NZ330983A - mattress with first resilient member, typically foam, and plurality of second resilient members, typically coil springs, with latter being located to provide suitable characteristics for particular type of person - Google Patents

Abstract

A posturised mattress configuration that includes a first resilient member (2) and a plurality of second resilient members. A bore 5 in the foam resilient member (2) is provided to define an enclosure to match the spring (7). The resilient member 2 in the preferred embodiment with a plurality of transverse bores 5 arranged at predetermined intervals across the resilient member 2 between the normal mattress support sides preferably in rows R, such that the web portion 6 is created between each bore 5. The preferred embodiment provides a posturised mattress that is able to be tailored or tuned to varying overall body weights or physical body dimensions.

Description

Patents Form No. 5 Our Ref: PT502257 NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION NO. 330983 dated 13 July 1998 IMPROVEMENTS IN RESILIENT MATTRESS CONFIGURATIONS We, SLEEPYHEAD MANUFACTURING COMPANY LIMITED, a New Zealand company of 41-71 Great South Road, Otahuhu, Auckland, New Zealand hereby declare the invention, for which We pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: 'I WiiU-Lco.l. M- ' . ' CT NZ PT0524942 2 8 JUL 1993 RECEIVED The invention includes methodology for achieving predetermined posturisation of the mattress by variation of the resilience of the mattress in comparison with measurements taken from the intended user or class of users prior to predetermining the resilient bias provided by the mattress in use.

This invention relates to improvements in mattress configurations and methods of manufacture of mattress configurations and in particular, in respect of the primary resilient member of a mattress, commonly known as the mattress armature or core.

In the past, except for fluid supported beds, such as water beds, air beds and the like, the primary resilient member for a mattress has generally either been formed in an inner spring configuration, incorporating an assembly of interlinked metal compression springs arranged inside the mattress to provide appropriate resilience when housed within appropriate coverings, tickings and like, or alternatively, has been provided by a block or similar portion of resilient form material and the like. Furthermore, such as disclosed in USA patent specifications Nos. 5,327,596 and 4,862,540, combinations of such arrangements have been provided. All such prior art assemblies encounter use and/or manufacturing problems which the present invention attempts to come some way in addressing.

In relation to traditional metal coil spring armatures, or so-called "innerspring" mattresses, there are a variety of problems associated therewith including cost and complication of manufacture, the tendency for springs to each influence one another when deflected and resultant sleeping partner disturbance and the like. A further problem is that with the springs interlinked spring armatures tend to operate in unison and create a plannar or "board like" feel to the mattress which cannot be readily disguised even with substantial overpadding. Attempts have been made to overcome these problems by positioning the compression springs separately in individual sheet metal "pockets" which are themselves secured one with the other to form the mattress armature. Varying resilience or strength springs have been provided to vary the mattress resilience over the mattress supporting area for posturisation, however, such constructions are relatively complex, are prone to wear, particularly interspring wear. Furthermore, in manufacture the above arrangements are in the mam complicated in their operational planning/construction and therefore tend to result in a very expensive product which does not always perform to customer expectations over the reasonable economic life of the product.

A strongly preferred feature of any bed and particularly the mattress is for an edge of the mattress to have enhanced resistance to deflection compared to the surrounding areas, to create the feeling of a firm mattress edge. Whilst firm mattress edges are relatively economically achievable with springing arrangements incorporating interlinked metal coil spring mattress armatures as described above, (by engaging wires secured with and interlinking outer spring edges), this is not possible in the above-mentioned individual pocketed spring assemblies where significant difficulties in providing the preferred firm edge for the mattress are encountered thus leading to users often feeling "insecure" when resting on the mattress near to the mattress edge.

Alternative mattress arrangements have incorporated foam rubber latex or polyurethane foam blocks as a core resilient member. Such arrangements provide a relatively low cost alternative mattress core to an "inner sprung" mattress, however do not generally have the product life, nor the resilient feel of an inner spring mattress, for which the majority of the market has indicated a clear preference.

Furthermore, it is known that such foam mattresses have a generally shorter product life of acceptable resilience for use.

Inevitably, with any mattress there is a compromise between a requisite "softness" of resilience and a need for structural integrity of the resilient core required to provide sufficient mattress longevity. In addition, the degree of overall support required must ultimately be sufficient to prevent, for example mattress deflection through the length/width of the mattress, or other adverse deflection of the mattress on a temporary or gradually permanent basis.

There is developing a growing need for manufacturer responsibility in respect of product disposal. Historically, the disposal of mattresses has been associated with some difficulty. In particular, mattresses incorporating an innerspring armature are relatively difficult to dispose of, as a result of the mixture of materials used, coupled with the fact that it is relatively difficult for the metal armature of the mattress to be dismantled or otherwise handled in a manner suitable for at least partial economic recycling. Prior art mattress types present a difficulty in tailoring or "tuning" the mattress to the specific user characteristic has presented manufacturers with a problem hitherto unable to be economically addressed in constructions and arrangements which also have the desirable properties of prior art constructions outlined above.

Accordingly, it is an object of this invention to come some way in overcoming the above-mentioned problems or at least provide the public with a useful choice.

Other objects of this invention which should be considered in all its novel aspects will become apparent from the following description.

For the purposes of this specification, "posturisation" in relation to a mattress is the "tailoring" or "tuning", of the deflection/resilience and support characteristics of the mattress relative to a person or a class of persons for whom the mattress is intended, for example, enabling the mattress to be tailored or tuned to varying overall body weights, varying physical body dimensions and varying positioning of ">$> relative portions of the body weight, for example, taking into account persons with relatively broad shoulders and narrow hips, or alternatively, persons with large abdomen/hip region and the like. A posturised mattress is thus a mattress that has been produced by "posturisation".

According to one aspect of this invention a posturised mattress including a first resilient member supporting at least partially a plurality of second resilient members, wherein said posturised mattress has a predetermined variation of resilience characteristics across said posturised mattress.

According to a further aspect of this invention there is provided a method of posturising a mattress (as defined above) including the steps of: forming a first resilient member in a first resilient material, forming a plurality of apertures in said first resilient member, and positioning a plurality of second resilient members in said apertures in a predetermined pattern to account for the physical characteristics of the person or class of persons for whom the mattress is intended.

Other aspects of this invention, which should be considered in all its novel aspects will become apparent from the following description. Modifications and developments are envisaged and may be incorporated without departing from the scope or spirit of the invention as defined in the appended claims.

The preferred form of the invention will be described in more detail, including reference to the accompanying drawings which: Figure 1: Is a substantially diagrammatic partially cut away perspective view of a typical mattress configuration incorporating the resilient member of the invention.

IimiT' ' rci'JAL PROPERTY CT. ICE OF NZ. 1 5 DEC 2G90 Figure 2: Is a substantially diagrammatic cross sectional view of a portion of the typical preferred mattress configuration of Figure 1, according to lines AA.

Figure 3: Is a substantially schematic plan view of a mattress according to the present invention showing schematic persons representing differing weight and dimension characteristics resting thereon.

Figure 4: Is a substantially schematic plan view of the mattress according to the present invention showing schematic persons representing differing weight and dimension characteristics resting thereon, in an alternative form of the invention.

Figure 5: Is a cross sectional view similar to that of Figure 2, showing alternative spring members to the compression spring members as depicted in Figure 2.

In the preferred embodiment of the invention, the resilient member 2 is foamed polyurethane or foamed latex having a density of between 15 kg per m3 and 40 kg per m3 and in the preferred for of the invention approximately 32 -33 kg per m3. Further, in the preferred form of the invention, the wire coil compression springs 7 are each provided of a diameter of between 40 mm and 80 mm and preferably approximately 50 - 55 mm, and of a length substantially similar to the depth of the bore 5 in the foam resilient member 2.

The bore 5 in the foamed resilient member 2 is provided to define an enclosure substantially to match the spring 7 sizes and in the preferred embodiment, the springs 7 are each from a rest state provided of a substantially similar characteristic having a common resilient bias such as at 25% deflection a bias or hardness of between 200 grams and 400 grams and preferably 300 grams. The spacing of the springs 7 relative to one another in the preferred embodiment varies between centre spacings of approximately 50 mm, to approximately 150 mm, dependent on the relation of spring 7 hardness and resilient member 2 foam density for example, where relatively high density foam is utilised, springs 7 can be decreased in their spacing one relative to the other, and where the foam density is lower, the springs can be positioned to situate closer one relative to the other, to thus "tune" the resilience of the mattress of a whole to the requirements of the user and to provide varying mattress resilient effects, utilising substantially common materials.

In this form the mattress 1 is intended for normal use situated above a supporting bed base in itself supported from a supporting service by legs and the like. The invention is not limited to this configuration, however, it is envisaged that in alternative arrangements the mattress 1 can be used without a bed base, supported on a slatted base or some other supporting structural arrangement.

The mattress 1 incorporates the primary resilient member 2 according to the invention, and is preferably formed as a block in either foamed rubber latex or foamed polyurethane as described hereinafter, which, after the positioning of appropriate spring members 7 is overlaid with appropriate padding materials such as spun dacron sheet and the like, and appropriate quilted ticking so as to present on an exterior, an appearance, configuration and feel as is desirable and required with a mattress construction.

Whilst this invention is described with reference to this configuration, the construction and arrangement is not limited to the methods and materials utilised and in alternative arrangements it is envisaged that other materials and techniques can be utilised within the scope or spirit of the invention as defined in the appended claims.

Turning now to the drawings and in particular Figure 1, the / mattress as indicated by arrow 1 is preferably arranged with a primary resilient member 2 as an inner core and providing the primary resilient unit for the mattress 1. In the preferred form of the invention, the resilient member 2 is provided as a block of foamed rubber latex material, substantially as a block having side edges 3 defining the basic perimeter area of the mattress 1 and providing at least one supporting upper surface 4.

In the preferred form of the invention, the resilient member 2 is substantially double sided, thus reducing the need to ensure its orientation during manufacture, however, in alternative forms of the invention, the resilience of the resilient member 2 may be variable from one surface to the other by either foam density or thickness or both, thus enabling accommodation of user preferences.

Referring now to Figures 1 and 2, the resilient member 2 in the preferred form of the invention is preferably provided with a plurality of transverse bores 5 arranged at predetermined intervals across the resilient member 2 between the normal mattress support sides preferably in rows R, such that the web portion 6 is created between each bore 5.

The resilient member is preferably formed with a series of bores spaced thereacross and oriented so as to extend a longitudinal axis thereof, from adjacent one intended mattress side, to the substantially opposite side. The method and apparatus of the present invention facilitates the "posturisation" of the mattress 1 to provide a varying resilience for the resilient member 2, substantially as shown, particularly with reference to Figure 3. The spacing and layout of the bores 5 are variable according to predetermined arrangements and preferably according to measurements taken from the intended user of the bed, thus enabling a bed to be specifically manufactured to the particular users requirements, and to enable, for example, a double mattress to be posturised to suit the weight, physical dimension and comfort characteristics/requirements of the intended users, by for example providing varying resilience for the resilient member 2 over its normal support area as outlined hereinafter.

The web portions 6 are provided to be of relatively narrow thickness with the bores 5 closely spaced. In one form of the invention, the resilient member 2 is formed with a series of blind bottomed, open topped bores 5 therein, such that the bores 5 form in the resilient member a series of open topped pockets into which compression springs 7 are positioned.

In the preferred form of the invention, preferably the resilient member 1 is provided from a blank of foamed polyurethane of the required dimensions, which is drilled according to variable spacing dimensioning to provide the bores 5 extending there through, as shown in the drawings.

The compression springs 7 are each provided in the preferred form as metal wire coil springs 7 of a diameter to each fit snugly within a bore 5 with their axes substantially parallel with the axis of the bore 5 and of a length, such that ends of the springs 7a are situated adjacent both the bottom and the top of the bore 5. Tips 8 of the wire from which the spring 7 are formed are preferably oriented inwardly of the springs 7 so as to prevent the spring 7 from engaging into the adjacent foamed material in use, and perhaps becoming engaged therewith.

The resilient member 2 substantially encloses the compression springs 7 in the bores 5 by an overlay member 9 engaged thereover. The overlay member 9 is preferably arranged on each side of the apertured portion as a sheet of similar material to the material from which the remaining portions of the resilient member 2 are manufactured. In the preferred form of the invention, a flexible mesh reinforcement overlay sheet 9a is sandwiched between the overlay member 9 and the opposing surfaces of the apertured portion to spread any load imposed on the assembly as the surface of the mattress 1 is deflected in a manner as to compress the resilient member 2 in use. The overlay member 9 and flexible mesh sheet 9a is secured with the opposing surface of the remaining portions of the resilient member via an adhesive, welding (for example radio frequency welding) or the like. In the preferred form of the invention, the flexible mesh overlay 9a is formed in mesh monofilament extrudent plastics material, for example nylon or the like, however, this composition is not essential to the invention.

The spring members 7 are thus substantially encapsulated within, and are thus at least partially supported by, the bores 5, with their ends 7a substantially adjacent opposing surfaces of the ends of the bores.

Upon a person lying on the mattress, or otherwise the mattress being exposed to an inward deflection force, both the springs 7 and the remaining foamed resilient portions of the resilient member 2 will provide a return bias. Each of the springs 7 are able to operate independently of one another and yet will be separated from one another by their independent enclosure each in one bore 5.

To posturise the resilient member 2, and thus the resultant mattress 1, the manufacturer predetermines a spacial positioning of the bores 5 relative to one another, substantially as diagrammatically shown in Figure 3. With reference to Figure 3, preferably the surface area of a double mattress is notionally divided up into a plurality of regions 20. Although not essentially, the support surface of the mattress is conceptually arranged with an X axis which in this form extends through an intended head 21 and foot 22 of the mattress and a Y axis which extends through opposing side edges 23 of the mattress 1.

Furthermore, according to the Y axis the mattress is conceptually divided up into one or a number of regions as shown by the broken lines A, B, C and D, which regions are also potentially able to be varyingly rn ■ rcruAL property 0""IC: OF NZ. 1 5 DEC 2000 arrariged on the X axis for intended users (in the case of a double mattress), being a first user area 24, and a second user area 25.

The preferred embodiment of the invention provides for the use of standard resilience spring members 7 and variability in spacing of the bores 5 in the resilient member 2 which is probably of a standard resilience or density, to thus conveniently "posturise" the regions of the mattress to suit the intended user on one or both of the X and Y axes, and in particular, in the regions, for example, regions A, B, C and D defined.

It will be appreciated that by varying the spacing of the spring members 7 one relative to the other, varying resilience characteristics of the mattress 1 can be achieved to suit both dimensional and physical characteristics of the user and the users specific comfort requirement. Where a user is at a higher level of weight the spacing of the spring members 7 and bores 5 will be arranged to be relatively closer on either the X axis or the Y axis or both, so as to provide a greater resilient bias overall for the mattress 1, relative to bore 5 and spring member spacing 7 utilised for a person at a lower level of weight. As an example and with reference to figure 3, utilising a common density foam resilient member 2, should a user have greater mass and therefore weight in a shoulder and hip region, the spacing of the spring members 7 in the bores 5 relaive to each other can be reduced in the regions B and C so as to provide an additional resilient bias for the mattress in that region, such that when the mattress 1 is deflected under the weight of the person resting upon the mattress, the mattress will provide additional support in those regions B and C for the weight as is shown in Figure 3.

In a further example, and with reference to figure 4, should a user have a large frame, and a wider hip region relative to a shoulder region, it is envisaged that the resilient member 2 forming the mattress may be provided in a more dense foam material, providing greater resilient bias on deflection than the example described with reference to figure 3, and for example the spacing of the spring members 7 in the bores can be increased to reduce the resilient bias of the mattress 1 in the regions B and C, to thus enable greater deflection of those regions in use, to reduce pressure upon those parts of the users body, and for example, to enable the users spine to remain relatively straight when resting thereon. In this form of the invention, it would be appreciated that greater reliance is placed upon the resilience of the foam, in the regions B and C, whereas in region A and D, greater reliance is placed upon the springs 7.

Whilst the invention provides for posturisation of the mattress 1 in one preferred embodiment of the invention by the spacing of the spring members 7 and the bores 5 relative to one another, in alternative arrangements of the invention it is envisaged that in addition, even further flexibility of posturisation could be achieved by variation in spring resilience characteristics as well, however this leads to significantly increased cost and complication in manufacture.

The resilient member 2 is formed by initially boring the apertures 5 into a block of resilient foamed material arranged substantially in the intended size of the mattress. Preferably edge portions thereof are arranged to have a substantially higher density foamed material portions arranged peripherally thereabout, substantially as is shown by Figures 2 and 4. Preferably the bores 5 are blinded on one side by the attachment of the overlay member 9 to one side of the apertured portion of the resilient member 2, although, in an alternative arrangement it is envisaged that the bores 5 may be bored or otherwise formed so as to be substantially blind when created, for example, by leaving a portion of the opposing surface from that which is bored, unbored and by removing the bored material from the created blind bore 5.

Thereafter, the springs 7 are inserted so that they snugly fit into the bores 5, with a first end portion 7a substantially adjacent the blinded or blind end and the opposite end portion 7a substantially aligned with the open top of the bore 5 within which it is engaged.

Thereafter, suitable adhesives or other attachment means are utilised to secure a second overlay member 9 on the opposite side of the resilient member 2 to the first overlay member 9 used to initially blind the bores 5 to substantially close the open topped bores 5, enclosing the springs 7 therein.

In this form of the invention, preferably the thickness of the foam overlay member 9 is preferably substantially similar on both sides, however in alternative forms of the invention, perhaps where alternative surface softness is required and the like. Further, it is anticipated that varying density laminates of additional resilient material can be provided over the surface of the mattress incorporating a layer of greater density foamed material immediately adjacent the spring ends 7a, but with lesser density foamed material outwardly thereof, to thus enhance the surface softness and tactile nature of the mattress surface.

Additionally, in certain instances, and over a predetermined area of the resilient member 2 side edge additional reinforcement 10 for the side edge, may be provided as shown in Figure 2 for example by securing stiffening means for the mattress side edge in the form of stiffening sheet material 10, for example sheet plastics material secured via adhesives and the like to the surface of the side edge at predetermined intervals therealong, spanning between a junction of the side edge and upper and lower surfaces of the resilient member 2. It will appreciated that such configurations will provide additional stiffness yet retain some flexibility of the mattress 2 in that area, and thus enable the mattress 2 to resist a tendency to feel as though it has a "soft edge" or create a "roll off" feel in use.

The invention has been described with reference to the preferred form of the invention incorporating a spring member 7 arranged as a metal wire coil compression spring of substantially helical configuration.

The invention is not limited to this configuration, and as shown in Figure 4, it is envisaged that the spring member 7 may be alternatively provided, for example as a resilient airbag 7b having a deflectable or elastic periphery, or alternatively, a "slug" of resilient material 7c of differing predetermined characteristics of resilience to the bore 5 defining portion thereof.

Notwithstanding that posturisation has been achieved in some sense with prior art arrangements utilising varying spring strengths or deflection resilience, such prior art arrangements are relatively complicated, time consuming and expensive to perform. It has been found by the applicant that a somewhat similar posturisation effect can be achieved harnessing adjustments in the spacing of secondary resilient means in association with a primary common or standard resilient means to provide a significantly more efficient, economic, cost effective and efficient method of mattress core production less prone to "rate limiting" steps and enabling volume production to be tailored or tuned at least to some extent to the specific requirements of the person or class of persons for whom the mattress is intended.

It will be appreciated that by this invention there is provided a mattress 1 resilient member 2 configuration which provides some of the best features of both a spring armature and a foam core resilient member and provides a simple and convenient method for manufacture of a mattress 1 where the objectives of efficiency in manufacture and performance and longevity in use are achieved.

One significant additional advantage of the present invention over prior art arrangements is that the primary resilient member of the mattress, once ticking or coverings are removed, is readily able to be reduced to recyclable components, for example by passing through an appropriate shredding device. The shredded residue will comprise readily recyclable resilient foam material, and relatively simply separable discrete portions of metal, both of which can be relatively simply recycled, or reconstituted according to known techniques.

Whilst this invention has been described with reference to the preferred embodiment, modifications are envisaged and may be incorporated without departing from the scope or spirit of the invention as defined in the appended claims. )^>

Claims (33)

WHAT WE CLAIM IS:

1. A posturised mattress (as herein defined) including a first resilient member supporting at least partially a plurality of second resilient members, wherein said posturised mattress has a predetermined variation of resilience characteristics across said posturised mattress.

2. The posturised mattress as claimed in Claim 1 wherein the predetermined variation of resilience characteristics across said posturised mattress is achieved by: (a) predetermined variable spatial positioning of said plurality of second resilient members across said first resilient member; or (b) predetermined resilience variation of individual, or groups of individual, second resilient members across said first resilient member; or (c) a combination of (a) and (b).

3. A posturised mattress as claimed in Claim 2 wherein the second resilient members are spatially positioned relative to one another in at least two directions.

4. A posturised mattress as claimed in any one of the preceding claims wherein at least two regions of differing resilience characteristics are provided over the mattress.

5. A posturised mattress as claimed in Claim 4 wherein the resilience of said first resilient member and the resilience of said second resilient members differ.

6. A posturised mattress as claimed in any one of the preceding I !^T1< LECfl'AL PIOPi.TTY I CY1C2 OF N Z. I | 1 5 DEC 2G00 -16- claims wherein the positioning of said second resilient members is arranged to be relatively closer together in areas where the mattress is intended for greater use deflection and is arranged to be relatively less close together, in areas where the mattress is intended for lesser use deflection.

7. A posturised mattress as claimed in any one of claims 1 to 5 wherein the positioning of said second resilient members is arranged to be relatively wider apart in areas where the mattress is intended for greater use deflection and relatively closer together, in areas where the mattress is intended for lesser use deflection.

8. A posturised mattress as claimed in any one of the preceding claims wherein the first resilient member includes apertures and is formed from a resilient foamed material and wherein said secondary resilient members are compression spring means adapted to be at least partially enclosed within the apertures of said first resilient member and oriented substantially perpendicular to an intended supporting surface of said mattress, whereby adjacent portions of said spring means abutt adjacent aperture surfaces of said first resilient member at least when said mattress compressed by use.

9. A posturised mattress as claimed in Claim 8 wherein the secondary resilient member in a rest state substantially equates with the length of the aperture in the primary resilient member in a rest state, within which the secondary resilient member is enclosed.

10. A posturised mattress as claimed in any one of the preceding claims wherein the secondary resilient member is a metal wire coil spring.

11. A posturised mattress as claimed in Claim 10 wherein at least one end of the wire forming said coil spring is turned inwardly of the spring away from the adjacent spring end portion. rCi1'AL PfiOrcRTY I 0"rl^ OF N.Z. 1 5 DEC 2G00 P r-, ^ ^ ^ 7 ^ I U .A L ^ . . 1 J / \ /

12. A posturised mattress as claimed in any one of Claims 1 to 8 wherein the secondary resilient means is a resilient fluid filled bag.

13. A posturised mattress as claimed in any one of the preceding claims wherein the first resilient member is formed from foam latex and/or foamed polyurethane.

14. A posturised mattress as claimed in any one of the preceding claims wherein the secondary resilient member is substantially enclosed within the periphery of said first resilient member.

15. A posturised mattress as claimed in any one of the preceding claims wherein said second resilient members are pre-determinedly arranged over said first resilient member and said first resilient member and said second resilient members are adapted to define in said mattress at least two regions of differing resilience under deflection.

16. A posturised mattress as claimed in any one of the preceding claims wherein the positioning of said second resilient members relative to one another is adjusted relative to a set of predetermined patterns which take into account the physical characteristics of the person or class of persons for whom mattresses are to be posturised.

17. A posturised mattress as claimed in any one of the preceding claims wherein the first resilient means is a foamed material having a density of between about 15 kg per m3 and about 40 kg per m3.

18. A posturised mattress as claimed in any one of the preceding claims wherein the second resilient means has a resilient bias or hardness of between about 100 grams and about 400 grams at 25% deflection.

19. A posturised mattress as claimed in any one of the preceding claims INTELLECTUAL PROPERTY OEFICE OF NZ. 1 5 DEC 2GQ3 r> -a n t U O J. 1 .1 U . CV -18- wherein at least one side portion of said first resilient member is reinforced to provide a region of increased firmness relative to remaining portions thereof.

20. A posturised mattress as claimed in Claim 19 wherein said reinforced side portion is provided as a region of greater density in the foamed material forming said primary resilient member.

21. A posturised rriattress as claimed in Claim 19 or Claim 20 wherein said reinforcement is provided in the form of a panel of flexible material secured adjacent a side edge of the primary resilient member.

22. A method of posturisation (as herein defined) of a mattress including the steps of: forming a primary resilient member in a first resilient material, forming a plurality of apertures in said first resilient member and positioning a plurality of second resilient members in said apertures in a predetermined pattern to account for the physical characteristics of the person or class of persons for whom the mattress is intended.

23. The method claimed in Claim 22 including the step of spacing the apertures and the second resilient members one relative to the other by reference to data taken from the physical characteristics of a person or class of persons for whom the mattress is intended.

24. The method as claimed in Claims 22 or 23 including the step of predetermining a range of spacings for said apertures and secondary resilient members one relative to the other over at least two regions of said mattress and varying said spacing in said at least two regions.

25. The method as claimed in any one of Claims 22 to 24 including the step of establishing a set of predetermined spacings of said I •' ,-n FC'L'AL PROi-ZRTY « O.TICE OF NZ. j 1 5 DEC 2GG0 | -19- apertures and said secondary resilient members which account for differing physical characteristics of persons or classes of persons for whom mattresses are intended, and arranging the spacing of said apertures and said secondary resilient members in a mattress which most closely approximates said predetermined spacings.

26. A method of posturisation (as herein defined) of a mattress including the steps of: forming a first resilient member in a first resilient material, forming a plurality of apertures in said first resilient material, and positioning a plurality of second resilient members in said apertures, wherein said second resilient members have varying resilience and are positioned in a predetermined manner dependent on resilience.

27. A posturised mattress (as herein described) including a first resilient member supporting at least partially a plurality of second resilient members, wherein the resilience of said first resilient member and the resilience of said second resilient members differ across said mattress, and said mattress has a predetermined variation of resilience across said mattress.

28. The posturised mattress according to claim 27 wherein the resilience of individual, or groups of individual, second resilient members differs across said posturised mattress.

29. The mattress according to claim 27 or 28 wherein the spatial positioning of said apertures and said second resilient members varies across said first resilient member.

30. Apparatus substantially as hereinbefore described with particular reference to any one or more of Figures 1, 2 and 3 of the accompanying drawings. ^ 0 c % -20-

31. Apparatus substantially as hereinbefore described with particular reference to Figure 4 of the accompanying drawings.

32. Apparatus substantially as hereinbefore described with particular reference to Figure 3 of the accompanying drawings.

33. A method of posturising a mattress substantially as herein described with particular reference to the drawings. SLEEPYHEAD MANUFACTURING COMPANY LIMITED By their Attorneys PSPEC19230 END OF CLAIMS