NZ721444A - Configurable Multi-Layer Mattress - Google Patents

Abstract

configurable multi-layer mattress that provides for different firmness “feels” depending on the raw material composition of each layer, the nature of the engineered fabrication of each layer and the orientation and relative position of each layer. Two or more layers of different materials, physical design, or both are easily stacked together by end-users in different configurations to provide for different firmness “feels” of the resulting mattress. Individual layers may have a different firmness overall as well as a different firmness for each of its sides. An interior cover may secure some or all of the layers together for easier reconfiguring and durability and to form a complete mattress interior structure and reduces or eliminates the need for harmful adhesives. Further the mattress interior may be split down the middle such that specific firmness “feel” configuration can be made different for one side of the mattress from the other. al design, or both are easily stacked together by end-users in different configurations to provide for different firmness “feels” of the resulting mattress. Individual layers may have a different firmness overall as well as a different firmness for each of its sides. An interior cover may secure some or all of the layers together for easier reconfiguring and durability and to form a complete mattress interior structure and reduces or eliminates the need for harmful adhesives. Further the mattress interior may be split down the middle such that specific firmness “feel” configuration can be made different for one side of the mattress from the other.

Description

Configurable Multi-Layer Mattress Background of the Invention Field of the invention: This invention relates to the general field of mattresses, and more specifically toward a configurable multi-layer mattress that provides for different firmness “feels” depending on the orientation and relative position of each layer within the mattress. Two or more layers of different materials, physical design, or both are easily stacked together by end- users in different configurations to provide for different firmness “feels” for the resulting mattress. Individual layers may have a different firmness overall as well as a different firmness for each of its sides. An interior cover may secure the layers together to enhance durability and to form the complete mattress while reducing or eliminating the need for harmful adhesives.

Various foam, memory foam, Latex and wire micro-coils mattresses previously known in the marketplace claim to be “perfect for everyone” or a “one firmness feel that fits all” product.

Unfortunately, people have different sleep requirements and desires, sometimes quite extreme differences, that make a single firmness of a mattress unfit for many users, much less everyone.

On the other hand, there is a benefit to manufacturers, distributors, and retailers in limiting the physical number of product stock keeping units (SKUs). Marketing a single product is more cost effective than multiple different products. Logistics are more easily managed with fewer SKUs.

It is also difficult for consumers to determine what is in a prefabricated mattress.

Traditional mattress purchases are generally blind purchases, raising considerable doubt over what is really inside the mattress. A consumer may travel to a store, lay on top of various different mattresses for a few minutes each, before deciding on which mattress to purchase. The mattress is then delivered to the consumer’s home. The mattress is enclosed with its outer cover, and the consumer must rely on the honesty and integrity of a salesperson as to what makes up the mattress and how it was made.

Thus there has existed a long-felt need for a mattress that can be configured to a consumer’s potentially changing needs and preferences as well as for a greater transparency into what makes up the mattress and how the mattress is made.

Summary of the Invention The current invention provides just such a solution by having a configurable multi-layer mattress interior that provides for different firmness “feels” depending on the orientation and relative position of each layer. Two or more layers of different raw materials, physical design, or both are easily stacked together by end-users in different configurations to provide for different firmness “feels” of the resulting mattress. Individual layers may have a different firmness overall as well as a different firmness for each of its sides. A cover secures the layers together to form the complete mattress and reduces or eliminates the need for harmful adhesives.

Particular embodiments of the foam mattress are designed to counter other various foam mattresses already in the marketplace that claim to be “perfect for everyone” or a “one firmness feel that fits all” product. A mattress according to particular embodiments of the current disclosure also provides for the inclusion of various mattress technologies in such a way that the consumer, by virtue of their having the opportunity for a “hands on” experience with these technologies during assembly, is able to confirm their existence.

Embodiments of the current disclosure also provide for a mattress that by virtue of the nature of its physical breakdown in a “ready to assemble” format allows for various different kinds of packaging that can reduce its packaged size as well as make it easier to handle.

The mattress according to embodiments disclosed herein allows for a large number of mattress designs based not only on builds that include state of the art raw materials, such as foam, memory foam, Latex, synthetic Latex and wire micro-coils but it also naturally accommodates fabricated mattress construction elements such as support balancing technology (SBT) and active response technology (ART) elements, putting them all (because of the ability to mix up in filed assembly configurations) to their highest potential consumer benefit. Key among the initial efforts to make good use of this potential is the inclusion of SBT construction elements to provide for soft, medium, and firm feels in one mattress. SBT construction elements provide for differing restoring forces, a more rapid immersion into the support surface, greater conformability due to enhanced point elastic performance and other improved physical support surface physics.

It is an object of the current disclosure to provide a single mattress that can be configured to provide soft, medium, and firm surfaces.

It is an additional object of the current disclosure to provide a mattress that can be configured independently on each sides of the mattress to accommodate side-by-side sleepers.

It is another object of the current disclosure to provide a mattress whose materials and configurations are visible to a user.

It is a further object of the current disclosure to provide a mattress that allows for various different kinds of packaging.

Various different kinds of packaging results from providing the mattress that can be broken down or delivered in a Ready To Assemble (RTA) format, where the separate packaging of discrete mattress components allows for a departure from packaging that is always, otherwise, a reflection of the rolled and compressed single rectangular, cubular shape.

Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.

Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration.

There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. The features listed herein and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.

Brief Description of the Figures The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of this invention.

Fig. 1 is a perspective view of a user removing a portion of a mattress from packaging according to selected embodiments of the current disclosure.

Fig. 2 is a perspective view of a mattress cover with a layer of the mattress rolled up according to selected embodiments of the current disclosure.

Fig. 3 is a perspective view of a user laying out a first layer of the mattress on top of a mattress cover according to selected embodiments of the current disclosure.

Fig. 4 is a perspective view of a user laying out a second layer of the mattress on top of a first layer of the mattress according to selected embodiments of the current disclosure.

Fig. 5 is a perspective view of a user closing a cover around the layers of a mattress according to selected embodiments of the current disclosure.

Fig. 6 is a perspective view of a user closing a fastener around the cover of a mattress according to selected embodiments of the current disclosure.

Fig. 7 is a side view of a user lying on a mattress according to selected embodiments of the current disclosure.

Fig. 8 is a partial side view of three configurations of a layered mattress according to selected embodiments of the current disclosure.

Detailed Description of the Invention Many aspects of the invention can be better understood with the references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings.

In a particular embodiment, a mattress is provided that has two layers and a mattress cover. Each layer has a different firmness overall and, potentially, a different firmness depending upon its orientation to the user and other layer. Figs. 1 – 6 show a sequence of steps of removing and assembling a mattress according to selected embodiments of the current disclosure.

Fig. 1 is a perspective view of a user removing a portion of a mattress from packaging according to selected embodiments of the current disclosure. A user may receive the mattress system in packaging that is relatively easy to transport by a single individual. The user can then remove the various parts of the mattress system from the packaging. As shown in this figure, the user is removing the cover 10 from the packaging 90, where the cover is rolled up. The user may also remove the first layer 20 and second layer (not shown in this figure).

The cover as shown and described herein is an internal cover, that is, a cover that surrounds the multiple layers of the mattress, but is not necessarily intended to be visible to consumers during normal, every day use of the mattress.

Fig. 2 is a perspective view of a mattress cover with a layer of the mattress rolled up according to selected embodiments of the current disclosure. The cover 10 is laid out upon a bed surface, such as a box spring or bed frame. On top of the cover 10 is the first layer 20 that is still rolled up.

Fig. 3 is a perspective view of a user laying out a first layer of the mattress on top of a mattress cover according to selected embodiments of the current disclosure. The user unrolls the first layer 20 on top of the cover 10.

Fig. 4 is a perspective view of a user laying out a second layer of the mattress on top of a first layer of the mattress according to selected embodiments of the current disclosure. The user unrolls the second layer 30 on top of the first layer 20.

Fig. 5 is a perspective view of a user closing a cover around the layers of a mattress according to selected embodiments of the current disclosure. The second layer 30 resides on top of the first layer 20. The cover 10 is pulled over the two layers.

Fig. 6 is a perspective view of a user closing a fastener around the cover of a mattress according to selected embodiments of the current disclosure. The user fastens the cover 10 with fastener 11 over the first layer and second layer. The first layer 20 is still visible in this figure.

The fastener 11 is a zipper as shown in this figure; however, other fasteners are possible without departing from the scope of the current disclosure, including without limitation buttons, snaps, hook and loop fasteners, and magnets.

Fig. 7 is a side view of a user lying on a mattress with the cover removed according to selected embodiments of the current disclosure. The user is resting upon the second layer 30, oriented in an upward direction. The second layer 30 is resting upon the first layer 20.

Fig. 8 is a partial side view of three configurations of a layered mattress according to selected embodiments of the current disclosure. The firmness of the mattress is determined by the configuration of the layers. In a particular embodiment, the first layer 20 is a layer made to provide a relatively firm surface.

The second layer 30 can provide for a first firmness on one side, and a second firmness on the other side. This can be achieved in different manners. In one embodiment, the second layer is made from a continuous material with one side that has an irregular surface that provides for a softer feel. The side without the irregular surface provides a firmer feel. The irregular surface has portions of the surface that are removed to decrease the support (firmness) provided by that surface, such as SBT and ART configurations. In another embodiment, the second layer is made from multiple materials that provide a firmness on one surface that is greater than the second, opposing surface.

For a softer feeling mattress, in other words less firm, the first layer 20 (firmest layer) is placed below the second layer 30. The softer side of the second layer 30 is oriented upward, while the firmer side of the second layer 30 is oriented downward and is adjacent to the first layer 20.

For medium firmness, the first layer 20 is still placed below the second layer 30.

However, in this configuration, the second layer 30 is flipped over such that the firmer side of the second layer 30 is oriented upward, while the software side of the second layer 30 is oriented downward and is adjacent to the second layer.

For a firm mattress, the second layer 30 is now placed below the first layer 20, where the user sleeps proximate to a surface of the first layer. If the first layer 20 has a relatively high firmness, then the orientation of the second layer 30 (whether the softer side is oriented upward or downward) is of little consequence. However, if the first layer 20, while firmer than the second layer 30, does not have a relatively high firmness, then the orientation of the second layer may have an impact on the overall firmness of the mattress. As will be appreciated, orienting the softer side of the second layer 30 upwards such that it is adjacent to the first layer 20 will result in a slightly softer feel, while orienting the firmer side of the second layer 30 upwards such that it is adjacent to the first layer 20 will result in a slightly firmer feel.

SBT and ART provide for cut and/or fabricated flexible polyurethane foam mattress construction elements (non-latex and non-memory foam elements) that, by way of their specific surface shapes and the behavior of these shapes under compression, mimic the load bearing and finished mattress “feels” characteristic of memory foam or latex, synthetic latex and micro coil materials, respectively.

Another embodiment of the current disclosure includes a multilayered mattress system with three layers: a first layer that is the firmest, a second layer that is the softest, and a third layer that is firmer than the second layer yet softer than the first layer. Using these three layers, users can configure a mattress to their particular taste by varying the order in which the layers are stacked.

Further, it should be appreciated that where the configured multi-layer mattress is made up of sheets or layers other than flat planner sheets of any raw material, for example where fabricated layers such as SBT and ART elements are used, there is a significant increase in point elastic performance of the resulting surface. Such a surface provides the physics that, compared to other surface configurations, are flat with a high degree of area elastic behavior. For example, the two compared surfaces have significantly different surface tension, which represents the significant basis for consumers to clearly different firmness “feels.” Many times, consumers will have difficulty determining the difference between one support surface and another where the surfaces are merely different materials, particularly in lower compression resistant memory foam.

It should be understood that while the preferred embodiments of the invention are described in some detail herein, the present disclosure is made by way of example only and that variations and changes thereto are possible without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims I regard as my invention.

Claims (20)

CLAIMS 1. That which is claimed:

1. A mattress comprising a first layer, where the first layer has a firmness; a second layer, where the second layer has a first side and an opposing second side, where the first side has a firmness, where the second side has a firmness, where the firmness of the first side is greater than the firmness of the second side; and a cover, where the cover encloses the first layer and the second layer; where the firmness of the first layer is greater than the firmness of the first side of the second layer.

2. The mattress of claim 1, wherein the second side of the second layer has a surface, where portions of the surface are removed from the second side, where the removal of portions of the surface of the second side of the second layer reduces the firmness of the second side of the second layer relative to the first side of the second layer.

3. The mattress of claim 1, wherein the first side of the second layer comprises a material, where the second side of the second layer comprises a material, where the material of the first side of the second layer is different than the material of the second side of the second layer.

4. The mattress of claim 1, wherein the first layer is positioned below the second layer.

5. The mattress of claim 4, wherein the first side of the second layer is adjacent to the first layer.

6. The mattress of claim 4, wherein the second side of the second layer is adjacent to the first layer.

7. The mattress of claim 1, wherein the second layer is positioned below the first layer.

8. The mattress of claim 1, wherein the first layer consists of a single continuous piece of material.

9. The mattress of claim 1, further comprising a third layer, where the third layer has a firmness, where the firmness of the third layer is different than the firmness of the first layer, the first side of the second layer, and the second side of the second layer.

10. The mattress of claim 9, wherein the firmness of the third layer is less than the firmness of the first layer, and where the firmness of the third layer is greater than the firmness of the first side of the second layer.

11. A method of using a mattress comprising the steps of laying out a first layer of the mattress on top of a mattress cover, where the first layer has a firmness; laying out a second layer of the mattress on top of the first layer of the mattress; where the second layer has a first side and an opposing second side, where the first side has a firmness, where the second side has a firmness, where the firmness of the first side is greater than the firmness of the second side, and where the firmness of the first layer is greater than the firmness of the first side of the second layer; and closing the mattress cover around the first layer and second layer of the mattress.

12. The method of claim 11, wherein the second side of the second layer has a surface, where portions of the surface are removed from the second side, where the removal of portions of the surface of the second side of the second layer reduces the firmness of the second side of the second layer relative to the first side of the second layer.

13. The method of claim 11, wherein the first side of the second layer comprises a material, where the second side of the second layer comprises a material, where the material of the first side of the second layer is different than the material of the second side of the second layer.

14. The method of claim 11, wherein the first side of the second layer is adjacent to the first layer.

15. The method of claim 11, wherein the second side of the second layer is adjacent to the first layer.

16. A method of using a mattress comprising the steps of laying out a first layer of the mattress on top of a mattress cover, where the first layer has a first side and an opposing second side, where the first side has a firmness, where the second side has a firmness, where the firmness of the first side is greater than the firmness of the second side; laying out a second layer of the mattress on top of the first layer of the mattress; where the second layer has a firmness, and where the firmness of the second layer is greater than the firmness of the first side of the first layer; and closing the mattress cover around the first layer and second layer of the mattress.

17. The method of claim 16, wherein the second side of the first layer has a surface, where portions of the surface are removed from the second side, where the removal of portions of the surface of the second side of the first layer reduces the firmness of the second side of the first layer relative to the first side of the first layer.

18. The mattress of claim 1, wherein the first side of the first layer comprises a material, where the second side of the first layer comprises a material, where the material of the first side of the first layer is different than the material of the second side of the first layer.

19. A mattress consisting of a first layer, where the first layer has a firmness; a second layer, where the second layer has a first side and an opposing second side, where the first side has a firmness, where the second side has a firmness, where the firmness of the first side is greater than the firmness of the second side; and a cover, where the cover encloses the first layer and the second layer; where the firmness of the first layer is greater than the firmness of the first side.

20. The mattress of claim 19, wherein the second side of the second layer has a surface, where portions of the surface are removed from the second side, where the removal of portions of the surface of the second side of the second layer reduces the firmness of the second side of the second layer relative to the first side of the second layer.