GB2499630A

GB2499630A - Mattress system

Info

Publication number: GB2499630A
Application number: GB201203145A
Authority: GB
Inventors: Asif Ayub
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-02-23
Filing date: 2012-02-23
Publication date: 2013-08-28
Also published as: GB201203145D0

Abstract

A mattress comprising a resilient core 30 and a resilient frame 20. The mattress core 30 may have a lower stiffness than the resilient frame20. The mattress may have a divider (26, FIG 3) a topping 40 and a base. The topping may include a motion layer of foam having slots formed on a top or bottom surface. A base layer 70 may contain lumbar support (74). The divider may divide the frame into two compartments each containing a resilient mattress core.

Description

1

Improvements in and Relating to Mattresses

The present invention relates to mattresses and in particular, although not exclusively, to mattresses for use with bedsteads for forming beds and divans.

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Mattresses are well known. Typically, mattresses are supported horizontally on bedsteads and provide support for a sleeper or sleepers. A mattress has a width length and thickness where the length is determined by the head-to-toe direction of the intended sleeping position and the width the shoulder direction. The thickness or height of the mattress is the 10 dimension from a top surface that a sleeper rests upon to a bottom surface. The mattresses are resilient and the pressures applied by the mattress against the weight of the sleeper can greatly affect the comfort of the mattress. Known mattresses can be formed from a number of resilient constructions such as foam or springs. Foam mattresses include memory foam and springs include pocket springs, both of which are widely known and understood so a detailed 15 explanation is not necessary.

It will be appreciated that the comfort of a mattress impacts significantly on the sleeper as an uncomfortable mattress will lead to poorer sleep quality which can, amongst other things, cause a lack of concentration during waking hours. Poor mattress support is also 20 thought to cause back, shoulder and neck pain as well as leading to further problems such as impeding circulation and muscle imbalance.

Some mattress complaints are triggered by changes in the pressure applied to the sleeper when a second sleeper sharing the mattress moves. Other complaints worsen over 25 time due to uneven compression of the mattress or the mattress loosing resiliency and therefore applying reduced pressure to the sleeper, which is often characterised by the formation of dips in the mattress. The uneven compression or over compression can be caused by normal sleeping routine or by, for example, repeated sitting or standing as is this case when getting in or out of bed. For instance, as shown in Figure 1a, mattresses can 30 develop an arched central area or uneven sides. Additionally or alternatively, in Figures 1b and 1c, the mattress is shown as having a flattened side or bowed centre respectively. Each of these conditions causes unevenness across the width of the mattress which can cause un-comfort as the sleeper is drawn towards the lowest point thus altering the natural sleeping position. A more comfortable mattress is therefore desirable.

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It is an object of the present invention to attempt to overcome at least one of the above or other disadvantages. It is a further aim to provide a mattress that provides greater flatness across the width of the mattress and with reduced degradation over time. Further optional aims are to provide a mattress with increased isolation between one part of the mattress and

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another so that pressures applied to one sleeper are not greatly affected by movement of a sleeper sharing the mattress and to provide an adaptable mattress for tailoring the level of support provided to the comfort and preferences of the sleeper.

5 According to the present invention there is provided a mattress and method of forming a mattress as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

In the exemplary embodiments a resilient mattress core is bounded by a resilient frame 10 having a greater stiffness than the mattress core. A mattress comprises the mattress core and a frame. Both parts are resilient. The mattress core is arranged to have a stiffness, or a resistance to compression in a thickness direction of the mattress, that is less than the stiffness of the frame. The frame bounds the mattress core and may comprise frame members that provide support to the mattress core along width and length edges of the mattress core. 15 Typically, a mattress is rectangular or square, though other shapes are possible, and so bounded preferably means a substantially continuous border to the mattress core. The frame members are suitably joined so as to provide a one-piece frame.

Advantageously, the frame provides improved support to the mattress core, which can 20 reduce loss of resiliency or stiffness. For instance, the frame provides increased stiffness at the edges of the mattress which can suffer damage from being sat or trodden on. Additionally, the frame provides a cavity for receiving the mattress core, which enables the mattress core to be more easily replaced with a different core, for instance if the sleeper's preference changes or if the mattress core becomes degraded or is required to be upgraded.

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Preferably, the frame may include at least one divider. Here the divider suitably runs the length of the mattress and divides the frame in to left and right compartments relative to the width of the mattress. Suitably, the divider is central so that the left and right compartments correspond to left and right sleeping positions. Consequently, the frame provides first and 30 second cavities for receiving first and second separate mattress cores. Advantageously, the divider enables the mattress core for each sleeping position to be tailored to that specific sleeper. Thus, where previously springs of different compression strength may be stitched together in the manufacturing process, a more adaptable method is achieved whereby standard sized pieces of mattress core can be formed as stock parts for fitting into the frame 35 as required by the sleepers. Also, the stiffness of each side of the mattress can be changed independently.

Preferably, the divider has a stiffness the same or less than the periphery frame members but still greater than both mattress cores either side of the divider. Advantageously,

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the divider therefore provides resistance to the centre of the bed becoming bowed which reduces the risk of roll-together.

Optionally, an inside edge of the frame at the head and / or foot of the mattress may 5 include a chamfer to provide reduced stiffness to the shoulder or ankle of the sleeper.

The frame preferably has a thickness equal to the uncompressed thickness of the mattress core. Furthermore, the frame members running along the sides of the mattress may have a width that is greater than 5% or greater than 10% or greater than 15% of the width of 10 the mattress core. The divider may also have a width that is greater than 5% or greater than 10% or greater than 15% of the width of the mattress core. Suitably, the divider may have the same width as the frame members running along the sides of the mattress. The frame members running the width of the mattress may have a similar dimension in the length of the mattress as the width of the side members or the dimension may be around 150% or 200% 15 larger.

In the exemplary embodiments, the mattress suitably further includes a topping. Here, the topping is placed on top of the mattress core and frame. The topping may include multiple layers, with each layer providing additional support and functionality. The topping suitably 20 includes a motion layer. The motion layer is preferably a foam layer having slots formed in a top or bottom surface. Here the slots are formed to allow a portion of the respective top or bottom surface on one side of the slot to move relatively to a portion of the respective top or bottom surface on the other side of the slot.

25 Furthermore, in the exemplary embodiments, the mattress suitably includes a base.

The mattress core and frame are placed on top of the base. The base may include multiple layers, with each layer providing additional support and functionality. In the exemplary embodiments, the base includes a base layer and a lumber support insert. Here, one of the base layer or lumber support layer is arranged on top of the other so that respective surfaces 30 oppose each other. Suitably, said respective surface of the base layer is contoured and said respective surface of the lumber support is also contoured to mirror said respective contoured surface of the base layer.

It will be appreciated that the mattress core, frame and any topping or base may be 35 encased within a cover for being held together. Optionally, the cover may be removable to allow the mattress components to be replaced or swapped.

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For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

5 Figure 1 shows a related art mattress;

Figure 2 shows a mattress according to a first embodiment;

Figure 3 shows a mattress according to a second embodiment;

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Figure 4 shows a cross-sectional end view through the mattress of Figure 3 in use;

Figure 5 shows a perspective view of a frame for use in a mattress of a third embodiment;

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Figure 6 shows an exploded perspective view of a mattress according to a further embodiment;

Figure 7 shows a perspective view of a base layer for forming the mattress of Figure 6;

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Figure 8 shows a side view of a sleeper resting on a base of Figure 6;

Figure 9 shows a side view of a sleeper resting on a base, frame and mattress core of Figure 6;

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Figure 10 shows a perspective view of a motion layer of Figure 6; and

Figure 11 shows a perspective view of a comfort layer of Figure 6.

30 Referring to Figure 2, a mattress 10 includes a frame 20 and a mattress core 30. The frame 20 provides a cavity within which the mattress core is arranged. Consequently, the frame and mattress core are arranged to substantially have a top face coincident along a common plane for receiving and providing support to a sleeper. That is, both the frame and mattress core have a top surface that provides support to the sleeper. The frame has a

35 stiffness that is greater than the stiffness of the mattress core. Advantageously, this enables the frame to provide a support to the mattress core and provides increased stiffness at the edges of the mattress to counteract the affect of sleepers crushing the edges when getting in or out of bed. For instance by sitting on the edge of the bed.

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The mattress core 30 is shown as a block of springs such as pocket springs but may be other known mattress materials such as foam. The mattress core 30 may be formed from a number of pieces of mattress core material. For instance, the mattress core 30 may be formed from two or three or more blocks of material. This allows a sleeper to individually select the 5 preferred stiffness of material under, for instance, their legs, torso and shoulders to give the preferred level of support. Furthermore, the blocks of mattress core material can be made to a standard size for a number of different mattress sizes which enables the mattress to be formed adaptably and from stock components.

10 As shown in Figure 2, a topping 40 and base layer 50 may be provided for additional functionality and comfort. Here, the mattress further includes a cover 60 that encases the mattress components to hold the mattress components together. Suitably, the cover 60 may be detachable. For instance, a zip may be provided or other opening means such as a hook and loop system so that the cover can be removed and the mattress components repaired or 15 replaced. For instance, one or more of the mattress core blocks may be removed to alter the stiffness of the mattress or areas thereof or to restore the mattress core to the original, intended stiffness.

It will be appreciated that the mattress may be formed to any desirable shape or size. 20 Typically, rectangular mattresses are used. Here, whilst the frame may be cut or machined from a solid block, the frame is shown in Figure 2 as suitably being formed from four periphery frame members. Two of the periphery frame members 21, 22 form lateral sides and the other two 23, 24 form head and foot ends across the width of the mattress. The periphery frame members are adhered or otherwise fixed together. Although there are standard sizes, typically 25 a mattress is designed for either a single sleeper or two sleepers. In the exemplary embodiments, the frame may be formed to bound the edge of the mattress and the shape and size of the mattress adjusted by adjusting the shape and size of the frame.

Figure 3 shows a second embodiment of a mattress 10 suitable for accommodating two 30 sleepers. Here a divider 26 is arranged to divide the frame into two cavities. That is, the divider 26 extends from one portion of the frame to an opposed portion. Preferably, as shown, the divider runs lengthways and central to the mattress. Consequently, a left and right cavity is formed corresponding to a left and right side of the mattress. Advantageously, the divider separates the mattress core of the one side from the other side. This enables one cavity to be 35 filled with a mattress core 30R that is different to a mattress core 30L of the other side. That is, the stiffness characteristics of one side of the mattress can be easily altered independently to the other side. Furthermore, the divider 26 acts as an isolator. This reduces the effects of pressure changes in the mattress core of one side caused by a sleeper's movement from altering the pressure applied by the mattress core on the other side.

6

Suitably, as shown in Figure 3, the divider is substantially the same thickness as the frame and has a similar width to the frame members running the length of the mattress. The frame members forming the periphery of the frame may be formed from high density 5 polyurethane foam. The divider may be formed from medium density polyurethane foam. The divider is suitably fixed or adhered to the periphery frame members.

As shown in Figure 4a-c, the divider 26 having a stiffness greater than the stiffness of the mattress core on either side, provides a stiffened ridge along the mattress that helps 10 counteract sag of the mattress core and generally promotes a flatter mattress across the width direction. In addition, the periphery frame members, and in particular, the frame members 21, 22 running along the sides of the mattress provide increased stiffness at the edge to counteract the formation of flattened or uneven sides.

15 Referring to Figure 5, a frame suitable for forming a mattress of a further embodiment is shown. The frame 20 is formed from periphery frame members 21, 22, 23, 24 as herein described and the preferable divider 26 is attached thereto. In addition, the inside, top edge of the head 23 and foot 24 frame members include a cut-out 28. The cut-out 28 is a chamfer and provides reduced stiffness to allow a shoulder and foot of the sleeper to be opposed by a less 20 firm portion so that the shoulder or foot can sink further into the mattress.

Referring to Figures 6 to 11 an exemplary mattress is shown. The mattress 10 includes a topping 30, base 40 as well as a frame 20 and mattress core 30 as described herein. The base comprises a dual layer to provide support to the frame and mattress core. The topping 25 comprises a dual layer to provide comfort to the top surface of the frame and mattress core. It will be appreciated that depending on the quality of the mattress more or fewer layers may be provided and the layers may have any known formation to provide adequate comfort and support. The topping, base, frame and mattress core may be encased within a cover to maintain form as is well known.

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As shown in Figure 7, the base 40 may have a base layer 70 formed from machined foam. The foam may have series of areas 71 formed by machining slots 72 in a grid like pattern, whereby a top surface of each area is enabled to move relative to a top surface of an adjacent area. Here the slots 72 may be formed through at least half the thickness or more of 35 the base layer 70. Preferably, the slots are machined to have a width of between 0.005-0.012 m. The bottom of the slots may be machined to have a radius similar to the width. In addition, a central area of the base layer 70 in the length direction forms a cavity 73 having a reduced thickness. That is, the cavity may extend across a substantial length of the mattress leaving shoulder and neck support portions 76 at either end. Each of the neck and shoulder portions

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may have a length of between 5% and 21% of the length of the mattress. Preferably, each of the shoulder and neck portions has a length of around 12% of the length of the mattress. The shoulder and neck portions provide a relatively firm area for supporting the head and feet of a sleeper and whilst any length has been found to be advantageous, the particular lengths 5 mentioned have been found to provide a particularly comfortable mattress for the majority of sleepers.

The bottom of the cavity may be shaped and contoured to provide ridges across the width of the mattress to provide greater support at particular locations of the sleeper (see for 10 instance Figure 8). For instance, first and second ridges may be formed across the width of the mattress. The mattress is preferably symmetrical about a central width axis. The cross-sectional profile across the length direction being substantially constant (excluding the difference between a profile through a slot and through a non-slot). The bottom of the cavity may extend from the neck and shoulder portion in a substantially flat area. The substantially 15 flat area may extend around 25-30% of the length of the cavity and preferably around 27%-28%. Suitably, the bottom of the cavity extends away from the substantially flat area and towards the centre of the mattress in an area of increasing thickness of the base layer 70. This section may increase in thickness along a line of curvature when viewed from the side, with the line of curvature having a radius of between 0.8 and 0.950m or 3.5 to 5 times the 20 length of the section having increasing thickness. A central section of the bottom of the cavity may form a concave surface and therefore meet the two sections of increasing thickness to form said ridges. The concave area may have a radius of curvature around 17-19% of the length of the mattress. Suitably, as shown in Figure 7, a bottom surface of the base layer is substantially flat. Consequently, a lumber support insert 74 can be fitted into the top of the 25 base layer 70. Here, the lumber support insert mirrors the bottom surface of the cavity 73, so that a substantially flat top surface to the base 50 is provided. The lumbar support insert 74 may have a lower stiffness than the base layer 70 which can help to reduce negative pressure to the sleeper and therefore promote the sleeper to be supported in a natural position. As will be appreciated, the shoulder and neck portions 76 are not covered by the lumber support 30 insert 74 to provide firmer support. Moreover, although the ridges and shaped bottom surface of the cavity provide negative pressures to increase the comfort of the sleeper, the specific contours described above have been found to provide a particularly comfortable base layer for the majority of sleepers.

35 Referring back to Figure 6, the frame 20 and mattress core 30 are arranged on top of the base 50. The divider 26 is included to prevent roll-together and to provide addition support to the mattress core along a central spine of the mattress. In the exemplary embodiments, pocket springs are shown as the mattress core material. However, any other suitable material is envisaged such as foam, rubber, latex etc. Figure 9 shows the depression of the mattress

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core in response to the weight of a sleeper. As will be appreciated, the compression of the mattress allows the sleeper to be supported in as natural position as possible. That is, the mattress is intended to conform to the shape of the sleeper along the length direction.

5 The topping 40 has a motion layer 80 and upper comfort layer 90. The motion layer 80

is suitably formed from a machined foam block. Slots 81 are machined in the top surface of the motion layer 80 in a grid like pattern and to enable a top surface of one area to move relative to a top surface of an adjacent area. A central area 82 in the length direction has shallow, wide slots. Preferably, for instance, the slots may have a width of between 0.015 and 10 0.04 m and a depth of around 0.02 to 0.045m but in any event less than 50% of the height of the motion layer 80. Preferably, the slots here are tapered to get narrower towards the bottom of the slot. For instance, the width of the slot at the bottom may be around 70% to 80% of the width of the slot at the top or opening. In the exemplary embodiments, three widthways slots are formed to provide two areas either side of the central width axis. The areas on the outer 15 side of these two areas may be 2-3 times as long and extend to the start of intermediate areas 83, 84 to either side of the central area 82 which have narrower, deeper slots. For instance, the slots here may have a width of around 0.005-0.01 m and preferably around 0.007-0.008m and a depth at least 50$ through the thickness of the motion layer 80. In at least the intermediate areas, the slots are under-cut at the bottom of the slot so as to promote multi-axis 20 movement of the top surfaces of each area that is bounded by the slots (as shown in Figure 11). The comfort layer is shown in Figure 12 and provides comfort to the sleeper by promoting airflow and relieving pressure points. This is achieved by forming ribs 92, 94 running width ways across upper and lower surfaces of the comfort layer.

25 Although preferred embodiment(s) of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made without departing from the scope of the invention as defined in the claims.

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Claims

1. A mattress comprising:

a resilient mattress core; and 5 a resilient frame that bounds the resilient core; wherein the resilient mattress core has a lower stiffness than the resilient frame.

2. The mattress of claim 1, wherein both the resilient mattress core and resilient frame have a top surface for providing support to a sleeper.

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3. The mattress of any proceeding claim, wherein the resilient frame has lateral side members that extend in a length direction of the mattress and lateral end members that extend in a width direction of the mattress.

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4. The mattress of claim 3, wherein a top surface of the lateral side members of the resilient frame have a width at least 5% of the width of the resilient mattress core.

5. The mattress of claim 3 or 4 wherein a top surface of the lateral end members of the resilient frame have a length at least 5% of the length of the resilient mattress

20 core.

6. The mattress of any proceeding claim including at least one divider.

7. The mattress of any proceeding claim including a topping.

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8. The mattress of claim 7, wherein the topping includes a motion layer, wherein the motion layer is a foam layer having slots formed in a top or bottom surface, the slots being formed to allow a portion of the respective top or bottom surface on one side of the slot to move relatively to a portion of the respective top or bottom surface

30 on the other side of the slot.

9. The mattress of any proceeding claim, including a base.

10. The mattress of claim 9, wherein the base includes a base layer and a lumber 35 support insert, wherein one of the base layer or lumber support layer is arranged on top of the other so that respective surface oppose each other, said respective surface

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of the base layer being contoured and said respective surface of the lumber support being contoured to mirror said respective contoured surface of the base layer.

11. The mattress of claim 10, wherein the base layer includes a cavity within which 5 the lumber support is arranged.

12. A method of assembling a mattress, the method comprising;

arranging a resilient mattress core within a resilient frame.

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13. The method of assembling a mattress of claim 12, wherein the resilient mattress is formed from two or more blocks of resilient mattress core and the method comprises arranging two or more blocks of resilient mattress core within the resilient frame.

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14. The method of assembling a mattress of claim 12 or 13, wherein the resilient frame includes at least one divider for dividing the resilient frame in to at least two compartments and the method comprises arranging a first resilient mattress core in one compartment and arranging a second resilient mattress core within the other compartment.

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15. A method of altering a mattress, wherein the mattress has been assembled according to any of claims 12 to 14, the method comprising removing one or more of the resilient mattress cores and replacing said resilient mattress core with a new resilient mattress core.

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16. The mattress method of assembling a mattress or method of altering a mattress substantially as herein described and with reference to figures 2 to 11.