 63 which have been arranged on top of, but not bolted to, a base 65. The orbital springs are made from a thermoplastic elastomer (TPE), which is food grade and organic. This material combines the flexibility of rubber with the strength and processability of thermoplastics. This elastomer can flex in multiple directions cycle after cycle long after another less resilient material would break. As demonstrated by this embodiment, the mattress 41 foams are interchangeable and can be removed or switched out for foams of the same or different compressibility. The spring deck can be moved up towards the top of the mattress for the firmest feel and the most support. Additionally, those skilled in the art would appreciate that this same concept would apply if the user wished to have three layers of the mattress comprised solely of foams made from the softest material, or those comprised of foams made from the firmest material. Finally, those skilled in the art would appreciate that all sections of a mattress may be similarly vertically reconfigured. If there are two sleepers on the bed, both users could have the layers in each section configured in completely different patterns to satisfy their own needs. Since the springs are independent on the rubber spring decks, any movement is confined to a single spring, or a group is springs and is not transferred to the other spring deck or the other sleeper.

FIG. 6 shows a side cross-sectional view of the mattress section 36 with no orbital spring deck or layer included. As shown in this embodiment, the foams all have the same width and length, and but vary in thickness as in the embodiment in FIG. 4. Additionally, all foams are interchangeable both horizontally and vertically, as in the other embodiments. As demonstrated in this embodiment, the user may choose to have a section 46 of the mattress 48 completely comprised of foams, as long as the layers fill the entire depth of the section. Thus, as shown in this embodiment, the top layer 40 of the mattress is comprised of the softest material and compressibility, and it is the smallest thickness. The second and fourth layers 42 of the mattress are of medium firmness, compressibility, and thickness. The third layer 44 of the mattress is comprised of the firmest material and compressibility, and it has the largest thickness. Additionally, those skilled in the art would appreciate that this same concept would apply if the user wished to have a mattress comprised solely of foams made from the softest material, the material of medium firmness, the firmest material, or a different combination then shown in the embodiment. Finally, those skilled in the art would appreciate that this concept could apply to all six sections of the mattress. If there are two sleepers on the bed, both users could have the layers in each section configured in completely different patterns to satisfy their own needs. Since the springs are independent on the rubber spring decks, any movement is confined to a single spring, or a group is springs and is not transferred to the other spring deck or the other sleeper.

FIG. 7 shows the mattress section 36 with an alternative embodiment of a spring deck 49. Spring deck 49 is comprised only of orbital springs 61. In this embodiment, the foams 50, 52, 54 and spring deck 46 all have the same width, length, and thickness and are interchangeable both horizontally and vertically. The top layer 50 of the mattress may be comprised of the softest material and compressibility. The second layer 52 of the mattress is of medium firmness and compressibility. The third layer 54 of the mattress is comprised of the firmest material and compressibility. The orbital springs are made from a TPE, which is food grade and organic. This material combines the flexibility of rubber with the strength and processability of thermoplastics. This elastomer can flex in multiple directions cycle after cycle long another material, such as rubber would break. Since all the foams are the same thickness, those skilled in the art would appreciate that this same concept would apply if the user wished to have a mattress comprised solely of foams made from the softest material, the material of medium firmness, the firmest material, or a different combination then shown in the embodiment. Finally, those skilled in the art would appreciate that this concept could apply to all six sections of the mattress, as long as the layers fill the entire depth of the section, which may be about 40 cm deep. If there are two sleepers on the bed, both users could have the layers in each section configured in completely different patterns to satisfy their own needs. Since the springs are independent on the rubber spring decks, any movement is confined to a single spring, or a group is springs and is not transferred to the other spring deck or the other sleeper.

FIG. 8 shows a top view of the spring deck 46. The orbital springs 62 are secured to a base 64 by bolts 60. In this embodiment, the base 64 is a semi-rigid, rectangular mat that is about 2.5 cm thick. Additionally, the cross-section of the rubber mat 64 is cut to the same width and length as the foam layers shown in FIGS. 4-7. This allows for the spring deck 46 to be interchangeable with the different foam layers of the mattress. In this embodiment, the orbital springs 62 are arranged on the rubber mat 64 in a spaced apart honeycomb layout 68 and are secured right-side up to prevent having any pressure points. The honeycomb layout 68 provides support to the user like no other mattress spring. Since the orbital springs 62 are only attached to the rubber mat 64 by a single bolt at the bottom, it allows for 360 degrees of orbital movement of the springs 62, around the bolt 67. Thus, this allows the orbital springs 62 to provide full support for the user in all directions and positions.

FIGS. 9 and 10 show an intercalating foam insert 70 for the spring deck 46. Foam insert 70 is inserted onto the spring deck 70 on top of the base 64. As shown, the foam insert 74 has cutouts 72 in a honeycomb pattern, so it can fit between the orbital springs ## and provide additional support. The foam insert 74 is the same width and length as the base of the spring deck 70, and the same thickness as the orbital springs.

FIG. 11 shows an alternative embodiment of the spring deck 80, in accordance with the principles of the invention. The spring deck 80 includes a foam insert 84 with cutouts 82 in an perpendicular pattern, an lays between the orbital springs 78 which are similarly perpendicularly arranged. The foam insert 84 is the same width and length as the spring deck 80, and about the same thickness as the orbital springs 78.

FIG. 12 shows another alternative embodiment of the spring deck 81, in accordance with the principles of the invention. In this embodiment, the orbital springs 83 are arranged in a honeycomb pattern directly abutting against each other. Rather an than a single foam insert with cutouts for the orbital springs, this spring deck only includes circular foam inserts 89 around the outer edge 85 of the spring deck 81, to hold the orbital springs 83 on the outer perimeter of the spring deck 81, in place in a honeycomb pattern. In this embodiment, the orbital springs are more tightly compacted, i.e. there is a higher density of orbital springs within the deck. This embodiment includes foam inserts 89 having a semicircular shape. Those skilled in the art will appreciate that that inserts 89 may also optionally have flat upper surface.

FIGS. 13-15 show an orbital spring 90, in accordance with the principles of the invention. As shown, the orbital spring 90 has an outer shell 92 and inner shell 96 and is hollow between the shells of the spring 90, making the orbital spring 90 and the spring deck lighter. Additionally, the spring has a larger opening 94 defined by an inner bottom rim ## of the inner shell 96, and a smaller opening 98 defined by an outer bottom rim ## the outer shell 92. The smaller opening 98 is used to secure the orbital spring 90 to the base. The orbital spring ## also has a annular top ## connecting the inner shell 96 and outer shell 92.

FIG. 15 shows the orbital spring 90 is in the uncompressed position. In this embodiment, the orbital springs 90 are made from a TPE thermoplastic elastomer, which are food grade, organic, and fully recyclable. This material combines the flexibility of rubber with the strength and processability of thermoplastics. This elastomer can flex in multiple directions, cycle after cycle, long after rubber would break.

The construction of the orbital springs 90 has a variable compressibility which allows it to respond differently to different weights, e.g. a lighter weight person verses a very heavy person. The shape, design, and attachment mechanism to the rubber deck allows the orbital springs 90 to rock and support in all directions. The material of the orbital springs 90 flexes and recovers quickly making it a prime choice for a mattress spring. Additionally, the material is tear resistant, has low hysteresis, and has a high compressibility. The strength and abrasion resistance of the orbital springs 90 offers toughness, impact resistance, and will not creak like most mattress springs upon weight bearing, due to the attachment system used on the rubber deck. Finally, the orbital springs 90 have a broad service temperature for flexibility at low temperatures and good retention of mechanical properties at elevated temperatures, such as might be encountered in shipping.

FIG. 16 shows a side cross-sectional view of the orbital spring 90 in a compressed configuration. When the orbital spring 90 sufficiently compressed, the bottom of the inner shell impinges upon the outer shell 92. When sufficiently compressed, the effective resiliency of the orbital spring greatly increases because the bottom rim ## of the inner shell ## is buttressed by the outer shell 92. Thus, for the orbital spring ## to compress further, substantial weight must be applied. This buttressing of the inner shell 96 effectively increases the spring constant of the orbital spring. This is distinct from and an improvement over typical springs or foam layers which do not exhibit a stepwise increase in their effective spring constants.

The orbital spring 100 has an outer shell 102 and inner shell 106 and is hollow between the shells of the spring 100, making the orbital spring 90 and the spring deck lighter. Additionally, the spring has a larger opening 104 connecting to the inner shell 106, and a smaller opening 108 connecting to the outer shell 102. The smaller opening 108 is the hole for the bolt to secure the orbital spring 100 to the rubber mat. In the compressed position, the outer shell 102 of the orbital spring 102 curls in on itself, which increases its strength.

FIG. 17 shows a comparison between a typical multilayered mattress 110 and a multilayered mattress incorporating orbital springs 120, in accordance with the principles of the invention. This Figure illustrates how the two mattresses 110 and 120 differ when supporting a person of average weight. The mattress section 110, on the left, demonstrates how typical mattress springs 114 compress when in use, and the mattress section 120, on the right, demonstrates how the orbital springs 124 and 126 compress when in use. As shown in mattress section 110, the typical mattress springs 116 directly under the user 112 are almost fully compressed, whereas the springs 114 on the left and right of the weight offer only minimal support, and the support provided is substantially limited to a vertical direction. In the mattress 120, the orbital springs 126 directly under the user 122 are compressed, and the annular top surfaces ## of the orbital springs to the left and right of the user 122 have partially rotated from a horizontal configuration to a slanted configuration, thereby providing additional support to the sides of the user.

FIG. 18 shows a side cross-sectional comparison of a typical multilayered mattress 130 and a multilayered mattress 140 in accordance with the principles of the invention. This Figure demonstrates how two differing mattresses 130 and 140 may support the midsection of an extremely overweight, while laying on their back. The mattress section 130, on the left, demonstrates how typical mattress springs 134/136 compress when in use, and the mattress section 140, on the right, demonstrates how the orbital springs 144/146 compress when in use. As shown in mattress section 130, the typical mattress springs 136 directly under the user 132 are fully compressed and are barely proving any support to the user. Additionally, the springs 134 on the left and right of the weight do not offer any additional support to the user. This is unlike what is demonstrated by the mattress section 140 on the right. As shown in the mattress section 140, though the orbital mattress springs 146 directly under the user 142 are under a massive amount of compression, the more the orbital springs 146 are compressed, the stronger they become. Additionally, the compressed springs 146 have also rotated around the bolt they are secured by to provide additional support. Furthermore, the springs 144 on the left and right of the weight have also rotated and compressed to provide additional support to the user.

FIG. 19 is a graph 150 that illustrates the data displayed in FIGS. 17 and 18 of the multilayered, adjustable mattress system with orbital springs, in accordance with the principles of the invention. As shown, the x-axis 152 represents compressibility, and the y-axis 154 represents weight. The compressibility of typical mattress springs is demonstrated by the curve 158. As shown, the compressibility of typical mattress springs steadily increases up to a certain weight, at which point it begins to flatten out. The compressibility, which can be expressed mathematically as a spring constant that may or may not vary with the amount of compression, of orbital springs is demonstrated by the step function 156. As shown, as the weight increases, so does the compressibility and strength of the springs. Thus, when comparing the two options, one of ordinary skill in the art would appreciate that the orbital springs provide more compression, strength, and ultimately comfort to the user than typical mattress springs.

In use, the multilayered, adjustable mattress system with orbital springs can be fully customized to meet the user's needs and desires. Additionally, since all the components can be ordered separately after the initial purchase, the layers of each section can be altered with the user's changing needs. For example, if a pregnant woman wished to sleep on her stomach, the orbital springs could be removed and replaced with the softest layer of foam for the duration of her pregnancy. Once she has given birth, the mattress could be easily converted back to its original form. Another example of this would occur if an obese person purchased the mattress and a few years later loses a substantial amount of weight. Whereas in the beginning he may desire the spring decks in each of the six sections, after losing weight he may chose to replace the spring decks in the head and foot sections with foam. Since these individual foam layers can be easily ordered, the customizing process is readily available and more cost effective than buying a new mattress.

Likewise, if a customer damages one component, that item can be bought and replaced on the existing mattress. This is a huge benefit to the consumer because it allows them to keep the mattress like new without requiring them to replace the entire mattress. The components that can be replaced include the mattress encasement, zipper cover, all foams and latex, orbital springs, the rubber spring deck, and the edge support. Finally, customers can choose the type of materials used in the sections, giving them the advantage of controlling the total cost of the mattress. For example, a user concerned with their budget may choose to purchase foam layers instead of latex, since latex is more expensive. If the user wished to upgrade later, the latex components could be purchased and switched out with the foam layers in a matter of minutes. This is a major cost advantage to other mattresses on the market because the mattress can be maintained and even upgraded without having to be fully replaced.

Whereas, the present invention has been described in relation to the drawings attached hereto, other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Descriptions of the embodiments shown in the drawings should not be construed as limiting or defining the ordinary and plain meanings of the terms of the claims unless such is explicitly indicated. The claims should be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Claims

1. A multilayered, adjustable mattress system with orbital springs comprising:

a removeable cover for enclosing the mattress;

a zipper track having at least one zipper extending along at least one edge of the mattress;

a top foam cover;

a rectangular mattress encasement having at least one section configured to contain at least one layer;

an orbital spring layer comprising a plurality of orbital springs arranged in a honeycomb pattern;

at least one foam layer.

2. The multilayered, adjustable mattress system with orbital springs of claim 1 wherein the mattress encasement is divided into two head sections, two body sections, and two feet sections; and wherein each section comprises at least one foam layer.

3. The multilayered, adjustable mattress system with orbital springs of claim 2, wherein the at least one foam layer comprises two or more foam layers having different compressibility.

4. The multilayered, adjustable mattress system with orbital springs of claim 3, wherein the orbital springs are arranged in a honeycomb pattern.

5. The multilayered, adjustable mattress system with orbital springs of claim 4, wherein.

6. The multilayered, adjustable mattress system with orbital springs of claim 5, wherein the.

7. The multilayered, adjustable mattress system with orbital springs of claim 6, wherein the orbital spring layer and the foam layers are vertically interchangeable.

8. The multilayered, adjustable mattress system with orbital springs of claim 7, wherein the layers of the mattress can be interchanged horizontally between the mattress sections.

9. The multilayered, adjustable mattress system with orbital springs of claim 8, wherein the orbital spring layer further comprises an intercalating foam insert.

10. The multilayered, adjustable mattress system with orbital springs of claim 9, wherein each of the orbital springs are secured to a base by a bolt and a washer.

11. The multilayered, adjustable mattress system with orbital springs of claim 10, wherein the removeable cover is made from naturally, fire resistant wool.

12. A multilayered, adjustable mattress system with orbital springs comprising:

a removeable cover for enclosing the top of the mattress;

a zipper track having at least one zipper along the edge of the mattress; wherein the zipper can unzip the removable cover in both directions;

a top foam cover;

an open box, rectangular, mattress encasement;

a rubber spring deck; wherein the orbital springs are arranged in a honeycomb pattern;

multiple foam layers of the same thickness and compressibility;

13. The multilayered, adjustable mattress system with orbital springs of claim 12 wherein the open box is divided into two head sections, two body sections, and two feet sections.

14. The multilayered, adjustable mattress system with orbital springs of claim 13, wherein the first three foam layers of the mattress are composed solely of soft foam, medium foam, firm foam, or a combination of all.

15. The multilayered, adjustable mattress system with orbital springs of claim 14, wherein the fourth layer of the mattress is the rubber spring deck with orbital springs.

16. The multilayered, adjustable mattress system with orbital springs of claim 15, wherein the layers of the mattress can be interchanged vertically within the mattress section.

17. The multilayered, adjustable mattress system with orbital springs of claim 16, wherein the layers of the mattress can be interchanged horizontally between the mattress sections.

18. The multilayered, adjustable mattress system with orbital springs of claim 17, wherein the rubber spring deck includes a foam insert between the orbital springs.

19. The multilayered, adjustable mattress system with orbital springs of claim 18, wherein the orbital springs are secured to the rubber spring deck with a bolt.

20. The multilayered, adjustable mattress system with orbital springs of claim 19, wherein the removeable cover is made from naturally, fire resistant wool.