US20070044245A1 - Mattress with triple zone topper - Google Patents

Mattress with triple zone topper Download PDF

Info

Publication number
US20070044245A1
US20070044245A1 US11/218,230 US21823005A US2007044245A1 US 20070044245 A1 US20070044245 A1 US 20070044245A1 US 21823005 A US21823005 A US 21823005A US 2007044245 A1 US2007044245 A1 US 2007044245A1
Authority
US
United States
Prior art keywords
topper
mattress
upper surface
zones
base unit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/218,230
Inventor
Steve Bryant
Maury O'Brien
Ross Olinski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SPRING AIR INTERNATIONAL LLC
Original Assignee
Spring Air Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Spring Air Co filed Critical Spring Air Co
Priority to US11/218,230 priority Critical patent/US20070044245A1/en
Assigned to THE SPRING AIR COMPANY reassignment THE SPRING AIR COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BRYANT, STEVE, O'BRIEN, MAURY, OLINSKI, ROSS M.
Publication of US20070044245A1 publication Critical patent/US20070044245A1/en
Assigned to AMERICAN CAPITAL FINANCIAL SERVICES, INC., A DELAWARE CORPORATION reassignment AMERICAN CAPITAL FINANCIAL SERVICES, INC., A DELAWARE CORPORATION INTELLECTUAL PROPERTY SECURITY AGREEMENT TO THAT CERTAIN REVOLVING LOAN, NOTE AND EQUITY PURCHASE AGREEMENT Assignors: ACKERMAN MANUFACTURING COMPANY, A MISSOURI CORPORATION, ALABAMA BEDDING MFG. CO., INC., AN ALABAMA CORPORATION, AMERICAN BEDDING INDUSTRIES, INC., A FLORIDA CORPORATION, ASSOCIATED TRUCKING COMPANY, INC., AN ALABAMA CORPORATION, ATLAS BEDDING MANUFACTURING CORPORATION, A MASSACHUSETTS CORPORATION, CHATTAM & WELLS, INC., A DELAWARE CORPORATION, CONSOLIDATED BEDDING, INC., A DELAWARE CORPORATION, NATURE'S REST MARKETING, L.L.C., A DELAWARE LIMITED LIABILITY COMPANY, NATURE'S REST, INC., A FLORIDA CORPORATION, SPRING AIR -- MOUNTAIN WEST, INC., A UTAH CORPORATION, SPRING AIR BEDDING COMPANY, A GEORGIA CORPORATION, SPRING AIR CALIFORNIA-DELUXE BEDDING CO., INC., A CALIFORNIA CORPORATION, SPRING AIR MATTRESS COMPANY OF COLORADO, A COLORADO CORPORATION, SPRING AIR MATTRESS COMPANY, AN ARIZONA CORPORATION, SPRING AIR PARTNERS -- CALIFORNIA, INC., A NEW JERSEY CORPORATION, SPRING AIR PARTNERS -- NEW JERSEY, INC., A NEW JERSEY CORPORATION, SPRING AIR PARTNERS -- NORTH AMERICA, INC., A DELAWARE CORPORATION, SPRING AIR WEST, L.L.C., A WASHINGTON LIMITED LIABILITY COMPANY, THE SPRING AIR COMPANY, AN ILLINOIS CORPORATION, TSAC MERGER SUB, INC., AN ILLINOIS CORPORATION
Assigned to L&P FINANCIAL SERVICES, CO. reassignment L&P FINANCIAL SERVICES, CO. SECURITY AGREEMENT Assignors: ACKERMAN MANUFACTURING COMPANY, ALABAMA BEDDING MFG. CO., INC., AMERICAN BEDDING INDUSTRIES, INC., ASSOCIATED TRUCKING COMPANY, INC., ATLAS BEDDING MANUFACTURING CORPORATION, CHATTAM & WELLS, INC., CONSOLIDATED BEDDING, INC., NATURE'S REST MARKETING, L.L.C., NATURE'S REST, INC., SPRING AIR - MOUNTAIN WEST, INC., SPRING AIR BEDDING COMPANY, SPRING AIR CALIFORNIA-DELUXE BEDDING CO., INC., SPRING AIR MATTRESS COMPANY, SPRING AIR MATTRESS COMPANY OF COLORADO, SPRING AIR PARTNERS - CALIFORNIA, INC., SPRING AIR PARTNERS - NEW JERSEY, INC., SPRING AIR PARTNERS - NORTH AMERICA, INC., SPRING AIR PARTNERS - TEXAS, INC., SPRING AIR WEST, L.L.C., THE SPRING AIR COMPANY, TSAC MERGER SUB, INC.
Assigned to THE SPRING AIR COMPANY, SPRING AIR - MOUNTAIN WEST, INC., SPRING AIR MATTRESS COMPANY OF COLORADO, ALABAMA BEDDING MFG. CO., INC., ASSOCIATED TRUCKING COMPANY, INC., AMERICAN BEDDING INDUSTRIES, INC., CHATTAM & WELLS, INC., CONSOLIDATED BEDDING, INC., NATURE'S REST MARKETING, L.L.C., NATURE'S REST, INC., SPRING AIR CALIFORNIA-DELUXE BEDDING CO., INC., SPRING AIR PARTNERS - CALIFORNIA, INC., SPRING AIR PARTNERS - NEW JERSEY, INC., SPRING AIR PARTNERS - NORTH AMERICA, INC., TSAC MERGER SUB, INC., ATLAS BEDDING MANUFACTURING CORPORATION, ACKERMAN MANUFACTURING COMPANY, SPRING AIR BEDDING COMPANY, SPRING AIR MATTRESS COMPANY, SPRING AIR WEST, L.L.C. reassignment THE SPRING AIR COMPANY RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: AMERICAN CAPITAL FINANCIAL SERVICES, INC., L&P FINANCIAL SERVICES, CO.
Assigned to SPRING AIR PARTNERS - TEXAS, INC. reassignment SPRING AIR PARTNERS - TEXAS, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: L&P FINANCIAL SERVICES, CO.
Assigned to SPRING AIR INTERNATIONAL LLC reassignment SPRING AIR INTERNATIONAL LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ACKERMAN MANUFACTURING COMPANY, ALABAMA BEDDING MFG. CO., INC., AMERICAN BEDDING INDUSTRIES, INC., ASSOCIATED TRUCKING COMPANY, INC., ATLAS BEDDING MANUFACTURING CORPORATION, CHATTAM & WELLS, INC., CONSOLIDATED BEDDING, INC., NATURE'S REST MARKETING, L.L.C., NATURE'S REST, INC., SPRING AIR - MOUNTAIN WEST, INC., SPRING AIR BEDDING COMPANY, SPRING AIR CALIFORNIA-DELUXE BEDDING CO., INC., SPRING AIR MATTRESS COMPANY, SPRING AIR MATTRESS COMPANY OF COLORADO, SPRING AIR PARTNERS - CALIFORNIA, INC., SPRING AIR PARTNERS - NEW JERSEY, INC., SPRING AIR PARTNERS - NORTH AMERICA, INC., SPRING AIR PARTNERS - TEXAS, INC., SPRING AIR WEST, L.L.C., THE SPRING AIR COMPANY, TSAC MERGER SUB, INC.
Application status is Abandoned legal-status Critical

Links

Images

Classifications

    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/04Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
    • A47C27/05Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
    • A47C27/056Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers with different layers of foamed material
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/142Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
    • A47C27/144Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities inside the mattress or cushion
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/142Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
    • A47C27/146Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/148Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers

Abstract

A mattress comprises a base unit. A topper is supported above the base unit. The topper comprises an elongate rectangular body having a center zone joined between opposite end zones. The topper is of a select foam material of substantially uniform firmness and the center zone has a density greater than density of the end zones. A cover fabric layer surrounds the base unit and the topper.

Description

    FIELD OF THE INVENTION
  • This invention relates to an elongate topper or cushion in a mattress for supporting a recumbent human body and, more particularly, to a triple zone topper.
  • BACKGROUND OF THE INVENTION
  • A mattress, in its most basic form, comprises a base unit surrounded by a cover fabric layer. The base unit may be a conventional spring assembly having open coils secured internally and by upper and lower border wires. The spring assembly could alternatively include individual fabric pocketed coils and could eliminate the border wire. Another type of mattress, known as foam encased, includes a bottom foam layer. Four foam side walls are adhered to an upper surface of the bottom foam layer at its peripheral edges to provide a rectangular frame or box section. A support component, such as a spring assembly, foam, or the like, is loosely positioned in the box section. A top foam layer, pad or fiber, may be adhered to the tops of the side walls. With any of these designs, various layers of foam and/or upholstery fabrics may be included between the cover fabric layer and the base unit to provide varying degrees of comfort. Firmness of the mattress is generally determined by firmness of the base unit.
  • Various forms of foam cushions or pad, also known as toppers, have been integrated into mattress designs. Conventional mattress toppers may be traditional flat foam or may comprise convoluted cushions which reduces pressure points. An example of a convoluted foam cushion is shown in Nunez et al. U.S. Pat. No. 6,041,459, assigned to the assignee of the present application. The convoluted foam cushion described therein comprises an elongate rectangular body of uniform firmness and density including distinct comfort and support zones using different patterns of convolution.
  • The present invention is directed to further improvements in mattress design.
  • SUMMARY OF THE INVENTION
  • In accordance with the invention, there is provided a mattress including a topper having multiple zones of density and/or firmness.
  • There is disclosed in accordance with one aspect of the invention a mattress comprising a base unit. A topper is supported above the base unit. The topper comprises an elongate rectangular body having a center zone joined between opposite end zones. The topper is of a select foam material of substantially uniform firmness and the center zone has a density greater than density of the end zones. A cover fabric layer surrounds the base unit and the topper.
  • It is a feature of the invention that the topper is of polyethylene foam construction.
  • It is another feature of the invention that the topper has a planar bottom surface engaging the base unit and a convoluted upper surface.
  • It is a further feature of the invention that the convoluted upper surface has alternating peaks and valleys arranged in a checkerboard configuration.
  • It is yet another feature of the invention that the convoluted upper surface has a plurality of convolution zones providing different amounts of support.
  • It is still a further feature of the invention that the convoluted upper surface has a different convolution pattern in the center zone than in the end zones to providing different amounts of support.
  • It is yet a further feature of the invention that convoluted upper surface has at least five convolution zones providing different amounts of support.
  • It is an additional feature of the invention that the convoluted upper surface has seven convolution zones providing highest support in a central area and gradually decreasing support at longitudinal ends of the topper.
  • It is yet another feature of the invention that the topper has a planar bottom surface engaging the base unit and a planar upper surface having a plurality of upwardly opening slots in a grid pattern of a first size in the central zone and a second size in the end zones.
  • It is still another feature of the invention that the center zone has a density at least 25% greater than density of the end zones.
  • There is disclosed in accordance with another aspect of the invention a mattress comprising a base unit. A topper is supported above the base unit. The topper comprises an elongate rectangular body having a center zone joined between opposite end zones. The topper has a planar bottom surface engaging the base unit and a patterned upper surface. The center zone has a density greater than density of the end zones. A cover fabric layer surrounds the base unit and the topper.
  • Further features and advantages of the invention will be readily apparent from the specification and the drawings.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is an exploded, partial perspective view, with parts removed for clarity, of a mattress including a triple zone topper according to the invention;
  • FIG. 2 is a plan view of the topper of the mattress of FIG. 1;
  • FIG. 3 is a sectional view taken along a line 3-3 of FIG. 2;
  • FIG. 4 is a plan view of a mattress topper according to a first alternative embodiment of the invention;
  • FIG. 5 is a sectional view taken along the line 5-5 of FIG. 4;
  • FIG. 6 is a plan view of a mattress topper according to a second alternative embodiment of the invention;
  • FIG. 7 is a sectional view taken along the line 7-7 of FIG. 6; and
  • FIG. 8 is a plan view of a mattress topper according to a third alternative embodiment of the invention;
  • FIG. 9 is a sectional view taken along the line 9-9 of FIG. 8.
  • DETAILED DESCRIPTION OF THE INVENTION
  • Referring initially to FIG. 1, there is illustrated a mattress 10 including a foam pad or cushion, referred to herein as a topper, 12 according to the invention. Overall, the mattress 10 is generally conventional in construction and includes a base unit 14. In the illustrated embodiment of the invention, the base unit 14 comprises a conventional spring assembly having open coils secured internally and by upper and lower border wires. The base unit 14 could alternatively include individual fabric pocketed coils and could eliminate the border wire or comprise a foam encased mattress unit. The invention is not intended to be limited to any particular construction for the base unit. A plurality of lower fiber layers 16 rest on the base unit 14. The topper 12 sits on the lower fiber layers 16. Several additional upper fiber layers 18 are disposed between the topper 12 and a cover fabric layer 20. As is apparent, the cover fabric layer 20 surrounds the entire mattress 10.
  • As is apparent, the topper 12 can be used in various mattress configurations. The particular configuration illustrated in FIG. 1 is but one example of such a mattress. Also, the topper 12 could be provided as a separate unit which can be selectively placed atop a mattress. Moreover, the topper 12 could also be used as an insert layer in a quilt top mattress, such as a replacement for the insert layer shown in Nunez et al. U.S. Pat. No. 5,974,609, assigned to the assignee of the present application, the specification of which is incorporated by reference herein.
  • The topper 12 is configured to provide comfort and support to a human body, represented at B. As is apparent, different levels of comfort and support are advantageously provided for different portions of the body B. In accordance with the invention, the topper 12 is provided with three distinct zones providing different firmness and/or density and/or support.
  • Referring to FIG. 2, the topper 12 has a length L and width W. The length L is typically on the order of 79″. The width W varies according to the mattress size, such as twin, double, full, queen or king size. The topper 12 includes a first end zone 22 and a second end zone 24 on opposite ends of a center zone 26. Each zone 22, 24 and 26 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam. Each zone 22, 24 and 26 is made separately and then laminated together. Particularly, the first end zone 22 and center zone 26 are laminated together at a first joint 28. Similarly, the second end zone 24 and the center zone 26 are laminated together at a second joint 30. The joints 28 and 30 may comprise butt joints, or overlapping joints, or the like, as necessary or desired. In the illustrated embodiment of the invention, each zone 22, 24 and 26 has a similar firmness with the center zone 26 being of a higher density. For example, the topper 12 may have a firmness of 10 ILD (initial load deflection). The end zones 22 and 24 may have a density of about 1.2 lbs. per cubic foot, while the center zone 26 may have a density of about 3 lbs. per cubic foot. This provides greater cushioning durability in the center zone 26.
  • In an illustrated embodiment of the invention, each end zone 22 and 24 may have a length of about 24″, with the center zone 26 having a length of about 31″. The topper 12 includes a planar top surface 32 and an opposite planar bottom surface 34. The topper 12 may have a thickness on the order of about 1″. The end zones 22 and 24 being of identical construction, allows the mattress 10 to be turned so that either end zone 22 or 24 can be used as the head end or the foot end. As is apparent, the relative lengths of the zones 22, 24 and 26 could be varied to provide greater or lesser amounts of enhanced cushioning durability, as is apparent. Likewise, the firmness in the end zones 22 and 24 could be different from that in the center zone 26. Likewise, the density in each zone 22, 24 and 26 could be of a different amount from that mentioned above.
  • Referring to FIGS. 4 and 5, a topper 112 according to a first alternative embodiment of the invention is illustrated. For simplicity, the topper 112 will be described using reference numerals 100 higher than corresponding elements in the topper 12 of FIGS. 2 and 3.
  • The topper 112 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam, and includes a first end zone 122 and a second end zone 124 longitudinally separated by a center zone 126. The first end zone 122 is joined to the center zone 126 at a joint 128. The second end zone 124 is joined to the center zone 126 at a joint 130. The length and width of each zone 122, 124 and 126 is similar to those discussed with respect to the topper 12 discussed above. The topper 112 includes a generally planar top surface 132 and a generally planar bottom surface 134. The topper 112 has a thickness on the order of 2¼″. The firmness is substantially similar in each zone 122, 124 and 126, while the density in the center zone 126 is substantially greater than in the end zones 122 and 124. In an illustrative example, the end zones 122 and 124 have a firmness of 21 ILD and a density of 1.2 lbs. per cubic foot. The center zone 126 has a firmness of about 23 ILD and a density of about 1.65 lbs. per cubic foot. As is apparent, other firmness and densities could be used, including those discussed above relative to the topper 12.
  • The top surface 132 includes surface treatment in the form of a plurality of slots 140 cut through the top surface 132 in a grid pattern. A different set of slots 142 is cut through the top surface 132 of the center zone 126, also in a grid pattern. The slots 140 and 142 are about ½″ in depth. Grid spacing of the slots 140 in the end zones 122 and 124 is about 3″. Grid spacing of the slots 142 in the center zone 126 is about 6″. This provides greater cushioning support in the center zone 126.
  • Referring to FIGS. 6 and 7, a topper 212 according to a second alternative embodiment of the invention is illustrated. Again, for simplicity, the topper 212 uses reference numerals similar to those with respect to the embodiments of FIGS. 2 and 3 and 4 and 5, except being in the 200 number series.
  • The topper 212 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam, and includes first and second end zones 222 and 224 longitudinally separated from a center zone 226 by respective joints 228 and 230. The topper 212 includes a top surface 232 and a bottom surface 234. The bottom surface 234 is planar. The topper 212 differs in that the top surface 232 comprises a surface treatment in the form of a patterned convoluted surface. The top surface 232 includes what is known as “egg crate” convolutions throughout. Particularly, the convoluted top surface 232 has alternating peaks 240 and valleys 242 arranged in a checkerboard configuration. In this embodiment, each of the zones 222, 224 and 226 include a similar pattern of convolutions throughout.
  • Alternatively, the mattress topper 212 could include different convolution patterns in each of the zones, 222, 224 and 226. Indeed, the convolution patterns could be the same in the end zones 222 and 224, but different in the center zone 226. Alternatively, the convolutions could be zoned independently of the three different foam zones. For example, the top surface 232 could include seven zones of convolution as shown in U.S. Pat. No. 5,974,609, incorporated by reference above.
  • Referring to FIGS. 8 and 9, a topper 312 according to a third alternative embodiment of the invention is illustrated. Again, for simplicity, the topper 312 uses reference numerals similar to those with respect to the previous embodiments, except being in the 300 number series.
  • The principal difference between the topper 212 and the topper 312 is that a top surface 332 includes seven different zones of convolution. The convolutions are formed by alternating peaks 340 and valleys 342. The peaks 340 and valleys 342 are arranged in rows, with adjacent rows being staggered to form a checkerboard pattern, as is apparent. The topper 312 can be manufactured using conventional processes for convoluted foam cushions. In the illustrated embodiment of the invention, the peaks 340 have flat top surfaces. In an illustrative embodiment of the invention, the topper 312 has a height of about 2″ measured from the planar bottom surface 334 to the top of the peaks 340. The topper 312 has a base thickness of about 1½″ measured from the planar bottom surface 334 to the base of the valleys 342. The peaks 340 and valleys 342 are generally rectangular in shape, albeit having rounded edges, as is well known. The top surface 332 includes seven zones of convolution numbered 351, 352, 353, 354, 355, 356 and 357. The outermost zones 351 and 357 are similar. The next innermost zones 352 and 356 are similar. The next innermost zones 353 and 355 are similar. In the zones 351 and 357, the peaks and valleys have a lateral dimension of about 1″. In the zones 352 and 356, the peaks and valleys have a longitudinal dimension of about 2″. In the zones 353 and 355, the peaks and valleys have a longitudinal dimension of about 3″. Innermost zone 354 has peaks and valleys with a longitudinal dimension of about 5″ in length. As such, the center most convolution zone 354 provides the greatest amount of support, with support gradually decreasing moving longitudinally from the center convolution zone 354 to either end most convolution zone 351 or 357. As is apparent, the convolution zones do not and need not correspond to the three foam zones.
  • The topper 312 could alternatively be provided with a different number of convolution zones such as, for example, three zones or five zones. The borders of the convolution zones need not match up with the borders of the foam zones.
  • The invention is not limited to a particular type of surface treatment. Also, the surface treatment could be applied to the bottom surface. The surface treatment could be, for example, contoured, such as body contouring.
  • Each topper described herein can be constructed of polyurethane foam or of latex. Also, it could be formed of a visco-elastic memory foam.
  • Thus, in accordance with the invention, there is provided a triple zone mattress topper providing greater durability and support in a center zone compared to end zone.

Claims (20)

1. A mattress comprising:
a base unit;
a topper supported above the base unit, the topper comprising an elongate rectangular body having a center zone joined between opposite end zones, the topper being of a select foam material of substantially uniform firmness and the center zone having a density greater than density of the end zones; and
a cover fabric layer surrounding the base unit and the topper.
2. The mattress of claim 1 wherein the topper is of polyethylene foam construction.
3. The mattress of claim 1 wherein the topper has a planar bottom surface engaging the base unit and a convoluted upper surface.
4. The mattress of claim 3 wherein the convoluted upper surface has alternating peaks and valleys arranged in a checkerboard configuration.
5. The mattress of claim 3 wherein the convoluted upper surface has a plurality of convolution zones providing different amounts of support.
6. The mattress of claim 3 wherein the convoluted upper surface has a different convolution pattern in the center zone than in the end zones to providing different amounts of support.
7. The mattress of claim 3 wherein the convoluted upper surface has at least five convolution zones providing different amounts of support.
8. The mattress of claim 7 wherein the convoluted upper surface has seven convolution zones providing highest support in a central area and gradually decreasing support at longitudinal ends of the topper.
9. The mattress of claim 1 wherein the topper has a planar bottom surface engaging the base unit and a planar upper surface having a plurality of upwardly opening slots in a grid pattern of a first size in the central zone and a second size in the end zones.
10. The mattress of claim 1 wherein the center zone has a density at least 25% greater than density of the end zones.
11. A mattress comprising:
a base unit;
a topper supported above the base unit, the topper comprising an elongate rectangular body having a center zone joined between opposite end zones, the topper having a planar bottom surface engaging the base unit and a patterned upper surface, the center zone having a density greater than density of the end zones; and
a cover fabric layer surrounding the base unit and the topper.
12. The mattress of claim 11 wherein the topper is of polyethylene foam construction.
13. The mattress of claim 11 wherein the topper is of elastic memory foam construction.
14. The mattress of claim 11 wherein the upper surface is convoluted having alternating peaks and valleys arranged in a checkerboard configuration.
15. The mattress of claim 11 wherein the upper surface is convoluted having a plurality of convolution zones providing different amounts of support.
16. The mattress of claim 11 wherein the upper surface is convoluted having a different convolution pattern in the center zone than in the end zones to providing different amounts of support.
17. The mattress of claim 11 wherein the upper surface is convoluted having at least five convolution zones providing different amounts of support.
18. The mattress of claim 17 wherein the convoluted upper surface has seven convolution zones providing highest support in a central area and gradually decreasing support at longitudinal ends of the topper.
19. The mattress of claim 11 wherein the patterned upper surface has a plurality of upwardly opening slots in a grid pattern of a first size in the central zone and a second size in the end zones.
20. The mattress of claim 11 wherein the center zone has a density at least 25% greater than density of the end zones.
US11/218,230 2005-09-01 2005-09-01 Mattress with triple zone topper Abandoned US20070044245A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/218,230 US20070044245A1 (en) 2005-09-01 2005-09-01 Mattress with triple zone topper

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/218,230 US20070044245A1 (en) 2005-09-01 2005-09-01 Mattress with triple zone topper

Publications (1)

Publication Number Publication Date
US20070044245A1 true US20070044245A1 (en) 2007-03-01

Family

ID=37802014

Family Applications (1)

Application Number Title Priority Date Filing Date
US11/218,230 Abandoned US20070044245A1 (en) 2005-09-01 2005-09-01 Mattress with triple zone topper

Country Status (1)

Country Link
US (1) US20070044245A1 (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090089933A1 (en) * 2007-10-09 2009-04-09 Sealy Technology, Llc Pressure dispersion support systems
US20100325806A1 (en) * 2007-10-09 2010-12-30 Sealy Technology, Llc Pressure dispersion support systems
US20110067183A1 (en) * 2009-09-18 2011-03-24 Hawkins Steven D Cushioning device and method of manufacturing
EP2706888A1 (en) * 2011-05-12 2014-03-19 Sealy Technology LLC Tension relief foam and mattress constructions
US20160270546A1 (en) * 2015-03-17 2016-09-22 Richard Codos Mattress
US9504334B2 (en) 2014-05-19 2016-11-29 Welspun India Limited Ergonomic mattress pad with polyester fill
US9661932B2 (en) * 2015-03-17 2017-05-30 Richard Codos Mattress
US20170258242A1 (en) * 2015-03-17 2017-09-14 Richard Codos Spring Unit for a Mattress

Citations (26)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3210781A (en) * 1962-01-30 1965-10-12 Harold Van B Pollock Mattress
US3278955A (en) * 1964-06-11 1966-10-18 Dayco Corp Foam rubber article
US3521311A (en) * 1968-03-01 1970-07-21 Paul P Cohen Mattress
US3846857A (en) * 1972-03-10 1974-11-12 Neurological Res And Dev Group Multi-section variable density mattress
US4389743A (en) * 1981-06-22 1983-06-28 Simmons U.S.A. Corporation Mattress arrangement having a removable side-insertable center core structure
US4449261A (en) * 1981-06-22 1984-05-22 Simmons U.S.A. Corp. Bed mattress having an improved pillow top
US4706313A (en) * 1986-05-01 1987-11-17 Comfortex, Inc. Decubitus ulcer mattress
US5025519A (en) * 1986-10-22 1991-06-25 Span-America Medical Systems, Inc. Multi-section mattress overlay for systematized pressure dispersion
US5101527A (en) * 1990-10-29 1992-04-07 Convo Corporation Modular body support system
US5107558A (en) * 1990-07-11 1992-04-28 Lueck Werner Mattress with removable insert
US5136740A (en) * 1990-05-11 1992-08-11 Eugene Kraft Varying firmness mattress
US5303436A (en) * 1991-09-06 1994-04-19 Jay Medical, Ltd. Anti-decubing mattress pad
US5604021A (en) * 1994-12-23 1997-02-18 Ohio Mattress Company Licensing And Components Group Multi-layer support pad having regions of differing firmness
US5671492A (en) * 1995-03-14 1997-09-30 Simon; Keith Douglas Contoured asymmetrical mattress
US5701623A (en) * 1996-03-11 1997-12-30 Latex Foam Products, Inc. Composite mattress and mattress topper having a latex foam core
US5819349A (en) * 1991-08-20 1998-10-13 Schwartz; Jack Mattress
US5953779A (en) * 1996-06-05 1999-09-21 Schwartz; Jack Mattress assembly
US5960496A (en) * 1998-07-14 1999-10-05 Boyd; Dennis Mattress system
US6003179A (en) * 1997-11-18 1999-12-21 Farley; David L. Inclined anatomic support surface
US6055689A (en) * 1997-04-07 2000-05-02 Cavazos; Frank G. Modular mattress and innerspring
US20010054200A1 (en) * 1998-05-06 2001-12-27 Hill-Rom, Inc. Mattress or cushion structure
US6651283B1 (en) * 1998-08-24 2003-11-25 The Nautilus Group, Inc. Air bed
US6922863B2 (en) * 2001-03-07 2005-08-02 Gualtiero G. Giori Adjustable foam mattress
US20050210595A1 (en) * 2004-03-23 2005-09-29 Di Stasio Anthony A Mattress having reticulated viscoelastic foam
US20070113352A1 (en) * 2005-08-10 2007-05-24 Craig Poulos Therapeutic mattress
US20070157394A1 (en) * 2006-01-06 2007-07-12 Carl Pete Giggleman Therapeutic mattress

Patent Citations (26)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3210781A (en) * 1962-01-30 1965-10-12 Harold Van B Pollock Mattress
US3278955A (en) * 1964-06-11 1966-10-18 Dayco Corp Foam rubber article
US3521311A (en) * 1968-03-01 1970-07-21 Paul P Cohen Mattress
US3846857A (en) * 1972-03-10 1974-11-12 Neurological Res And Dev Group Multi-section variable density mattress
US4389743A (en) * 1981-06-22 1983-06-28 Simmons U.S.A. Corporation Mattress arrangement having a removable side-insertable center core structure
US4449261A (en) * 1981-06-22 1984-05-22 Simmons U.S.A. Corp. Bed mattress having an improved pillow top
US4706313A (en) * 1986-05-01 1987-11-17 Comfortex, Inc. Decubitus ulcer mattress
US5025519A (en) * 1986-10-22 1991-06-25 Span-America Medical Systems, Inc. Multi-section mattress overlay for systematized pressure dispersion
US5136740A (en) * 1990-05-11 1992-08-11 Eugene Kraft Varying firmness mattress
US5107558A (en) * 1990-07-11 1992-04-28 Lueck Werner Mattress with removable insert
US5101527A (en) * 1990-10-29 1992-04-07 Convo Corporation Modular body support system
US5819349A (en) * 1991-08-20 1998-10-13 Schwartz; Jack Mattress
US5303436A (en) * 1991-09-06 1994-04-19 Jay Medical, Ltd. Anti-decubing mattress pad
US5604021A (en) * 1994-12-23 1997-02-18 Ohio Mattress Company Licensing And Components Group Multi-layer support pad having regions of differing firmness
US5671492A (en) * 1995-03-14 1997-09-30 Simon; Keith Douglas Contoured asymmetrical mattress
US5701623A (en) * 1996-03-11 1997-12-30 Latex Foam Products, Inc. Composite mattress and mattress topper having a latex foam core
US5953779A (en) * 1996-06-05 1999-09-21 Schwartz; Jack Mattress assembly
US6055689A (en) * 1997-04-07 2000-05-02 Cavazos; Frank G. Modular mattress and innerspring
US6003179A (en) * 1997-11-18 1999-12-21 Farley; David L. Inclined anatomic support surface
US20010054200A1 (en) * 1998-05-06 2001-12-27 Hill-Rom, Inc. Mattress or cushion structure
US5960496A (en) * 1998-07-14 1999-10-05 Boyd; Dennis Mattress system
US6651283B1 (en) * 1998-08-24 2003-11-25 The Nautilus Group, Inc. Air bed
US6922863B2 (en) * 2001-03-07 2005-08-02 Gualtiero G. Giori Adjustable foam mattress
US20050210595A1 (en) * 2004-03-23 2005-09-29 Di Stasio Anthony A Mattress having reticulated viscoelastic foam
US20070113352A1 (en) * 2005-08-10 2007-05-24 Craig Poulos Therapeutic mattress
US20070157394A1 (en) * 2006-01-06 2007-07-12 Carl Pete Giggleman Therapeutic mattress

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090089933A1 (en) * 2007-10-09 2009-04-09 Sealy Technology, Llc Pressure dispersion support systems
US7845035B2 (en) 2007-10-09 2010-12-07 Sealy Technology Llc Pressure dispersion support systems
US20100325806A1 (en) * 2007-10-09 2010-12-30 Sealy Technology, Llc Pressure dispersion support systems
US20110067183A1 (en) * 2009-09-18 2011-03-24 Hawkins Steven D Cushioning device and method of manufacturing
US8613120B2 (en) * 2009-09-18 2013-12-24 Carpenter Co. Cushioning device and method of manufacturing
EP2706888A1 (en) * 2011-05-12 2014-03-19 Sealy Technology LLC Tension relief foam and mattress constructions
EP2706888A4 (en) * 2011-05-12 2014-10-01 Sealy Technology Llc Tension relief foam and mattress constructions
US9504334B2 (en) 2014-05-19 2016-11-29 Welspun India Limited Ergonomic mattress pad with polyester fill
US20160270546A1 (en) * 2015-03-17 2016-09-22 Richard Codos Mattress
US9661932B2 (en) * 2015-03-17 2017-05-30 Richard Codos Mattress
US20170258242A1 (en) * 2015-03-17 2017-09-14 Richard Codos Spring Unit for a Mattress
US9949571B2 (en) * 2015-03-17 2018-04-24 Richard Codos Spring unit for a mattress
US10188219B2 (en) * 2015-03-17 2019-01-29 Richard Codos Mattress

Similar Documents

Publication Publication Date Title
US3493980A (en) Mattress
US5701623A (en) Composite mattress and mattress topper having a latex foam core
US7191480B2 (en) Mattress or cushion structure
US8245341B2 (en) Symmetrical pressure relief foam mattress
EP0453363B1 (en) Bedding configuration having variable support characteristics
US6807698B2 (en) Bed having low body pressure and alignment
US7845035B2 (en) Pressure dispersion support systems
US6874185B1 (en) Mattress with semi-independent pressure relieving
US4449261A (en) Bed mattress having an improved pillow top
AU690889B2 (en) Multilayer mattress
US20090165213A1 (en) Reticulated material body support and method
US5642546A (en) Inflatable mattress with improved border support wall
US20090100606A1 (en) Mattress
US6243900B1 (en) One-sided mattress construction
US8918935B2 (en) Channel-cut cushion supports
EP1768520B1 (en) Pocketed bedding or seating product having inflatable members
US8356372B2 (en) Systems and methods for hinged bedding assemblies
US20100325806A1 (en) Pressure dispersion support systems
US6701551B1 (en) Upholstered slat box spring/bed
US5604021A (en) Multi-layer support pad having regions of differing firmness
AU749630B2 (en) Cavitated pad and innerspring assembly combination having springs with free terminal convolutions
US5259079A (en) Double bed arrangement with combination mattress
US6829797B2 (en) Contour and topography adjusting massaging mattress
US7185379B2 (en) Foam encased innerspring with internal foam components (triple case)
US4213214A (en) Multiple firmness multiple sleeper mattress

Legal Events

Date Code Title Description
AS Assignment

Owner name: THE SPRING AIR COMPANY, ILLINOIS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BRYANT, STEVE;O'BRIEN, MAURY;OLINSKI, ROSS M.;REEL/FRAME:017308/0215

Effective date: 20050824

AS Assignment

Owner name: AMERICAN CAPITAL FINANCIAL SERVICES, INC., A DELAW

Free format text: INTELLECTUAL PROPERTY SECURITY AGREEMENT TO THAT CERTAIN REVOLVING LOAN, NOTE AND EQUITY PURCHASE AGREEMENT;ASSIGNORS:CONSOLIDATED BEDDING, INC., A DELAWARE CORPORATION;NATURE'S REST MARKETING, L.L.C., A DELAWARE LIMITED LIABILITY COMPANY;NATURE'S REST, INC., A FLORIDA CORPORATION;AND OTHERS;REEL/FRAME:019562/0032

Effective date: 20070625

AS Assignment

Owner name: L&P FINANCIAL SERVICES, CO., MISSOURI

Free format text: SECURITY AGREEMENT;ASSIGNORS:CONSOLIDATED BEDDING, INC.;NATURE'S REST, INC.;NATURE'S REST MARKETING, L.L.C.;AND OTHERS;REEL/FRAME:020451/0163

Effective date: 20070625

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION

AS Assignment

Owner name: NATURE'S REST, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: NATURE'S REST MARKETING, L.L.C., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: AMERICAN BEDDING INDUSTRIES, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: TSAC MERGER SUB, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: THE SPRING AIR COMPANY, ILLINOIS

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR PARTNERS - NORTH AMERICA, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR PARTNERS - NEW JERSEY, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR PARTNERS - CALIFORNIA, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: CHATTAM & WELLS, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR CALIFORNIA-DELUXE BEDDING CO., INC., FL

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: ACKERMAN MANUFACTURING COMPANY, MISSOURI

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR MATTRESS COMPANY OF COLORADO, COLORADO

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR - MOUNTAIN WEST, INC., UTAH

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR WEST, L.L.C., WASHINGTON

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR MATTRESS COMPANY, ARIZONA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: SPRING AIR BEDDING COMPANY, GEORGIA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: ATLAS BEDDING MANUFACTURING CORPORATION, MASSACHUS

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: CONSOLIDATED BEDDING, INC., FLORIDA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: ALABAMA BEDDING MFG. CO., INC., ALABAMA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

Owner name: ASSOCIATED TRUCKING COMPANY, INC., ALABAMA

Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:L&P FINANCIAL SERVICES, CO.;AMERICAN CAPITAL FINANCIAL SERVICES, INC.;REEL/FRAME:022764/0900

Effective date: 20090526

AS Assignment

Owner name: SPRING AIR PARTNERS - TEXAS, INC., NEW YORK

Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:L&P FINANCIAL SERVICES, CO.;REEL/FRAME:022773/0737

Effective date: 20090526

AS Assignment

Owner name: SPRING AIR INTERNATIONAL LLC, MASSACHUSETTS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CONSOLIDATED BEDDING, INC.;NATURE'S REST, INC.;NATURE'S REST MARKETING, L.L.C.;AND OTHERS;REEL/FRAME:022813/0908

Effective date: 20090526