CA2801789A1 - Modular component mattress - Google Patents
Modular component mattress Download PDFInfo
- Publication number
- CA2801789A1 CA2801789A1 CA2801789A CA2801789A CA2801789A1 CA 2801789 A1 CA2801789 A1 CA 2801789A1 CA 2801789 A CA2801789 A CA 2801789A CA 2801789 A CA2801789 A CA 2801789A CA 2801789 A1 CA2801789 A1 CA 2801789A1
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- Canada
- Prior art keywords
- core
- topper
- main
- mattress
- cavity
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C21/00—Attachments for beds, e.g. sheet holders, bed-cover holders; Ventilating, cooling or heating means in connection with bedsteads or mattresses
- A47C21/04—Devices for ventilating, cooling or heating
- A47C21/048—Devices for ventilating, cooling or heating for heating
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/001—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with several cushions, mattresses or the like, to be put together in one cover
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/08—Fluid mattresses or cushions
- A47C27/081—Fluid mattresses or cushions of pneumatic type
- A47C27/082—Fluid mattresses or cushions of pneumatic type with non-manual inflation, e.g. with electric pumps
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/08—Fluid mattresses or cushions
- A47C27/085—Fluid mattresses or cushions of liquid type, e.g. filled with water or gel
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/08—Fluid mattresses or cushions
- A47C27/10—Fluid mattresses or cushions with two or more independently-fillable chambers
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/18—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays in combination with inflatable bodies
Landscapes
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
In accordance with the present invention is a modular component mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam or heater that is inserted into each side of a topper cavity or main core cavity of a mattress cover which can be and easily assembled and exchanged by customer without returning the entire mattress having a low cost satisfaction guarantee.
Description
MODULAR COMPONENT MATTRESS
Cross Reference to Related Application This application is a continuation in cart. of 12/322,415 filed 02/03/2009 BACKGROUND-field of invention- This invention relates to a modular component mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam or heater that is inserted into each side of a topper cavity or main core cuv ity of a mattress cover which can be and easily assembled by customer and partly exchanged without returning the entire mattress.
Background -Description of prior art Generally, mattresses are formed with a mattress central portion or core surrounded by a mattress hnrder construction. The mattress central portion, or core, may comprise a series of coil springs connected together and encased in a quilted fabric.
Alternatively, the mattress core portion may consist ofpolyurethane, latex foam layers, or synthetic or natural fibers, optionally in combination with springs, and encased in quilted fabric. The core portion might also constitute an air mattress or water mattress or other body-.supporting mattress structure.
Cross Reference to Related Application This application is a continuation in cart. of 12/322,415 filed 02/03/2009 BACKGROUND-field of invention- This invention relates to a modular component mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam or heater that is inserted into each side of a topper cavity or main core cuv ity of a mattress cover which can be and easily assembled by customer and partly exchanged without returning the entire mattress.
Background -Description of prior art Generally, mattresses are formed with a mattress central portion or core surrounded by a mattress hnrder construction. The mattress central portion, or core, may comprise a series of coil springs connected together and encased in a quilted fabric.
Alternatively, the mattress core portion may consist ofpolyurethane, latex foam layers, or synthetic or natural fibers, optionally in combination with springs, and encased in quilted fabric. The core portion might also constitute an air mattress or water mattress or other body-.supporting mattress structure.
2 Mattress border constructions stabilize the edge or border portion of the mattress. It is desirable to have a more firm or more rigid border portion surrounding a less firm, body-snppc rting mattress central portion. Mattress border constructions of various types have been disclosed in the prior art. U.S. Pat. No. 5,537,699 discloses a mattress border construction formed with a foam rail. sleeve surrounding a plurality of springs arranged in a row. The foam rail sleeve defines a core into which the row of springs is inserted. The foam is slit along its length so that it may be opened to permit insertion of the row of springs. U.S. Pat. No. 5,101,623 shows a composite mattress topper, as opposed to a complete mattress construction. The topper has a latex foam rubber core section surround by border sections of urethane foam. The border sections are attached to the core section with adhesive to create the finished topper. The topper is placed in a cover with the mattress core.
Water beds have used the foam border construction to house bladders in a traditional cover so to appear as a conventional mattress. The water bed has a benefit over other mattresses in that when you initially enter the water bed it is already warm.
The present invention.also obtains with non waterbeds by adding a low powered heater under the air bladder or mattress core. By using this water bed style of heater in an air bed would seem impnssihie because there is seems to be no mass (water) or way of conducting the heat through the mattress. As well, the control for water beds typically must be very precise to obtain a comfort temperature, requiring a temperature sensor in a remote location a distance from the heater placed under the water bed bladder. As well, the invention's water bed type of temperature control could not function as a on /off type of control due to slow heat transfer of the air, the heater would form an overheated area causing damage to bladder or fire, as is the case of an empty water bed bladder. By having a heater which has approximately 1 /3 the power of a water bed and a simple control, the invention can achieve a warm air mattress upon entry and allow the room temperature to be reduced in the evening to save energy. This was not possible in waterbeds since the under powered heater would take days to bring the large mass of water up to the temperature of comfort
Water beds have used the foam border construction to house bladders in a traditional cover so to appear as a conventional mattress. The water bed has a benefit over other mattresses in that when you initially enter the water bed it is already warm.
The present invention.also obtains with non waterbeds by adding a low powered heater under the air bladder or mattress core. By using this water bed style of heater in an air bed would seem impnssihie because there is seems to be no mass (water) or way of conducting the heat through the mattress. As well, the control for water beds typically must be very precise to obtain a comfort temperature, requiring a temperature sensor in a remote location a distance from the heater placed under the water bed bladder. As well, the invention's water bed type of temperature control could not function as a on /off type of control due to slow heat transfer of the air, the heater would form an overheated area causing damage to bladder or fire, as is the case of an empty water bed bladder. By having a heater which has approximately 1 /3 the power of a water bed and a simple control, the invention can achieve a warm air mattress upon entry and allow the room temperature to be reduced in the evening to save energy. This was not possible in waterbeds since the under powered heater would take days to bring the large mass of water up to the temperature of comfort
3 level required- Many wRterhedc have the water bladder in direct contact with the person's body, resulting in substantial conduction of heat and a chilled feeling.
Mutosko US 6,553,591 adds a thin "U" shaped water bladder cushions at the surface of the mattress to reduce the bladder weight to one tenth that of conventional water beds and under a layer of foam to and eliminate the heater. The desired waterbed effect may not be satisfying in terms of feel and depth of support.
} licks US 6,421,589 also has a water bladder on top of an air bladder with more greater depth of water but offers no heater for the bladder. This would result in the patient losing body heat.
i3oth Mutosko and Hicks have mattresses that are specifically designed custom components for their mattress.
The prior art shows the general approach to heating a mattress is by heating and circulating warm air through the mattress by a blower fan. This is an expensive method and would require all or partial replacement with this custom engineered mattress. This is seen in art references of US 6,701,552 Suzuki, US 6,711,767 Klamm, US
6,546,576 Lin and US 6,006,524 Park who show this type of approach. The other type of design is to direct heating elcmcnt,5 on the or within the mattress as shown by US
Mutosko US 6,553,591 adds a thin "U" shaped water bladder cushions at the surface of the mattress to reduce the bladder weight to one tenth that of conventional water beds and under a layer of foam to and eliminate the heater. The desired waterbed effect may not be satisfying in terms of feel and depth of support.
} licks US 6,421,589 also has a water bladder on top of an air bladder with more greater depth of water but offers no heater for the bladder. This would result in the patient losing body heat.
i3oth Mutosko and Hicks have mattresses that are specifically designed custom components for their mattress.
The prior art shows the general approach to heating a mattress is by heating and circulating warm air through the mattress by a blower fan. This is an expensive method and would require all or partial replacement with this custom engineered mattress. This is seen in art references of US 6,701,552 Suzuki, US 6,711,767 Klamm, US
6,546,576 Lin and US 6,006,524 Park who show this type of approach. The other type of design is to direct heating elcmcnt,5 on the or within the mattress as shown by US
4,455,472 Moss and US 4,423,308 Callaway. The sealed mattress would not allow access to the lower portion of the mattress to make it easy for placement of such, a heater.
This invention simplifies the solution in terms of product cost as well as reduces power consumption due to the direct application of heat and the insulated configuration of heater as compared to the prior art. A heater can also be inserted under one side ofquccn or king mattress to heat one side more than the other using a single beater.
The present modular or component design allows a heater to not only to be used with a air bladdcr, but also a spring core, since the heater can be placed inside the mattress under the core and then mattress zipped shut.
The mattress has generally been retailed through retail stores where the mattress could be lied upon and felt for comfort at the point of sale. Surprisingly, people will buy mattresses without ever lying upon it through a.n online, interact or catalogue purchase.
The air bed has made delivery by common courier possible due to it's compact size, however its greatest feature is the adjustable firmness, so that a firmness satisfaction is guaranteed for the...person but also their spouse can adjust the air pressure to obtain the firmness for their side bf the mattress.
The main object of this invention is to provide a comfort guarantee, but without the associated cost. Some of the larger competitors would offer various guarantees. The customer could exchange the mattress for another one and the retailer could donate the old one to a charity for a tax write off. The cost would be factored into the overall overhead of the store. The cost is significant in terms of return processing and transport to the store and then transport or disposal cost from the store. This invention eliminates the transport cost since the individual components can be transported in a small car. A king mattress has the main core and topper is half the width of the mattress and will fold or rull up into a small bundle. The customer can try the different topper and /or main core and either purchase the desired component or exchange it, depending on the guarantee policy.
A new issue of bed bugs has further complicated the guarantee. Many U.S.
States will not allow a delivered mattress back into the delivery truck even if it has not been opened, due to the tough control measures needed to curb these bed bugs. Some four star hotels have had to go to great expense to guard their reputation once these bed bugs were brought into their hotel by personal pillows and bcd products ctc. This invention allows for washing or replacement of individual components of the mattress but not the entire mattress. For instance, the cover can be removed from the cores and foam rails dry cle;rnerl, and the air pump, vinyl or rubber air bladders, spring and water tubes can be washed.
Some stores tried to resell a barely used mattress to find out that the new owner was allergic to cat dander, which contaminated the mattress from the previous owner's cat sleeping on the mattress once or twice.
A second issue concerning comfort with an air bed is the comfort or feel, even though the firmness is adjustable, the surface they are lying upon will have a different feel than what they prefer. This invention offers a method to allow the customer to select or change the sleeping component on top of the air core bladder, thus giving the feel as well as adjustability of the firmness they desire. This is accomplished by allowing the topper core to be unzipped and a spring, water or various foam topper core inserted on their side of the mattress. These topper cores are thin enough to allow the firmness adjustment of the air bladder to be felt while still providing the personal preference of say pocket coil, memory or latex foam that they are familiar with.
It also allows say a softer pocket coil spring to be placed on top of a firmer set of springs.
The mattress also is a waterbed that overcomes the main objection of waterbeds in that the buttocks sinks down too deep, resulting in back pain. This system would allow the thin water bladder or tubes to be placed on the adjustable air bladder so that their buttocks will rest on the air bladder main core or any othcr main core that is selected. These features of the .invention makes it even less important to actually lay on the bed before buying it, thus a safer buy for someone living in a remote area where it would not be worth the long drive to purchase a mattress.
Mattresses are now air, coil springs, and memory foam core having a separate material in the perimeter for reasons of increased vertical perimeter support. In the case of coi l springs, the foam perimeter gives the feel or sensation of a soft mattress edge or side when the mattress is compressed laterally when sat or leaned against.
Traditionally, this feel is made by gluing the coils or rowed sleeve of coils to the foam rail. A
fabric rail sleeve, as in this invention, was not bossible to sew to the cover as it would leave a visible stitch mark on the surface and interfere with quilting patterns. The invention has the fabric rail sleeve sewn to the perimeter and the bottom cover of the mattress.
Mattresses have historically been assembled in the manufacturing facility.
With manufacturing moving overseas to countries such as China, there was an economic advalatage to rcducc the shipping volume, since the shipping containers would not be close to their maximum weight capacity. Compressing components such as spring assemblies, or complete spring mattresses made economic sense. A problem occurred with mattresses using foam rails, in that the foam rail that was glued to the inner maltres cover would not return to it's original shape and wrinkles would result. This invention eliminates the gluing operation.
A mattress assembly shown in U.S. Pat. No. 5,953,779 has a stack of foam mattress elements positioned one atop the other and joined together at their peripheral edges with hook and loop fasteners (VELCRO®). The fasteners keep the foam mattress elements aligned in stacked relation. The mattress so formed does not have a mattress border construction, and a retainer rope is secured around the outer edge of the mattress to hold the elements together. Additional holding support is provided by containment blocks optionally attached with VELCRO® to the head and foot of the mattress a.sscrnbty.
U.S. Pat. No. 2,326,441 shows a mattress covering in which strips of fabric are secured to the sidewall of a foam sponge nihher mattress core with an adhesive. The fabric'strips form an anchor onto which the mattress covering material may be stitched. No mattress border construction is provided around the sponge rubber mattress core.
Summary In acr..orriance with the present invention is a modular component mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam, lumbar support, or heater that is inserted into each side of a topper cavity or main core cavity of a mattress cover which can be and easily assembled and exchanged by customer without returning the entire mattress. The smaller retailer can offer multiple selection using a single queen size bed, switching components until the customer is satisfied, and then guaranteeing long term comfort at low cost, as well as replacement of individual worn or damaged components. The entire king size bed or it's components will fit in a compact size car or can becouriered.
Or1LWCTS AND ADVANTAGES OF THE INVENTION
This novel approach has the following advantages in that it:
- Provides a modular corrtponent mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam, lumbar support, or heater that is inserted into a topper cavity or main core cavity of a mattress cover which can be and easily assembled by customer and partially exchanged without returning the entire mattress.
- Provides reduced floor space, inventories and warehouse space as several colors and fabric designs would be available and rail types and core types would be compatible with the different types of mattress cover.
- Provides a comfort guarantee, but without the associated cost. With the conventional guarantee, the customer could exchange the mattress for another one and the retailer could donate the old one to a charity for a tax write off. The cost would be factored into the overall overhead of the store. The cost is significant in terms of return processing and transport to the store and then transport or disposal cost from the store.
This invention eliminates the transport cost since the individual components can be transported in a.
small car. A king mattress has the main core and topper is half the width of the mattress and will fold or roll up into a small bundle. The customer can try the different topper and /or main core and either purchase the desired component or exchange it. A
dissatisfied customer is able to exchange spring with say foam or air cores in the topper cavity, main cute cavity or both, without exchanging the cover (thus preventing full destruction of product for hygienic considerations), thus allowing a low cost satisfaction warranty to be offered. The invention allows any type of mattress surface or core be installed by the customer until they are satisfied. It is difficult to determine if a mattress is suitable at the point of sales, and for many, several nights or weeks of sleeping on the mattress will be needed to evaluate the mattress and determine satisfaction.
A small skew count for smaller stores to offer a wide range of selection without taking up much floor space or inventory space.
- Each side of queen or king mattress can be selected to meet individual preference.
-Coil springs on air bladders allow for the novel pocket coil firmness adjustability.
-Airbladders also allow for adjustable water bladder firmness adjustability on conventional low cost single bladder or tube type water bladders.
-This invention allows for washing or replacement of individual components of the mattress but not the entire mattress. For instance, the cover can be removed from the cores and foam rails dry cleaned. and the air pump, vinyl or rubber air bladders, spring and water tubes can be washed.
- A second issue concerning comfort with an air bed is the comfort or feel, even though the firmness is adjustable, the surface they are lying upon will have a different feel than what they prefer. This invention ofFers a method to allow the customer to select or change the sleeping component on top of the air core bladder, thus giving the feel as well as adjustability of the firmness they desire. This is accomplished by allowing the topper core to be unzipperl and a spring, water or various foam topper core inserted on their side of the mattress. These topper cores are thin enough to allow the firmness adjustment of the air bladder to be felt while, still providing the personal preference of say pocket coil.
memory or latex foam that they are familiar with. It also allows say a softer pocket coil spring to be placed on top of a firmer set of springs.
The mattress also is a waterbed that overcomes the main objection, of waterbeds in that the buttocks sinks down too deep, resulting in back pain. This system would allow the thin water bladder or tubes to be placed on the adjustable air bladder to that their buttocks will rest on the air bladder main core or any other main core that is selected. What should be understood about water beds is that someone floating on water would be mostly submerged, and would feel weightless without pressure points. This is not the case. What is mechanically happening is the weight of the water pushing the perimeter of the bladder stretches vinyl surface and effectually hammocks the person. This causes a hammocking configuration with a resulting slouched, sore spine. This invention allows the underlying air bladder to support the buttocks area and prevent slouching with an under-filled water bladder or tubes.
The conventional single air bladder mattress must sacrifice support of the buttocks high pressure for conformity (softness) with low pressure. The present invention has a thin height air bladder that rests on top of a conventional air bladder, both having adjustability. By allowing the pressure to be low enough, in the top air bladder, to prevent stretching of the surface vinyl, allows it to conform and shape about the pressure points of the body, while providing the lower air bladder to give support to buttocks area which tends to sink down.
- Components are designed to fit into. their specific cavities in terms of height, length and width, and openings are located in the cover for hoses and heater wires to provide one mattress that can be altered into any type of mattress - Vinyl air or water bladders and spring packs can be cleaned for resale or exchange.
The customer can eventually replace a damaged or worn out component of the mattress rather than the whole mattress.
-Allows for manufacturer and customer compact transport of mattress, even a king size mattress in a small vehicle in it's unassembled state. The foam rails are then inserted in the perimeter foam rail sleeves. The core is then placed on the cover or foam and between the foam rail assemblies. A layer of foam maybe placed in the mattress cover if desired.
has a zipper for both topper and main core cavities for easy access.
-The zippers have a cover so that they are not visible or felt -The foam rail zipper eliminates the glue operation.for securing foam rails which in turn prevents wrinkling, as well as incomplete recovery, when the rails are compressed for shipping. This is a problem since most adhesives take up to 2.weeks to fully cure and once a product it is on the assembly line it must be packaged as the last step of the production. To package mattresses with spring cores, the finished mattress arc put in a plastic bag which then have the air evacuated resulting in compression of spring assembly (core) and rails into a flattened state, which is then rolled and placed in a box.
Since the adhesive is riot fully cured, it causes the folded or wrinkled outer cover side fabric which is glued to the rail or rail enclosure, to adhere to it's self resulting in inability to come back to its full height once removed from the plastic bag.
It also reduces discoloration from glue seepage to the outside of the cover and prevents the cover rotating or twisting relative to the foam rails and/or contents of cover preventing outer line or edge to remain straight and along the corner of the mattress edge. A
sleeve is easier to assemble rather than securing with Velcro tabs or strips, between cover and foam rail, which require alignment before pressing together. It also allows the mattress cover to be folded in a space efficient way over a mattress cover which has the foam rails attached.
-The heater can be installed in the topper core or main core cavity.
-When you initially enter the bed it is already warm- This invention also solves this problem by adding a low powered heater under the air bladder. As well, the control for water beds must be very precise to obtain a comfort temperature, requiring a temperature sensor in a remote location a distance from the heater placed under the water bed bladder.
This temperature control would not function as a on /off type of control due slow heat transfer of the air, the heater would form an overheated area causing damage to bladder or combustion, as is the case of an empty water bed bladder. By having a heater Which has approximately 1 /3 the power of a water bed and a simple control, the invention can achieve a warm air mattress upon entry and allow the room temperature to be reduced in the evening to save energy. This was not possible in waterbeds since the under powered heater would take days to bring the large mass of water up to the temperature of Wrnfort level required, Since many waterbeds have the water in direct contact with the sleeping surface resulting in conduction of heat from the person's body.
-This invention simplifies the solution in terms of product cost as well as reduces power consumption due to the direct application of heat and the insulated configuration of heater as compared to the prior art.
-The multi tap heater elements provide a range of heat settings and eliminates expensive power controls that add cost and electrical noise.
-The heater can also vary the heat for each side of the bed by allowing the user to adjust the heater position or contact area between the two sides of the bed. The amount of area under each bladder will determine the temperature of each side of a king or queen mattress which are usually two joined bladders. for adjoining spring cores, a barrier of say vinyl or fabric will 'prevent an unwanted heating effect on one side.
- One size heater can be used for all sizes and types of beds due to the low watt density of the heater.
- A foam lumbar or adjustable pneumatic lumbar cushion or support can be placed on or under water tubes, spring cores or air cores in either topper core cavity or main core cavity in its personally preferred location along the length of the mattress.
Every person is different in height and preference and can easily access the lumbar to rind a comfortable location for their side of the bed.
Brief Drawing-Description Fig 1- shows an exploded view of the mattress assembly.
Fig 2- shows the topper core cavity with a heater and pneumatic lumbar Fig 3- shows the main core cavity with a heater Fig 4- shows a single air core.
Fig 5- shows a double air core in a king or queen size main core cavity.
Fig 6- shows the topper core cavity with a memory foam topper core on one side and a multi-zoned latex (middle zone ) and polyurethane (head and foot) inserted in it.
Fig 7= shows a topper core cavity with spring topper core on one side and water bed tubes and foam lumbar on the other.
Fig 8- shows a single spring core. The topper spring core would generally be thinner than the main spring core.
Fig 9-shows a single water tube.
Fig 10- shows a mattress cover quitted top panel.
Fig 1 l -'shows a cross sectional view with an air main core and spring topper core.
Fig 12- shows the sectional view of the mattress cover zipper.
Fig ] 3- shows the main core cavity with a spring cure and a foam core Fig 14- shows a low thickness topper air core in the topper cavity on an air core in main core cavity. An air rail is shown instead of a foam rail.
Fig 15- shows an alternative embodiment of a pillow top design with interchangeable foam sheet.
Fig 16- shows the low power heater and heater control.
REFERENCE NUMERALS OF DRAWINGS
1. main core cavity 2. zipper 3. foam rail 4. topper core cavity
This invention simplifies the solution in terms of product cost as well as reduces power consumption due to the direct application of heat and the insulated configuration of heater as compared to the prior art. A heater can also be inserted under one side ofquccn or king mattress to heat one side more than the other using a single beater.
The present modular or component design allows a heater to not only to be used with a air bladdcr, but also a spring core, since the heater can be placed inside the mattress under the core and then mattress zipped shut.
The mattress has generally been retailed through retail stores where the mattress could be lied upon and felt for comfort at the point of sale. Surprisingly, people will buy mattresses without ever lying upon it through a.n online, interact or catalogue purchase.
The air bed has made delivery by common courier possible due to it's compact size, however its greatest feature is the adjustable firmness, so that a firmness satisfaction is guaranteed for the...person but also their spouse can adjust the air pressure to obtain the firmness for their side bf the mattress.
The main object of this invention is to provide a comfort guarantee, but without the associated cost. Some of the larger competitors would offer various guarantees. The customer could exchange the mattress for another one and the retailer could donate the old one to a charity for a tax write off. The cost would be factored into the overall overhead of the store. The cost is significant in terms of return processing and transport to the store and then transport or disposal cost from the store. This invention eliminates the transport cost since the individual components can be transported in a small car. A king mattress has the main core and topper is half the width of the mattress and will fold or rull up into a small bundle. The customer can try the different topper and /or main core and either purchase the desired component or exchange it, depending on the guarantee policy.
A new issue of bed bugs has further complicated the guarantee. Many U.S.
States will not allow a delivered mattress back into the delivery truck even if it has not been opened, due to the tough control measures needed to curb these bed bugs. Some four star hotels have had to go to great expense to guard their reputation once these bed bugs were brought into their hotel by personal pillows and bcd products ctc. This invention allows for washing or replacement of individual components of the mattress but not the entire mattress. For instance, the cover can be removed from the cores and foam rails dry cle;rnerl, and the air pump, vinyl or rubber air bladders, spring and water tubes can be washed.
Some stores tried to resell a barely used mattress to find out that the new owner was allergic to cat dander, which contaminated the mattress from the previous owner's cat sleeping on the mattress once or twice.
A second issue concerning comfort with an air bed is the comfort or feel, even though the firmness is adjustable, the surface they are lying upon will have a different feel than what they prefer. This invention offers a method to allow the customer to select or change the sleeping component on top of the air core bladder, thus giving the feel as well as adjustability of the firmness they desire. This is accomplished by allowing the topper core to be unzipped and a spring, water or various foam topper core inserted on their side of the mattress. These topper cores are thin enough to allow the firmness adjustment of the air bladder to be felt while still providing the personal preference of say pocket coil, memory or latex foam that they are familiar with.
It also allows say a softer pocket coil spring to be placed on top of a firmer set of springs.
The mattress also is a waterbed that overcomes the main objection of waterbeds in that the buttocks sinks down too deep, resulting in back pain. This system would allow the thin water bladder or tubes to be placed on the adjustable air bladder so that their buttocks will rest on the air bladder main core or any othcr main core that is selected. These features of the .invention makes it even less important to actually lay on the bed before buying it, thus a safer buy for someone living in a remote area where it would not be worth the long drive to purchase a mattress.
Mattresses are now air, coil springs, and memory foam core having a separate material in the perimeter for reasons of increased vertical perimeter support. In the case of coi l springs, the foam perimeter gives the feel or sensation of a soft mattress edge or side when the mattress is compressed laterally when sat or leaned against.
Traditionally, this feel is made by gluing the coils or rowed sleeve of coils to the foam rail. A
fabric rail sleeve, as in this invention, was not bossible to sew to the cover as it would leave a visible stitch mark on the surface and interfere with quilting patterns. The invention has the fabric rail sleeve sewn to the perimeter and the bottom cover of the mattress.
Mattresses have historically been assembled in the manufacturing facility.
With manufacturing moving overseas to countries such as China, there was an economic advalatage to rcducc the shipping volume, since the shipping containers would not be close to their maximum weight capacity. Compressing components such as spring assemblies, or complete spring mattresses made economic sense. A problem occurred with mattresses using foam rails, in that the foam rail that was glued to the inner maltres cover would not return to it's original shape and wrinkles would result. This invention eliminates the gluing operation.
A mattress assembly shown in U.S. Pat. No. 5,953,779 has a stack of foam mattress elements positioned one atop the other and joined together at their peripheral edges with hook and loop fasteners (VELCRO®). The fasteners keep the foam mattress elements aligned in stacked relation. The mattress so formed does not have a mattress border construction, and a retainer rope is secured around the outer edge of the mattress to hold the elements together. Additional holding support is provided by containment blocks optionally attached with VELCRO® to the head and foot of the mattress a.sscrnbty.
U.S. Pat. No. 2,326,441 shows a mattress covering in which strips of fabric are secured to the sidewall of a foam sponge nihher mattress core with an adhesive. The fabric'strips form an anchor onto which the mattress covering material may be stitched. No mattress border construction is provided around the sponge rubber mattress core.
Summary In acr..orriance with the present invention is a modular component mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam, lumbar support, or heater that is inserted into each side of a topper cavity or main core cavity of a mattress cover which can be and easily assembled and exchanged by customer without returning the entire mattress. The smaller retailer can offer multiple selection using a single queen size bed, switching components until the customer is satisfied, and then guaranteeing long term comfort at low cost, as well as replacement of individual worn or damaged components. The entire king size bed or it's components will fit in a compact size car or can becouriered.
Or1LWCTS AND ADVANTAGES OF THE INVENTION
This novel approach has the following advantages in that it:
- Provides a modular corrtponent mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam, lumbar support, or heater that is inserted into a topper cavity or main core cavity of a mattress cover which can be and easily assembled by customer and partially exchanged without returning the entire mattress.
- Provides reduced floor space, inventories and warehouse space as several colors and fabric designs would be available and rail types and core types would be compatible with the different types of mattress cover.
- Provides a comfort guarantee, but without the associated cost. With the conventional guarantee, the customer could exchange the mattress for another one and the retailer could donate the old one to a charity for a tax write off. The cost would be factored into the overall overhead of the store. The cost is significant in terms of return processing and transport to the store and then transport or disposal cost from the store.
This invention eliminates the transport cost since the individual components can be transported in a.
small car. A king mattress has the main core and topper is half the width of the mattress and will fold or roll up into a small bundle. The customer can try the different topper and /or main core and either purchase the desired component or exchange it. A
dissatisfied customer is able to exchange spring with say foam or air cores in the topper cavity, main cute cavity or both, without exchanging the cover (thus preventing full destruction of product for hygienic considerations), thus allowing a low cost satisfaction warranty to be offered. The invention allows any type of mattress surface or core be installed by the customer until they are satisfied. It is difficult to determine if a mattress is suitable at the point of sales, and for many, several nights or weeks of sleeping on the mattress will be needed to evaluate the mattress and determine satisfaction.
A small skew count for smaller stores to offer a wide range of selection without taking up much floor space or inventory space.
- Each side of queen or king mattress can be selected to meet individual preference.
-Coil springs on air bladders allow for the novel pocket coil firmness adjustability.
-Airbladders also allow for adjustable water bladder firmness adjustability on conventional low cost single bladder or tube type water bladders.
-This invention allows for washing or replacement of individual components of the mattress but not the entire mattress. For instance, the cover can be removed from the cores and foam rails dry cleaned. and the air pump, vinyl or rubber air bladders, spring and water tubes can be washed.
- A second issue concerning comfort with an air bed is the comfort or feel, even though the firmness is adjustable, the surface they are lying upon will have a different feel than what they prefer. This invention ofFers a method to allow the customer to select or change the sleeping component on top of the air core bladder, thus giving the feel as well as adjustability of the firmness they desire. This is accomplished by allowing the topper core to be unzipperl and a spring, water or various foam topper core inserted on their side of the mattress. These topper cores are thin enough to allow the firmness adjustment of the air bladder to be felt while, still providing the personal preference of say pocket coil.
memory or latex foam that they are familiar with. It also allows say a softer pocket coil spring to be placed on top of a firmer set of springs.
The mattress also is a waterbed that overcomes the main objection, of waterbeds in that the buttocks sinks down too deep, resulting in back pain. This system would allow the thin water bladder or tubes to be placed on the adjustable air bladder to that their buttocks will rest on the air bladder main core or any other main core that is selected. What should be understood about water beds is that someone floating on water would be mostly submerged, and would feel weightless without pressure points. This is not the case. What is mechanically happening is the weight of the water pushing the perimeter of the bladder stretches vinyl surface and effectually hammocks the person. This causes a hammocking configuration with a resulting slouched, sore spine. This invention allows the underlying air bladder to support the buttocks area and prevent slouching with an under-filled water bladder or tubes.
The conventional single air bladder mattress must sacrifice support of the buttocks high pressure for conformity (softness) with low pressure. The present invention has a thin height air bladder that rests on top of a conventional air bladder, both having adjustability. By allowing the pressure to be low enough, in the top air bladder, to prevent stretching of the surface vinyl, allows it to conform and shape about the pressure points of the body, while providing the lower air bladder to give support to buttocks area which tends to sink down.
- Components are designed to fit into. their specific cavities in terms of height, length and width, and openings are located in the cover for hoses and heater wires to provide one mattress that can be altered into any type of mattress - Vinyl air or water bladders and spring packs can be cleaned for resale or exchange.
The customer can eventually replace a damaged or worn out component of the mattress rather than the whole mattress.
-Allows for manufacturer and customer compact transport of mattress, even a king size mattress in a small vehicle in it's unassembled state. The foam rails are then inserted in the perimeter foam rail sleeves. The core is then placed on the cover or foam and between the foam rail assemblies. A layer of foam maybe placed in the mattress cover if desired.
has a zipper for both topper and main core cavities for easy access.
-The zippers have a cover so that they are not visible or felt -The foam rail zipper eliminates the glue operation.for securing foam rails which in turn prevents wrinkling, as well as incomplete recovery, when the rails are compressed for shipping. This is a problem since most adhesives take up to 2.weeks to fully cure and once a product it is on the assembly line it must be packaged as the last step of the production. To package mattresses with spring cores, the finished mattress arc put in a plastic bag which then have the air evacuated resulting in compression of spring assembly (core) and rails into a flattened state, which is then rolled and placed in a box.
Since the adhesive is riot fully cured, it causes the folded or wrinkled outer cover side fabric which is glued to the rail or rail enclosure, to adhere to it's self resulting in inability to come back to its full height once removed from the plastic bag.
It also reduces discoloration from glue seepage to the outside of the cover and prevents the cover rotating or twisting relative to the foam rails and/or contents of cover preventing outer line or edge to remain straight and along the corner of the mattress edge. A
sleeve is easier to assemble rather than securing with Velcro tabs or strips, between cover and foam rail, which require alignment before pressing together. It also allows the mattress cover to be folded in a space efficient way over a mattress cover which has the foam rails attached.
-The heater can be installed in the topper core or main core cavity.
-When you initially enter the bed it is already warm- This invention also solves this problem by adding a low powered heater under the air bladder. As well, the control for water beds must be very precise to obtain a comfort temperature, requiring a temperature sensor in a remote location a distance from the heater placed under the water bed bladder.
This temperature control would not function as a on /off type of control due slow heat transfer of the air, the heater would form an overheated area causing damage to bladder or combustion, as is the case of an empty water bed bladder. By having a heater Which has approximately 1 /3 the power of a water bed and a simple control, the invention can achieve a warm air mattress upon entry and allow the room temperature to be reduced in the evening to save energy. This was not possible in waterbeds since the under powered heater would take days to bring the large mass of water up to the temperature of Wrnfort level required, Since many waterbeds have the water in direct contact with the sleeping surface resulting in conduction of heat from the person's body.
-This invention simplifies the solution in terms of product cost as well as reduces power consumption due to the direct application of heat and the insulated configuration of heater as compared to the prior art.
-The multi tap heater elements provide a range of heat settings and eliminates expensive power controls that add cost and electrical noise.
-The heater can also vary the heat for each side of the bed by allowing the user to adjust the heater position or contact area between the two sides of the bed. The amount of area under each bladder will determine the temperature of each side of a king or queen mattress which are usually two joined bladders. for adjoining spring cores, a barrier of say vinyl or fabric will 'prevent an unwanted heating effect on one side.
- One size heater can be used for all sizes and types of beds due to the low watt density of the heater.
- A foam lumbar or adjustable pneumatic lumbar cushion or support can be placed on or under water tubes, spring cores or air cores in either topper core cavity or main core cavity in its personally preferred location along the length of the mattress.
Every person is different in height and preference and can easily access the lumbar to rind a comfortable location for their side of the bed.
Brief Drawing-Description Fig 1- shows an exploded view of the mattress assembly.
Fig 2- shows the topper core cavity with a heater and pneumatic lumbar Fig 3- shows the main core cavity with a heater Fig 4- shows a single air core.
Fig 5- shows a double air core in a king or queen size main core cavity.
Fig 6- shows the topper core cavity with a memory foam topper core on one side and a multi-zoned latex (middle zone ) and polyurethane (head and foot) inserted in it.
Fig 7= shows a topper core cavity with spring topper core on one side and water bed tubes and foam lumbar on the other.
Fig 8- shows a single spring core. The topper spring core would generally be thinner than the main spring core.
Fig 9-shows a single water tube.
Fig 10- shows a mattress cover quitted top panel.
Fig 1 l -'shows a cross sectional view with an air main core and spring topper core.
Fig 12- shows the sectional view of the mattress cover zipper.
Fig ] 3- shows the main core cavity with a spring cure and a foam core Fig 14- shows a low thickness topper air core in the topper cavity on an air core in main core cavity. An air rail is shown instead of a foam rail.
Fig 15- shows an alternative embodiment of a pillow top design with interchangeable foam sheet.
Fig 16- shows the low power heater and heater control.
REFERENCE NUMERALS OF DRAWINGS
1. main core cavity 2. zipper 3. foam rail 4. topper core cavity
5. quilted top
6. topper spring core
7. water tube
8, air core
9. main core cavity bottom
10. topper core cavity bottom
11 _ heater
12. air core hose
13 _ air core web
14. water tube filling port l5. memory foam 16. latex foam 17, poly urethane foam 18. foam rail sleeve 19. main spring core 20. mattress tape 21. zipper cover 22. main foam core 23. pocket coil sleeve 24. pillow top cavity 25. foam sheet 26. pillow top base 27. air rail 28. heater 29. vinyl I beam 30. heater control 31. heater element 32. heater circuit 33. selector switch 34. heater cord 35. pneumatic lumbar 36. pneumatic lumbar hose 37. foam lumbar Detailed Description of Drawings Fig I shows an exploded view of the mattress assembly having the main core cavity I
with a double air bladder 8 inside of it and the air hoses 12 coming out the bottom of it.
The topper core cavity 4 has a topper spring core 6 and 5 water tubes 7 Inside of it. The quilted top 5 has a zipper 2 that can be zipped to the upper zipper 2 of the topper core 4.
The lower zipper 2 of the topper core 4 can be zipped to the zipper 2 of the main core cavity 1. In this configuration both users can adjust the firmness of each of the water topper 7 and spring topper 6 by inflating their air core 8 to the desired pressure.
Fig 2- shows the topper core cavity 4 without any topper cores in it and with a pneumatic lumbar 36 and a heater I 'l located partially to one side, and having pneumatic lumbar hose 36 and the heater cord 34 protrude through an opening in the topper core cavity bottom through to the opening in the main core cavity bottom 9. The foam rails 3 are glued in the perimeter edge of the topper core cavity 4.
Fig 3- shows the main core cavity I without any main cores in it and with a heater 11 having the heater wire protrude through the opening in the main core cavity bottom 9.
The foam rails 3 are shown inside of the foam rail sleeve 18 which is secured closed by foam rail sleeve zipper 2 forming a closed sleeve in the perimeter of the main core cavity Fig 4- shows a single air core 8 with its air hose 12. The air hose is connected to an air pump so that firmness can be adjusted by the air pressure in the air core 8.
Fig S- shows a double air core 8 in a king or queen size main core cavity I, and having the air hose 12 protrude through an opening in the main core cavity bottom 9.
The air core web 13 is part of the double air core assembly S.
Fig 6- shows the topper core cavity 4 with a memory foam topper core 15 on one side and a multi-zoned topper core having a latex foam 17 middle zone, and polyurethane foam (head and foot) inserted in it. The foam rail 3 is usually of a firmer hardness than either of the uvr- foams in order to prevent sinking in while sitting on the edge of the bed.
Fig 7- shows a topper core cavity 4 with spring topper core 6 on one side and water bed tubes 7 on the other. A thin layer of preferred type of foam can also be placed on top of any type topper core or main core. A foam lumbar 37 is placed on the water tubes 7. It could also be placed under the water tubes 7 as well as on or under the topper spring core 6. Any type of lumbar can be placed in either topper core cavity or main core cavity, above or below the core in it's personally preferred location along the length of the rttattr+:ss-Fig 8- shows a single side main spring core 6. The topper spring core would generally be thinner than the main spring core. The preferred embodiment is a pocket coil spring assembly type of spring over Bonnet type of linked spring assembly.
Fig 9- shows a single water tube 7 with a water tube filling port 14. An alternative embodiment is a single water bladder to replace the 7 water tubes. A backup liner in case of leak can also be added.
Fig 10- shows a mattress cover quilted top 5 with a zipper 2 along it's perimeter. The preferred embodiment has I approximately 1 inch of memory foam 15 quilted in under the fabric top. An alternative embodiment uses polyurethane foam 1.7 instead of memory foam 15 Fig 11- shows a cross sectional view of the mattress with an air core 8 in the main core cavity I and spring topper core 6 consisting of a pocket coil spring in a pocket coil sleeve 23 assembly. The topper core cavity foam rail 3 may be a different size than the main core cavity I foam rail 3. A l inch layer of memory foam 15 is sewn to the quilted top 5.
This could also be poly urethane foam 17 or latex foam 16.
Fig 12- shows an enlargement of the Fig 11 sectional view of the zipper 2 of topper core cavity 4 having mattress tape 20 sewn around, zipper cover 21, quilted top 5, and one side of zipper 2. The other side of zipper is sewn to the upper edge of topper core cavity 4. The zipper 2 of main core cavity having mattress tape 20-sewn around zipper cover 21, lower edge of topper core cavity 4, topper core bottom 10, foam rail sleeve 18, upper edge of main core cavity 1, and one side of zipper 2. The other side of zipper is sewn to the upper cdge of main core cavity 1.
No 13- shows the main core cavity 1 with a main spring core 19 and a main foam core 22.
An alternative embodiment is to replace either or both of these cores with a water bed bladder or water tubes or any other type of sleeping surface combination or single core.
Fig 14- shows a low thickness topper air core 8 in topper cavity 4. This rests on an air core 8 in main core cavity 1. An air rail 27 is shown in foam rail sleevel8 instead of foam rail. The air rail is formed with two internal vinyl T beams 29 to shape sir rail 27.
Fig 15- shows an alternative embodiment of a pillow top design having the zipper 2 along the lower perimeter edge of the pillow top with an exchangeable layer of different types of foam sheet 25. This is a sectional view of a pillow top design having mattress tape 20 sewn around lower edge of pillow top cavity 24, zipper 2 of pillow top cavity 24, and zipper of pillow top inner base. The other side of zipper is sown to the upper edge of topper core cavity 4. The topper foam rail 3 and topper air core 8 support the foam sheet 25.
Fig 16- shows the low power heater 33 with heater wire 34 connecting it to'the heater control 36.1 he heater control 36 has-a selector switch to select the desired heat setting.
The heater has, in this preferred embodiment, 6 independent heater circuits 38 made of heater element 37. These are heater circuits are electrically configured in series or parallel or combination with each other by a selector switch that electrically powers some or all of the circuits. Managing the circuit connections eliminates the need for a variable power supply, however some high end models would have a variable power supply, as well independent heaters for each side of the bed. Although this heater is similar to a waterbed heater, in that it has a high temperature cut off switch, it has much lower watt density and overall power. However this heater remains with continuous power, with a means to reduce power by series circuits and phase shifting.
OPERATION
The mattress is unpackaged placed with main core cavity I open upwards and mattress opening towards the head end of the bed with all zippers 2 unzipped. The foam rails 3 (whether foam, air, or spring enclosure or any other type or combination of rail) are placed in foam rail sleeves 18 and the foam rail zippers 2 are closed.
An air rail 27 has a valve or connector port. The air rail can be inflated prior to or after insertion in sleeve. If the air rail is cvrrrrected to the air pump permanently, then the rails could be inserted non-inflated at the factory and secured in the rail sleeve with air hose available for plugging into.thc pump. Since air rails do not need to be adjusted for varying, firmness like the air core, it may be inflated by mouth and sealed and inserted in any type of core bed as well as replaced in the event of a leak. A heater 11 can be placed on the main core cavity bottom 9 in the center of the main core cavity I if both sides of the bed are to be heated equally, or to one side of the cavity if one side is to be heated.
The power cord for the heater 11 is brought out through the opening in the main core cavity bottom 9 and plugged into heater control.
A main core is selected and placed in the main core cavity 1 and for a queen or king size bed, two main cores are selected. If an air core(s) 8 is selected, the air core hose 12 is brought through the opening in main core cavity bottom and 9 and plugged into air pump.
The topper core cavity 4 is placed onto and zipped to the main core cavity I
by zipper 2.
The zipper cover 21. is pulled and inverted upwards to expose the zipper 2, and then folded down after zipped. If a heater is placed on the topper core cavity bottom 10, the power cord must be brought through the opening in the topper core cavity bottom 10 as well as the main core cavity bottom 9 before zipping closed. Foam rails 3 arc placed about perimeter of topper core cavity 4 and then a topper cores selected for each side and placed on topper core cavity bottom 10 between foam rails 3. The quilted top 5 is placed onto and zipped to the topper cavity core by zipper 2. If a pillow top 24 is used instead of a quilted top 5, then a foam sheet 25 is selected and placed into the pillow top cavity 24 and then the pillow top base is zipped closed with it's zipper 2. The pillow top 24 is flipped over and zipped onto the topper core cavity 4 with zipper 2. A dual pillow top core can also have each side placed and then zippered, similarly as dual topper and main cores are sulcutcd and placed in their appropriate cavities.
The heater control 36 has a selector switch to select the desired heat setting. Managing the circuit connections eliminates the need for a variable power supply, however some high end models would have a variable power supply, as well independent heaters for each side of the bed.
A foam lumbar or adjustable pneumatic lumbar cushion or support can be placed on or under water tubes, spring cores or air cores in either topper core cavity or main core cavity in it's personally preferred location along the length of the mattress.
Every person is different in height and preference and can easily access the lumbar to find a comfortable location for their side of the bed. The hose for a pneumatic lumbar support is placed in the topper core cavity 4 , the pneumatic lumbar hose 36 must be brought through the opening in the topper core cavity bottom 10 as well as the main core cavity bottom 9 before zipping closed.
CONCLUSIONS RAMIFICATIONS AND SCOPE
In accordance with the present invcntion is a modular component mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam, lumbar support or heater that is inserted into a topper cavity or main core cavity of a mattress cover to allow a customer to easily assemble and exchange components without returning the entire mattress. The smaller retailer can offer multiple selection using the floor space of one queen size bed, switching components until the customer is satisfied, and thus guaranteeing comfort at low cost, as well as long term replacement of individual worn or damaged components all with low transportation cost.
with a double air bladder 8 inside of it and the air hoses 12 coming out the bottom of it.
The topper core cavity 4 has a topper spring core 6 and 5 water tubes 7 Inside of it. The quilted top 5 has a zipper 2 that can be zipped to the upper zipper 2 of the topper core 4.
The lower zipper 2 of the topper core 4 can be zipped to the zipper 2 of the main core cavity 1. In this configuration both users can adjust the firmness of each of the water topper 7 and spring topper 6 by inflating their air core 8 to the desired pressure.
Fig 2- shows the topper core cavity 4 without any topper cores in it and with a pneumatic lumbar 36 and a heater I 'l located partially to one side, and having pneumatic lumbar hose 36 and the heater cord 34 protrude through an opening in the topper core cavity bottom through to the opening in the main core cavity bottom 9. The foam rails 3 are glued in the perimeter edge of the topper core cavity 4.
Fig 3- shows the main core cavity I without any main cores in it and with a heater 11 having the heater wire protrude through the opening in the main core cavity bottom 9.
The foam rails 3 are shown inside of the foam rail sleeve 18 which is secured closed by foam rail sleeve zipper 2 forming a closed sleeve in the perimeter of the main core cavity Fig 4- shows a single air core 8 with its air hose 12. The air hose is connected to an air pump so that firmness can be adjusted by the air pressure in the air core 8.
Fig S- shows a double air core 8 in a king or queen size main core cavity I, and having the air hose 12 protrude through an opening in the main core cavity bottom 9.
The air core web 13 is part of the double air core assembly S.
Fig 6- shows the topper core cavity 4 with a memory foam topper core 15 on one side and a multi-zoned topper core having a latex foam 17 middle zone, and polyurethane foam (head and foot) inserted in it. The foam rail 3 is usually of a firmer hardness than either of the uvr- foams in order to prevent sinking in while sitting on the edge of the bed.
Fig 7- shows a topper core cavity 4 with spring topper core 6 on one side and water bed tubes 7 on the other. A thin layer of preferred type of foam can also be placed on top of any type topper core or main core. A foam lumbar 37 is placed on the water tubes 7. It could also be placed under the water tubes 7 as well as on or under the topper spring core 6. Any type of lumbar can be placed in either topper core cavity or main core cavity, above or below the core in it's personally preferred location along the length of the rttattr+:ss-Fig 8- shows a single side main spring core 6. The topper spring core would generally be thinner than the main spring core. The preferred embodiment is a pocket coil spring assembly type of spring over Bonnet type of linked spring assembly.
Fig 9- shows a single water tube 7 with a water tube filling port 14. An alternative embodiment is a single water bladder to replace the 7 water tubes. A backup liner in case of leak can also be added.
Fig 10- shows a mattress cover quilted top 5 with a zipper 2 along it's perimeter. The preferred embodiment has I approximately 1 inch of memory foam 15 quilted in under the fabric top. An alternative embodiment uses polyurethane foam 1.7 instead of memory foam 15 Fig 11- shows a cross sectional view of the mattress with an air core 8 in the main core cavity I and spring topper core 6 consisting of a pocket coil spring in a pocket coil sleeve 23 assembly. The topper core cavity foam rail 3 may be a different size than the main core cavity I foam rail 3. A l inch layer of memory foam 15 is sewn to the quilted top 5.
This could also be poly urethane foam 17 or latex foam 16.
Fig 12- shows an enlargement of the Fig 11 sectional view of the zipper 2 of topper core cavity 4 having mattress tape 20 sewn around, zipper cover 21, quilted top 5, and one side of zipper 2. The other side of zipper is sewn to the upper edge of topper core cavity 4. The zipper 2 of main core cavity having mattress tape 20-sewn around zipper cover 21, lower edge of topper core cavity 4, topper core bottom 10, foam rail sleeve 18, upper edge of main core cavity 1, and one side of zipper 2. The other side of zipper is sewn to the upper cdge of main core cavity 1.
No 13- shows the main core cavity 1 with a main spring core 19 and a main foam core 22.
An alternative embodiment is to replace either or both of these cores with a water bed bladder or water tubes or any other type of sleeping surface combination or single core.
Fig 14- shows a low thickness topper air core 8 in topper cavity 4. This rests on an air core 8 in main core cavity 1. An air rail 27 is shown in foam rail sleevel8 instead of foam rail. The air rail is formed with two internal vinyl T beams 29 to shape sir rail 27.
Fig 15- shows an alternative embodiment of a pillow top design having the zipper 2 along the lower perimeter edge of the pillow top with an exchangeable layer of different types of foam sheet 25. This is a sectional view of a pillow top design having mattress tape 20 sewn around lower edge of pillow top cavity 24, zipper 2 of pillow top cavity 24, and zipper of pillow top inner base. The other side of zipper is sown to the upper edge of topper core cavity 4. The topper foam rail 3 and topper air core 8 support the foam sheet 25.
Fig 16- shows the low power heater 33 with heater wire 34 connecting it to'the heater control 36.1 he heater control 36 has-a selector switch to select the desired heat setting.
The heater has, in this preferred embodiment, 6 independent heater circuits 38 made of heater element 37. These are heater circuits are electrically configured in series or parallel or combination with each other by a selector switch that electrically powers some or all of the circuits. Managing the circuit connections eliminates the need for a variable power supply, however some high end models would have a variable power supply, as well independent heaters for each side of the bed. Although this heater is similar to a waterbed heater, in that it has a high temperature cut off switch, it has much lower watt density and overall power. However this heater remains with continuous power, with a means to reduce power by series circuits and phase shifting.
OPERATION
The mattress is unpackaged placed with main core cavity I open upwards and mattress opening towards the head end of the bed with all zippers 2 unzipped. The foam rails 3 (whether foam, air, or spring enclosure or any other type or combination of rail) are placed in foam rail sleeves 18 and the foam rail zippers 2 are closed.
An air rail 27 has a valve or connector port. The air rail can be inflated prior to or after insertion in sleeve. If the air rail is cvrrrrected to the air pump permanently, then the rails could be inserted non-inflated at the factory and secured in the rail sleeve with air hose available for plugging into.thc pump. Since air rails do not need to be adjusted for varying, firmness like the air core, it may be inflated by mouth and sealed and inserted in any type of core bed as well as replaced in the event of a leak. A heater 11 can be placed on the main core cavity bottom 9 in the center of the main core cavity I if both sides of the bed are to be heated equally, or to one side of the cavity if one side is to be heated.
The power cord for the heater 11 is brought out through the opening in the main core cavity bottom 9 and plugged into heater control.
A main core is selected and placed in the main core cavity 1 and for a queen or king size bed, two main cores are selected. If an air core(s) 8 is selected, the air core hose 12 is brought through the opening in main core cavity bottom and 9 and plugged into air pump.
The topper core cavity 4 is placed onto and zipped to the main core cavity I
by zipper 2.
The zipper cover 21. is pulled and inverted upwards to expose the zipper 2, and then folded down after zipped. If a heater is placed on the topper core cavity bottom 10, the power cord must be brought through the opening in the topper core cavity bottom 10 as well as the main core cavity bottom 9 before zipping closed. Foam rails 3 arc placed about perimeter of topper core cavity 4 and then a topper cores selected for each side and placed on topper core cavity bottom 10 between foam rails 3. The quilted top 5 is placed onto and zipped to the topper cavity core by zipper 2. If a pillow top 24 is used instead of a quilted top 5, then a foam sheet 25 is selected and placed into the pillow top cavity 24 and then the pillow top base is zipped closed with it's zipper 2. The pillow top 24 is flipped over and zipped onto the topper core cavity 4 with zipper 2. A dual pillow top core can also have each side placed and then zippered, similarly as dual topper and main cores are sulcutcd and placed in their appropriate cavities.
The heater control 36 has a selector switch to select the desired heat setting. Managing the circuit connections eliminates the need for a variable power supply, however some high end models would have a variable power supply, as well independent heaters for each side of the bed.
A foam lumbar or adjustable pneumatic lumbar cushion or support can be placed on or under water tubes, spring cores or air cores in either topper core cavity or main core cavity in it's personally preferred location along the length of the mattress.
Every person is different in height and preference and can easily access the lumbar to find a comfortable location for their side of the bed. The hose for a pneumatic lumbar support is placed in the topper core cavity 4 , the pneumatic lumbar hose 36 must be brought through the opening in the topper core cavity bottom 10 as well as the main core cavity bottom 9 before zipping closed.
CONCLUSIONS RAMIFICATIONS AND SCOPE
In accordance with the present invcntion is a modular component mattress with selectable and interchangeable mattress components, such as springs, water bladders, foam, lumbar support or heater that is inserted into a topper cavity or main core cavity of a mattress cover to allow a customer to easily assemble and exchange components without returning the entire mattress. The smaller retailer can offer multiple selection using the floor space of one queen size bed, switching components until the customer is satisfied, and thus guaranteeing comfort at low cost, as well as long term replacement of individual worn or damaged components all with low transportation cost.
Claims (20)
1. A component mattress system comprising; a topper cover, a plurality of various types of main core of similar dimension, a main core cavity, a main core zipper, a plurality of various types of topper core of similar dimension, a topper core cavity, a topper core zipper, wherein said main core and topper core are selected and inserted in to their respective said main core cavity and said topper core cavity and secured by their respective zippers.
2. The mattress of claim 1 further including a dual core main cavity and dual core topper cavity wherein said main core and said topper core are selected for each side of said mattress and inserted in to their respective said main core and said topper core cavity and secured by respective said main core and said topper core zipper.
3. The mattress of claim 1 further including a main core zipper and said topper core zipper wherein said topper core cavity is secured to said main core cavity by said main core zipper and wherein said topper cover is secured by said topper core zipper to said topper core cavity.
4. The mattress of claim 1 further including a pillow top cover and a plurality of exchangeable foam sheet wherein said foam sheet can be selected, accessed and exchanged within said pillow top cover on either side.
5. The mattress of claim 2 further including a main air core, topper air core, main spring core, topper spring core, main water core, topper water core, main foam core, topper foam core, topper gel core, wherein said main core and said topper core are selected and inserted in to their respective said main core cavity and said topper core cavity and secured by respective said main core and said topper core zipper.
6. The mattress of claim 1 further including at least one heater wherein said heater is placed inside of said main core cavity or said topper core cavity.
7. The heater of claim 6 further including a heater comprising a plurality or independent electrical circuits made from heater element and a switch wherein two or more circuits are electrically activated individually or activated connected in series or parallel with each other by means of said switch.
8. The mattress of claim 1 further including a zipper cover wherein said zipper cover is sewn to said topper cover to hide said topper core cavity zipper, and sewn to lower edge of said topper core cavity to hide main core cavity zipper.
9. The said zipper cover of claim 8 further including mattress tape wherein said zipper cover is sewn to said main core cavity within said mattress tape.
10.The topper spring core of claim 2 wherein said topper spring core is a pocket coil assembly.
11. The topper water core of claim 2 wherein said water core is comprised of a plurality of independent water tubes.
12. The mattress of claim 1 further including a plurality sheets of foam wherein said sheets of foam can be placed in said main core cavity and said topper core cavity to change the characteristic of said mattress.
13. The mattress of claim 1 further including foam rails wherein said rails form the perimeter edge of said mattress main core cavity and said topper core cavity.
14. The mattress of claim 1 further including an air inflated rails wherein said air rails form the perimeter edge of said mattress main core cavity and said topper core cavity.
15.The mattress of claim 13 further including a foam rail sleeve, foam rail sleeve zipper wherein said foam rail sleeve is sewn to main core cavity and a zipper opens said rail sleeve to allow insertion and securing of said foam rail or said air rail.
16.The mattress of claim 15 wherein said foam rails are individually packaged from said topper core cavity.
17.The mattress of claim 1 further including a lumbar support wherein said lumbar support can be placed in any preferred longitudinal location in said topper core cavity or said main core cavity above or below said topper foam core, said topper gel core, said main air core, said main spring core, said topper spring core, said main water core, said topper water core, said main foam core whereby selection, easy access for adjustment allows each side of the bed to be customized for comfort.
18.A component mattress system comprising; a topper cover, a plurality of various types of main core of similar dimension, a main core cavity, a main core zipper, a plurality of various types of topper core of similar dimension, a topper core cavity, a topper core zipper, wherein said main core and topper core are selected and inserted in to their respective said main core cavity and said topper core cavity and secured by their respective zippers, and further components comprising; a pillow top cover and a plurality of exchangeable foam sheets wherein said foam sheet can be accessed and replaced within said pillow top cover, a main air core, main spring core, topper spring core, main water core, topper water core, main foam core, topper foam core, topper gel core, heater, pocket coil assembly, water tubes, sheets of foam, foam rails, air inflated rails, lumbar support wherein said components are interchangeable, dimensionally compatible, and individually packaged, selected, warehoused and mailed.
19.The mattress of claim 18 further including a dual core main cavity and dual core topper cavity wherein said main core and said topper core are selected for each side of said mattress and inserted in to their respective said main core and said topper core cavity and secured by respective said main core and said topper core zipper and wherein said components can be individually selected, positioned and tried in various locations vertically and longitudinally between said components.
20.A method of selecting and demonstrating, at the point of purchase.
variations in comfort of various mattress materials using a single or dual core and a single or dual topper core mattress by exchanging said mattress materials in main core cavity and topper core cavity comprising; a plurality of various types of main, core of similar dimension, a main core cavity, a main core zipper, a plurality of various types of topper core of similar dimension, a topper core cavity, a topper core zipper, wherein said main core and topper core are selected and inserted in to their respective said main core cavity and said topper core cavity and secured by their respective zippers, a main air core, main spring core, topper spring core, main water core, topper water core, main foam core, topper foam core, topper gel core, pocket coil assembly, water tubes, sheets of foam, foam rails, air inflated rails, lumbar support, and heater, and further comprising; a pillow top cover and a plurality of exchangeable single or dual core foam sheets wherein said foam sheet can be accessed and replaced within said pillow top cover, whereby a single mattress can be used to show many types of mattresses, and wherein said components, can be individually selected, positioned and tried in various locations vertically and longitudinally between said components and wherein a final comparison can be made by the customer by moving from one side of the bed to the other.
variations in comfort of various mattress materials using a single or dual core and a single or dual topper core mattress by exchanging said mattress materials in main core cavity and topper core cavity comprising; a plurality of various types of main, core of similar dimension, a main core cavity, a main core zipper, a plurality of various types of topper core of similar dimension, a topper core cavity, a topper core zipper, wherein said main core and topper core are selected and inserted in to their respective said main core cavity and said topper core cavity and secured by their respective zippers, a main air core, main spring core, topper spring core, main water core, topper water core, main foam core, topper foam core, topper gel core, pocket coil assembly, water tubes, sheets of foam, foam rails, air inflated rails, lumbar support, and heater, and further comprising; a pillow top cover and a plurality of exchangeable single or dual core foam sheets wherein said foam sheet can be accessed and replaced within said pillow top cover, whereby a single mattress can be used to show many types of mattresses, and wherein said components, can be individually selected, positioned and tried in various locations vertically and longitudinally between said components and wherein a final comparison can be made by the customer by moving from one side of the bed to the other.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US80273110A | 2010-06-14 | 2010-06-14 | |
| US12/802,731 | 2010-06-14 | ||
| PCT/CA2011/000673 WO2011156891A1 (en) | 2010-06-14 | 2011-06-13 | Modular component mattress |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2801789A1 true CA2801789A1 (en) | 2011-12-22 |
Family
ID=45347608
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2801789A Abandoned CA2801789A1 (en) | 2010-06-14 | 2011-06-13 | Modular component mattress |
Country Status (3)
| Country | Link |
|---|---|
| CN (1) | CN103167818B (en) |
| CA (1) | CA2801789A1 (en) |
| WO (1) | WO2011156891A1 (en) |
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| USD919333S1 (en) | 2019-08-27 | 2021-05-18 | Casper Sleep Inc. | Mattress |
| USD927889S1 (en) | 2019-10-16 | 2021-08-17 | Casper Sleep Inc. | Mattress layer |
| US11116326B2 (en) | 2017-08-14 | 2021-09-14 | Casper Sleep Inc. | Mattress containing ergonomic and firmness-regulating endoskeleton |
| US11202517B2 (en) | 2014-04-21 | 2021-12-21 | Casper Sleep Inc. | Mattress |
| US11241100B2 (en) | 2018-04-23 | 2022-02-08 | Casper Sleep Inc. | Temperature-regulating mattress |
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| CN103300633A (en) * | 2012-03-15 | 2013-09-18 | 晓健科技（大连）有限公司 | Inflated warm-keeping mattress |
| WO2016067137A1 (en) * | 2014-10-28 | 2016-05-06 | Koninklijke Philips N.V. | A mattress for providing phototherapy to a subject |
| WO2017127030A1 (en) * | 2016-01-22 | 2017-07-27 | Raktrakul Nattakit | Triangular pillow and foldable mattress |
| CN106175259A (en) * | 2016-07-22 | 2016-12-07 | 武侯区华聚家私经营部 | A kind of double-layer and double-side can use mattress |
| CN106419288A (en) * | 2016-11-29 | 2017-02-22 | 美佳德科技（无锡）有限公司 | Healthcare mattress for female in menstrual period |
| CN107232868A (en) * | 2017-07-31 | 2017-10-10 | 张家港朱莉安睡眠科技有限公司 | A kind of adjustable mattress |
| US11786051B2 (en) * | 2018-07-02 | 2023-10-17 | Carleton Andrew | Multi-layered segment mattress |
| CN108991820A (en) * | 2018-10-17 | 2018-12-14 | 河北体日舒电热科技有限公司 | A kind of electric heating health mattress |
| CN109303441B (en) * | 2018-10-31 | 2021-12-14 | 浙江想能睡眠科技股份有限公司 | Mattress with adjustable hardness |
| GB2580396A (en) * | 2019-01-09 | 2020-07-22 | Green Sheep Group Ltd | Mattress for an infant |
| US11564499B2 (en) * | 2020-07-20 | 2023-01-31 | Lear Corporation | Seat adjuster |
| CN112167880B (en) * | 2020-10-20 | 2022-06-14 | 上海龙凤软家具有限公司 | Cold and warm dual-purpose mattress |
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| IL127197A (en) * | 1998-11-23 | 2000-06-01 | Lockshincky Meir | Modular double-bed mattress |
| AU2002309227A1 (en) * | 2002-06-03 | 2003-12-19 | Aeroflex Israel Ltd. | Adaptable modular mattress system |
| CN2706068Y (en) * | 2004-05-06 | 2005-06-29 | 李洪江 | Composite mattress |
| CN2694834Y (en) * | 2004-05-19 | 2005-04-27 | 庄东发 | Built-up mattress with multi-core |
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| CN2845587Y (en) * | 2005-07-11 | 2006-12-13 | 张志雄 | Magic cube combined mattress |
| CN201073141Y (en) * | 2007-08-07 | 2008-06-18 | 刘或松 | Free combination type bed mattress |
| CN201256802Y (en) * | 2008-07-29 | 2009-06-17 | 深圳天诚家具有限公司 | Bed mattress |
| CN201286519Y (en) * | 2008-09-26 | 2009-08-12 | 庄东发 | Exterior division type combined mattress |
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2011
- 2011-06-13 CN CN201180038889.7A patent/CN103167818B/en active Active
- 2011-06-13 WO PCT/CA2011/000673 patent/WO2011156891A1/en active Application Filing
- 2011-06-13 CA CA2801789A patent/CA2801789A1/en not_active Abandoned
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|---|---|---|---|---|
| US11202517B2 (en) | 2014-04-21 | 2021-12-21 | Casper Sleep Inc. | Mattress |
| US11622636B2 (en) | 2014-04-21 | 2023-04-11 | Casper Sleep Inc. | Mattress |
| US11116326B2 (en) | 2017-08-14 | 2021-09-14 | Casper Sleep Inc. | Mattress containing ergonomic and firmness-regulating endoskeleton |
| US11241100B2 (en) | 2018-04-23 | 2022-02-08 | Casper Sleep Inc. | Temperature-regulating mattress |
| USD919333S1 (en) | 2019-08-27 | 2021-05-18 | Casper Sleep Inc. | Mattress |
| USD990935S1 (en) | 2019-08-27 | 2023-07-04 | Casper Sleep Inc. | Mattress |
| USD992933S1 (en) | 2019-08-27 | 2023-07-25 | Casper Sleep Inc. | Mattress |
| USD992932S1 (en) | 2019-08-27 | 2023-07-25 | Casper Sleep Inc. | Mattress |
| USD993673S1 (en) | 2019-08-27 | 2023-08-01 | Casper Sleep Inc. | Mattress |
| USD927889S1 (en) | 2019-10-16 | 2021-08-17 | Casper Sleep Inc. | Mattress layer |
| USD932809S1 (en) | 2019-10-16 | 2021-10-12 | Casper Sleep Inc. | Mattress layer |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2011156891A1 (en) | 2011-12-22 |
| CN103167818A (en) | 2013-06-19 |
| CN103167818B (en) | 2015-07-15 |
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