Braced or (Self-)Supporting Mattress This invention relates to mattress construction and is particularly, but not exclusively concerned with ventilated mattress support.
In GB 0412998.7 and corresponding PCT**one of the joint Applicants proposed socalled 'environmentally conditioned' furniture.
A prime example was a ventilated bed - in which a ventilated mattress overlaid an open bed base frame. The base housed a plenum chamber and either an on board conditioning unit, or an umbilical connection to a remote facility.
The conditioner featured an electric powered ventilation fan, matrix heater and filter with controller.
Base platform infill provided support over the mattress plan form or footprint, yet allowed air passage from plenum to permeate the mattress.
The mattress itself, whilst permeable to conditioned air through flow from the plenunm, contributed reslient cushion action for occupant comfort.
A conventional mattress could be retained or substituted by a more permeable construction.
Fluid cell - eg air pillow bag - mattress variants were also envisaged.
Certain earlier work was recognised.
Prior Art - MattressVentilation
US 3,266.064 Figman teaches a ventilated box-spring mattress sitting upon a sprung base carcass.
Within the base is set an impeller fan housing, remote side wall intake filter.
Base interior space is surmounted by a metal screen or porous foam layer interface for a foam mattress The mattress features embedded vertical air flow discharge passageways sitting within a peripheral bed base frame upstand nm.
Figman reflects a bespoke or dedicated bed construction - appropriate for OEM, but not adaptation or conversion of an existing bed.
Bed occupant temperature is a prime consideration, rather than an anti-allergenic or asthmatic resolution through adoption of high performance filtration.
Even a conventional mattress makes a large contribution to bed performance.
Occupant comfort and support, resilient cushion deflectiion and recovery action under compression, along with ventilation are joint considerations.
In satisfying such requirements, a mattress is potentially the most complex part of a bed, in terms of construction and materials.
A mattress also represents a great added value opportunity - of enhanced performance without disproportionate cost.
Self-support to minimise reliance upon a separate frame, whilst accommodating forced th rough-flow ventilation are targets for some embodiments.
Prior Art - MattressSelf-Support
Supplementary pnor art in relation to mattress construction ...
WO 01/84082 Halo explores ventilated mattress construction in conjunction with an underlying plenum and diversity of conditioning.
US 4,407,031 Michiels envisages stiffeners in a mattress ofundulating elastomer elements sandwiched between elastomer sheets - but no plenum role for intervening internal voids.
US 6,308,354 Lilly deploys a steel wire grid lamination for mattress stiffening, but not intended to brace over an otherwise unsupported span.
US 4369534 Wright teaches localised mattress firmness fhrough plastic strips and overlaid wire grids at opposite mattress sides coupled to a spring core.
GB 1294071 Nail shows inflatable mattress compartments configured as tubular beams for load support.
GB 716961 Barnes teaches localised mattress reinforcement pads of spaced fibrous lines stacked in layers with intervening latex bonding.
WO 2004034842 Bernhard deploys a unitary mattress border rod of resilient polymer about a central spring core.
*** Whilst this art affected ventilation ambitions, the practicality of detailed construction was at issue.
The Applicant envisaged refinement for economic production - such as a plenum module, fabricated as a unitary moulding and configured as a shallow depth or slimline tray, with an inset conditioner unit.
The plenum chamber served as a reservoir for conditioned air from the conditioner unit.
A series of individual transverse slats bridged the tray to support an overlaid mattress.
Slat spacing allowed conditioned air to permeate from a plenum chamber through the mattress.
Embedded Mattress Features & Functionality A bespoke mattress construction is now proposed in which support features can be incorporated.
This might be referred to as an 'embedded approach' - for either ventilated or nonventilated formats.
Statement of Invention A braced mattress able to support its own and occupant weight without undue sag or deformation when disposed between spaced supports.
An internal brace to bolster bending stiffness, without undermining resilent cushion action, is envisaged.
This might feature transverse wire, strip or band spring elements - and which might in turn be linked to a pocket coil spring array - all embedded within an outer fabric liner and cushion padding.
A self-supporting mattress could overlay a minimal perimeter base frame, with mattress u nderpinning support confined to a peripheral edge.
An internal mattress stiffener could be concentrated at the edge periphery.
A peripheral stacked wire coil, strip or band could serve for this.
Transverse band to bolster bending stiffness could bridge between stacked edge coils.
A pocket coil array could sit upon a cluster of transverse bands.
An arched profile could be adopted for transverse bridging elements.
Convex and/or concave profiles could be adopted for transverse springs or a sandwich of tiered spring layers - with progressive waisted depth to mid-span.
Thus cantilever or suspsension bridge forms could be contrived - with structure locally bolstered where bending loads are greatest.
Overall, such internalisation or integration of thitherto disparate external elements concentrates mattress features and functionality, and a simplified bed base. Mattress Integration (Self-) Stiffening Elements (Ribs) Plenum Pocket / Profile A self-supporting mattress construction could allow a mattress to span a minimal open bed frame - without intervening support or braces, such as struts or ribs.
In fact, internal bracing for (self-)support is applicable, whether or not the mattress is ventilated.
Shared Mattress & Bed Base support A compromise configuration might be to contrive shared mattress support between the mattress structure itself and an underlying bed base frame.
Rib Pockets Discrete removable ribs might be located in loose fabric pockets set into a mattress underside.
Selective Rib - StiffnessVariation This would allow selective change in number or profile of ribs to vary mattress support stiffness.
Interfitting rib profiles could be employed for this.
Terminology The term 'wire' is used herein for simplicity to embrace diverse profiles, including, say, strip, strap or band.
Wire Frame Thus for a wire braced mattress, wound or wrapped stiffeners or braces could be integrated with peripheral boundary edge delineators.
A contiguous metal and/or plastics wire, cord and/or flat strip or band, wound internal reinforcement and cushion spring construction could be contemplated.
Coil and/or convoluted linear spring configurations could be adopted.
Strip or band springs could be used - say set in convoluted folds, of depth varying with span.
Thus arched profile embedded spring stiffeners are envisaged.
These would offer greater stiffness where bending loads are greater, such as occupant support loads carrid or transferred outboard of an occupant.
Some local mattress deflection beneath an occupant could thus be preserved, even with an occupant at mid-span, without inducing overall sag or distortion.
Thus through flow ventilation could be preserved without local compaction and flow obstruction.
A stiffer bounding frame need not be without resilience by judicious combination of internal springing for direct compression and banding load transfer from laterally offset mattress portions.
Internal stiffening could supplement or replace external braces, such as transverse slats set in an external underpinning bed frame.
Thus, say, a peripheral stacked coil configuration, series of wire loops could provide edge bracing.
Side tension suspension loads could be passed between opposite loop sides. Cushion Frame In order to avoid direct contact with a bed occupant, a concealed internal self-bracing support surrounded or enveloped by cushion layers is preferable to an exposed external mattress frame.
Profiled Mattress Underside A profiled mattress underside - such as with a peripheral depending rim - may itself contributed to stiffness and self-bracing and support.
Inset transverse and/or longitudinal ribs could be secured to and lie within a peripheral rim.
Plenum Recess A recessed mattress underside could serve as a partial or complete plenum chamber for ventilated bed variants.
Mattress Internal Frame Flex The internal bracing need not be absolutely rigid - rather some modest resilient flex or bend could be allowed for occupant comfort.
Thus the mattress frame support could contribute to mattress shock absorbency and cushion action.
Sliding Peripheral Plenum Seal For a ventilated bed, any distension or distortion of mattress plenum chamber(s) attendant such internal frame flex could be accommodated by a sliding (peripheral) edge seal action with an underlying bed frame and/or plenum closure chamber or plate.
Alternatively, a rolled seal section could be used.
Profiled Sliding Seal A complementary sliding interfit seal profile on mattress and base mating edge seals could bolster seal action whilst not inhibiting relative movement.
Noise Suppression & Vibration Damping Noise suppression and/or vibration damping of mechanical fan action could be assisted by spacing a mattress plenum from a fan housing or shroud.
Demountable Fan Module A demountable modular underslung fan housing could incorporate fan, fan motor, heater and motor control for ease of maintenance and repair access and isolation from a bed occupant.
A fire resistant or retardant fan housing, is desirable for safety.
Area Conditioning Temperature, humidity and/or conditioned air through-flow is a prime consideration for anti-allergenic or allergenic suppressant function.
Filtration could be bolstered by introducing multi-stage filters in serial passage array. Simple omission or bypass of some filter stages could set lower performance.
This also applies to wider (room) environmental impact than merely a bed itself. Variable Speed Fan Variable fan speed settings could be used for this - either continuous or stepped. Undue fan speed is undesirable given attendant noise generation, unless well suppressed.
Multi-stage Fans Similarly, multiple staged fans could be fitted - say in tandem. serial (one feeding another) or parallel array.
Inherent Mattress Filter The mattress itself - through construction and materials - could provide some filter action.
In contrast Fligman uses through passages, bypassing the primary mattress body, so minimal aeration would arise.
Filter Unclog A pulse purge (sudden reverse flow burst) filter cleansing or unclogging action could be contrived by volumetric displacement or compaction upon compression loading by bed occupancy.
Dust Trap An airborne dust, debris or contaminant trap could be fitted to catch and entrap filtrates thus disturbed.
Dust includes pollen and the like which might trigger allergic reactions.
A dust trap laterally offset, say in a blind bend, from a primary flow path and routed through a one-way valve could inhibit inadvertent dust recycling.
Interlinked Coils A co-operatively interlinked or tied array of mutually aligned or otherwise juxtaposed coil or pocket springs could serve as a stiffening limb.
Consideration would be given to noise attendant spring interaction upon relative movement.
Sleeved springs might be contemplated to reduce friction rubbing and scraping between spring surfaces.
Arched Profile Stiffener Beam An arched stiffener beam profile - with depth varying progressively from opposed outer ends to mid-span - would have bending stiffness related to distance from end support.
Cantilever Arch Thus a form of cantilever arch might be contrived.
Suspension Bridge An alternative could be a suspended beam approach, with a suspended span underslung between spaced end pillars.
Embodiments There now follows a description of some particular embodiments of the invention by way of example with reference to the accompanying diagrammatic and schematic illustrative drawings, in which: Figures 1 A and 1 B reflect integrated mattress construction with integrated selfsupport bracing or stiffeners and plenum chamber contribution through (under) surface profle; More specifically ...
Figure 1 A shows a translucent perspective view of a rectangular mattress outline with transverse internal stiffener ribs set in an array beneath pocket coil springs and buffer cushion layers of (foam) padding; Figure 1 B shows a transverse section of the internally braced mattress of Figure 15A with wire wound tubes entrained with upright coil springs; Figures 2A through 2E depict 3-D perspective views of variant mattress recessed underside face profiles; More specifically ...
Figure 2A shows a plain shallow rectangular recessed mattress underside face; Figure 2B shows a rectangular inset with peripheral edge rim seal upstand an integrated corner feet; Figure 2C shows a recessed mattress underside with demountable corner feet; Figure 2D shows an inset or recessed mattress face with curvilinear re-entrant convoluted maze outline; Figure 2E shows shows a recess mattress face with convoluted or serrated profile; Figures 3A and 3B show an exploded perspective view of a ventilated bed with plenum module set into a base and overlying permeable mattress with underside fabric pockets integrated with a cover or lining to accommodate transverse support slats; More specifically ...
Figure 3A shows a base with exposed plenum chamber to interface with an overlaid mattress; Figure 3B shows a juxtaposed permeable mattress with integrated bracing slat insertion to contrive mattress self-support for bridging a base frame perimeter; Figures 4A and 4B show internal wire bracing configurations with mattress in outline for clarity; More specifically ...
Figure 4A shows a 3-D perspective view of a perimeter bracing band of stacked wire coils; Figure 4B shows a transverse section of the mattress of Figure 4A with some additional detail of intermediate (pocket) coil springs tied to the perimeter stiffener band; Figures 5A through 5F show translucent transverse sections of variant ventilated selfsupporting mattress constructions, with arched or other variable spring depth with span configurations; More specifically ...
Figure 5A shows a convexed arched profile transverse stiffener band linking an array of individual pocket coil springs; Figure 5B shows a concave arched profile alternative stifferner to Figure 5A; Figure 5C shows opposed rectilinear tranverse stiffener elements at respective mattress faces, with intervening coils; Figure 5D shows transverse linkage or tie between coils of progressively different depth with span disposition; Figure 5E shows dual opposed convex arch curvature ties between coils set in complementary arch disposition; Figure 5F shows multi- (in this case twin) tiered coil springs, with a squat u nder set to contribute transverse bending stiffness; Figures 6A through 6F show ...
More specifically ...
Figure 6A shows waisted profile individual coils set upon a common transverse beam; Figure 6B shows a variant of Figure 6A with crossed tension wires configured to serve as a common coil support beam; Figure 6C shows a coil array set upon a concertina folded band'; Figure 6D shows a coil array set upon an arched underpinning band itself tied at opposite ends; Figure 6E shows a coil array set upon a laminated leaf spring end tied between opposite beams; Figure 6F shows a coil array set upon twin arched beams intercoupled at mid-span; Figures 7A through 7C show a convoluted transverse leaf beam array; More specifically ...
Figure 7A shows a translucent 3-D perspective view of a multiple juxtaposed convoluted leaf springs, with an arched underside profile; Figure 7B shows a transverse section of the mattress of Figure 7A; Figure 7C shows a variant of Figure 7B with a coil array stacked upon convoluted transverse leaf beams; Figures 8A and 8B show fluid cell mattress elements with internal stiffening; More specifically ...
Figure 8A shows a 3-D perspective view of a mattress fluid cell - in this case an air pocket; Figure 8B shows a translucent side elevation of the mattress of Figure 8A; Figures 9A and 9B show an internally braced ventilated mattress overlaid upon a base wi th plenum module and air conditioner unit.
More specifically ...
Figure 9A shows a 3-D perspective view; Figure 9B shows a transverse sectional view of Figure 9A; Figures 10A and 10B show an interlocking bracing slat arrangement of variable collective geometry for inserted stiffness adjustment; More specifically ...
Figure 10A shows a fragmentary 3-D perspective view of slat interlock; Figure 10B shows an end elevation of Figure 10A; Figures 11A and 11 B show internesting / interfitting bracing slats; More specifically ...
Figure 11A shows a fragmentary 3-D perspective view of dual interfitting slats; Figure 11 B shows an end view of Figure 11 A, with some three interfitting slats; Referring to the drawings ...
Generally, an internally braced mattress is capable of self-support between spaced elements.
Thus Figure 1 A depicts a mattress spanning edge supports 19 - in practice represented by the opposite sides of a bed base.
Such a braced, self-supporting mattress obivates underpinning divan base, platform, slats or the like.
Thus a minimal open format base may be employed - say with a simple perimeter base frame, with which a peripheral mattress underside edge makes contact. Partial-Shared Mattress Support That said, partial mattress self-support and shared support with a bed frame could be contemplated.
This would allow reduced mattress bracing.
Whether entirely self-supporing or partially supporting, some overall mattress form flex is admitted, consistent with occupant support and reslient deformation for comfort.
Thus undue stiffness or rigidity is not required, merely the ability to carry weight when the mattress bridges between remote bearers, without undue bend or sag - to user discomfort, or outright collapse.
Considerable vanation in internal bracing is possible, and so various examples given are merely indicative of wider general principles of bracing and support.
One such support action principle or mode is cantilever. That is a beam supported at one end.
Another is overhead suspension.
Mixed support - say combined cantilever and suspension - modes are also envisaged.
Sprung Cushion vs Fluid Cell Aside from sprung cushion contruction of Figures 1A through 7C, a fluid cell may be employed, such as reflected in Figures 8A and 8B.
Figures 1 A and 1B reflect an internally braced stuffed mattress 10 with an array of upright coils 12.
Coils 12 are optionally located within inidividual fabric pockets (not shown), or otherwise mutually isolated by internal padding to obviate direct contact.
Individual coils 12 have a waisted profile 13, for end-on collapse upon compression and present a large load distribution contact area to mattress faces.
Waisted coil profile 13 presents intervening voids for internal air displacement and air through flow in ventilated variants, such as Figures 9A and 9B.
That said, additional stuffing may be introduced within the mattress body, partially to fill such voids.
Fluid cells, such as self-contained air bags (not shown) might also be introduced into the voids.
Coils 12 are set upon transverse beam braces 16 - fabricated as straps and/or elongate tightly would coils - set between longitudinal side braces 17.
Both transverse and longitudinal braces 16, 17 are dipsosed at or adjacent mattress bottom corner edges, to allow load transfer to bed base bearers, without undue overall mattress deformation.
Paddding 15, enveloped within an overall fabric cover 18, isolates an occupant from coils 12.
Figures 2A through 2E reflect recessed mattress 20 underside profiles to create, or contribute to, a plenum chamber for air conditioned ventilated bed variants - along with a base such as of Figure 3A.
A minimal rectangular recess 24 in Figures 2A through 2C extends over most of the footprint and is bounded by a peripheral edge rim 22 of side wall 21.
More elaborate recess profiles are reflected in Figures 2D and 2E - to promote certain recirculatory and/or through flow characteristics.
Thus a convoluted recess 26 of Figure 2D promotes lateral re-distributive flow, and could be configured to localised area conditioning.
Figure 2E reflects a corrugated profile recess 28 to promote transverse air distribution and create a series of small reserve plenums.
These might be individually accessed for differential mattress conditioning - say a progressive banded temperature gradient from occupant head to toe.
Figures 2D relies upon a convoluted underside face seal 23 with a underlying base unit plenum module and/or conditioner unit (not shown) Figure 2E relies upon a peripheral underside dge seal 25 bounding corrugations 28. Figures 2B and 2C show mattress stub feet for corner location upon a base (not shown).
In Figure 2B corner feet 27 are integrated with side walls 21.
Demountable corner locator feed 29 are depicted in Figure 2C.
Feet 27, 29 might extend to a support surface (ie a floor), for a free-standing mattress 20.
A discrete base would then be optional.
Thus, say, conditioner units might be inserted under the mattress 20 to feed plenum chamber 24 - reliance being placed upon convection to permeate the mattress in upward flow of realtively warmer air.
Figures 9A and 9B reflect seamless ventilation feature integration within a mattress thus blurring any distinction between base and mattres.
Removable mattress bracing is reflected in Figures 3A and 3B by use of transverse slats 32 received in fabric pockets 33 in a mattress 30 underside.
Figures 10A through 11 B feature co-operative slat interconnection for bracing stiffness adjustment.
Juxtaposition of mattress 30 side walls with a peripheral ledge 37 of a plenum module 36 set in a base 35 providesedge sealing.
An upstanding rim 39 retains mattress 30 location upon base 35.
Localised mattress 40 bracing by a reinforced edge band 45, of stacked coils 46, set in peripheral side walls is reflected in Figure s 4A and 4B.
Figure 4B conveys how an array of coils 44 is entrained with a mattress cover 48 by tie links 47.
Variant configurations of transverse bracing elements for a self-supporting mattress 50 are explored in Figures 5A through 5F.
Linkage with a pocket coil array is envisaged, with in some cases a profiled, stacked or otherwise bespoke coil array.
Thus, arched bracing is explored inf Figures 5A through 5E.
Stacked coil arrays are depicted in Figure 5F.
In Figure 5A an arched band 51 penetrates a row of coils at progressively different depths according to span and terminates in opposite lower end ties 52.
An inverse arrangement of Figure 5A is depicted in Figure 5B, with a closed loop band, straight along an upper tie 54 for occupant support and concave along a lower arched band 53 for entrainment with a coil row.
Figure 5C shows straight upper and lower transverse tie band beams 55, 57 set at opposite ends of a coil row and between lateral braces 56. Figure 5D shows an upper concave tie 58 interlinking coils of progressively reduced depth towards mid -span, to promote occupant lateral retention. Figure 5E shows twin convex arched transverse bands 59A, 59B with intervening coil row sandwich also following a complementary arched profile. Figure 5F shows an upper bolster 150, with tall low spring rate (soft) coils, set upon a lower bolster 151, with squat high spring rate (ie stiff) coils.
Underpinned bracing for a self-supporting mattress 60 is explored in Figures 6A through 6F.
Figure 6A shows a coil row set upon a straight beam 61 - which could be built up from slats. Figure 6B shows cross tie braces 62 underpinning a coild row; Figure 6C shows a 'lazy' or slow spring rate convoluted or reverse folded brace 63. Figure 6D shows a convex arched brace 64. Figure 6E shows a stacked leaf spring brace 65. Figure 6F shows paired convex arched braces 66, 67 juxtaposed in end-to-end abutment, with a mid-span brace tie 69.
Elaborations in transverse brace profile, configured as a convoluted band 71, for a self-supporting mattress 70 are reflected in Figures 7A through 7C.
Figures 7A and 7B shows a lower braced bolster 72 of convex arched underside profile 73. Figure 7C shows an upper bolster slab 74 set upon braced bolster 72. Figures 8A and 8B show an air cushion mattresss 80 with reverse folded side wall bracing 81 about an inflated pocket 82. Figures 9A and 9B show a ventilated self-supporting mattress 90 with integrated plenum module 91 and plenum chamber 92 supplied by a conditioner unit 91 drawing ambient air from an intake 93. Figures 10A and 10B show full-span transverse slats 101 with intervening stub-slat spacers 102 as interconnecting links Re-entrant slot 104 and nose 105 profiles allow snap-action interfit of slats 101, 102.
If full span slats 101, 103 are interconnected in a cluster, their combined bracing stiffness is greater than, for say, spacers 102.
Figures 11 A and 11 B show interfitting or internesting slats 111, 112, 113 in selective combination for combined bracing stiffness.
A minimal outer slat 111 could thus be bolstered by an inner strengthening slat 112 and further stiffened by an innermost slat 113.
Closed (as illustrated) and/or open (say 'U' or 'C')-section slats could be employed.
Component List Figs 1 A, 1 B 10 internally braced mattress 11 bracing element array 12 coil 13 waisted coil profile 14 coil 15 cushion padding 16 transverse beam brace 17 longitudinal side brace 18 cover 19 edge support Figs 2A-2E 20 self-supporting mattress 21 side wall 22 edge rim 23 24 recess 25 26 convoluted recess 27 integrated foot 28 corrugated recess 29 demountable foot Figs 3A, 3B 30 self-supporting mattress 31 32 slat 33 fabric pocket 34 35 base 36 plenum module 37 ledge 38 39 rim Figs 4A,4B 40 mattress 41 42 43 44 pocket coil 45 edge band 46 stacked coil 47 tie link 48 cover 49 edge band Figs 5A-5F 50 mattress 51 convex arched band 52 lower end tie 53 concave arched band 54 upper tie 55 upper beam 56 lateral brace 57 lower beam 58 convex band 59A upper convex band 59B lower convex band 150 upper bolster 151 lower bolster 152 upper pocket coil 153 lower pocket coil Figs 6A-6F 60 mattress 61 platform brace 62 crossed tie brace 63 convoluted brace 64 convex arched brace 65 leaf spring brace 66 convex arched brace - 1/2 span 67 convex arched brace - 1/2 span 68 69 mid-span brace tie Figs 7A-7C 70 mattress 71 convoluted band 72 braced bolster 73 convex arched profile 74 upper bolster 75 76 77 78 79 Figs 8A-8B 80 mattress 81 bracing 82 inflated pocket 83 Figs 9A-9B 90 mattress 91 ventilator plenum module 92 plenum chamber 93 air intake Figs 10A-10B 100 mattress 101(full-span) slat 102 (short or intermediate span) spacer slat 103 (full-span) slat 104 re-entrant profile recess 105 re-entrant profile nose Figures 11 A-11 B 111 outer slat 112 inner slat 113 innermost slat 114