US20130283538A1

US20130283538A1 - Mattress assemblies and components employing passageways for ventilation and airflow

Info

Publication number: US20130283538A1
Application number: US13/857,563
Authority: US
Inventors: Julian Thomas Young; Christopher Dean Page; Michael Allman; Mark Stearley; Brian Towne
Original assignee: Nomaco Inc
Current assignee: Nomaco Inc
Priority date: 2012-04-05
Filing date: 2013-04-05
Publication date: 2013-10-31

Abstract

Embodiments disclosed herein include mattress assemblies and components employing passageways for ventilation and airflow. A mattress may contain a mattress core to provide cushioning and support. For example, the mattress core may comprise an innerspring, air bladder(s), and/or foam layer(s). A mattress assembly may include a foam base and/or at least one foam side support member to at least partially surround a mattress core to provide cushioning and structure. The foam base and/or at least one foam side support member may include at least one passageway for facilitating diffusion and air exchange between an exterior environment and an interior space of the enclosure containing the mattress core. In this manner, as stagnant air and humidity developing in the mattress core may be avoided or reduced from the mattress core, which may otherwise cause unhealthy conditions or unpleasant odors for users.

Description

PRIORITY APPLICATIONS

The present application claims priority to co-pending U.S. Provisional Patent Application Ser. No. 61/791,842 entitled “Mattress Assemblies and Components Employing Passageways for Ventilation and Airflow,” filed on Mar. 15, 2013, which is hereby incorporated herein by reference in its entirety.
The present application also claims priority to co-pending U.S. Provisional Patent Application Ser. No. 61/620,649 entitled “Mattress Assemblies And Methods Employing Foam Side Support Members With Attachment Members,” filed on Apr. 5, 2012, which is hereby incorporated herein by reference in its entirety.
The present application is a continuation-in-part application of co-pending U.S. patent application Ser. No. 13/738,391 entitled “Mattress Assemblies and Methods Employing Cloth Member(s) Thermally Bonded To Foam Side Support Member(s) To Form Mattress Encasements,” filed on Jan. 10, 2013, which claims priority to U.S. Provisional Patent Application Ser. No. 61/585,021 entitled “Mattress Assemblies And Methods Employing Foam Side Support Members With Attachment Members,” filed on Jan. 10, 2012, both of which are incorporated herein by reference in their entireties.

FIELD OF DISCLOSURE

The technology of the disclosure relates generally to foam mattress assemblies, mattresses, and related methods providing ventilation and airflow, which may be employed in bedding and seating applications.

BACKGROUND

Mattress cores 10 are one of many components contributing support and cushioning characteristics to a mattress or seating structure. Mattress cores 10 may be available in many varieties, for example, innerspring assemblies (“innersprings”), one or more foam layers, and air baffles. An exemplary innerspring 12 is depicted in FIG. 1A and provided as part of a mattress assembly 14. The innerspring 12 is comprised of a plurality of spring coils 16 arranged proximate to each other. The mattress core 10 may be located atop a foam base 18 to support a user's weight. The foam base 18 may contribute cushioning to the mattress assembly 14. The foam base 18 is used below the mattress core 10 and, in combination with at least one side support 20(1), 20(2) located around the side periphery of the mattress core 10, to form an enclosure 22 around the mattress core 10.
The enclosure 22 may serve many useful functions. The enclosure 22 may protect the mattress core 10 during transportation and installation by providing a more rugged exterior structure. The enclosure 22 may also provide additional support around the side periphery of the mattress core 10 where an individual user may disproportionally place weight on the mattress core 10, for example, during mounting onto and dismounting from the mattress assembly 14. The enclosure 22 may also prevent the mattress core 10 from separating from the mattress assembly 14.
The mattress assembly 14 in FIG. 1 may include a plurality of cushion layers 24 disposed atop the mattress core 10 and the enclosure 22. The plurality of cushion layers 24 typically closes off a top opening 26 of the enclosure 22 while providing soft cushioning to the user. However, stagnant air and humidity may collect within the enclosure 22 contributing to development of bacterial counts. There is a need for mattress assemblies and associated components that avoid stagnant air and humidity.

SUMMARY OF THE DETAILED DESCRIPTION

Embodiments disclosed herein include mattress assemblies and components employing passageways for ventilation and airflow. A mattress may contain a mattress core to provide cushioning and support. For example, the mattress core may comprise an innerspring, air bladder(s), and/or foam layer(s). A mattress assembly may include a foam base and/or at least one foam side support member to at least partially surround a mattress core to provide cushioning and structure. The foam base and/or at least one foam side support member may include at least one passageway for facilitating diffusion and air exchange between an exterior environment and an interior space of the enclosure containing the mattress core. In this manner, as stagnant air and humidity developing in the mattress core may be avoided or reduced from the mattress core, which may otherwise cause unhealthy conditions or unpleasant odors for users.
In this regard in one embodiment, a mattress assembly is provided. The mattress assembly may include a mattress core comprising a first support surface configured to face a user applying a weight of the user to the mattress core. The mattress core may also include a second support surface opposite the first support surface. The mattress core may also include a side periphery extending between the first support surface with the second support surface. The mattress assembly may include a foam base configured to support the weight of the user transmitted through the mattress core. The mattress assembly may further include at least one foam side support member disposed along the side periphery. The at least one foam side support member is configured to allow an airflow to exit from and enter into an interior space formed by an inner side surface of each of the at least one foam side support member and a portion of an inner base surface of the foam base. The portion of the inner base surface faces the mattress core. In this manner, stagnant air and humidity may be removed from the interior space.
In another embodiment, a mattress assembly is disclosed comprising a mattress core. The mattress core comprises a first support surface configured to face a user applying a weight of the user to the mattress core, a second support surface opposite the first surface, and a side periphery extending between the first support surface and the second support surface. The mattress core further comprises a foam base configured to support a weight of the mattress core. The foam base further comprises an inner base surface facing the mattress core. The mattress core further comprises at least one foam side support member configured to be disposed along the side periphery. The at least one foam side support member comprises an inner side surface facing the mattress core and an outer side surface opposite the inner side surface. The at least one foam side support member is configured to allow an airflow to exit from and enter into an interior space formed by the inner side surface of each of the at least one foam side support member and a portion of the inner base surface. The inner side surface and the outer side surface comprise closed cell foam. In this manner, stagnant air and humidity may be removed from the interior space.
In another embodiment, a mattress assembly is disclosed comprising a mattress core. The mattress core comprises a cushioning structure including a first support end configured to receive a weight of a user, a second support end opposite the first support end, and a side periphery. The mattress assembly further comprises an enclosure forming an interior space to contain the mattress core. The enclosure comprises a foam base including a first surface and a second surface opposite the first surface. The first surface is disposed adjacent to the second support end of the mattress core and configured to receive the weight of the user from the mattress core. The enclosure further comprises at least one foam side support member including an inner surface and an outer surface opposite the inner surface. The at least one foam side support member is disposed along the side periphery and is in communication with the foam base. The mattress core further comprises an inner surface forming at least one passageway to permit airflow between the interior space and an exterior environment. In this manner, stagnant air and humidity may be removed from the interior space.
In another embodiment, a foam side support member is disclosed. The foam side support member is disposed along a side periphery of a mattress core. The foam side support member comprises a foam body. The foam body comprises a first surface configured to receive a weight of a user. The foam body also comprises a second surface opposite the first surface to transfer the weight of the user to a foam base. The foam body also comprises an inner side surface configured to face an inner space containing a mattress core. The inner side surface connects the first surface to the second surface. The foam body also comprises an outer side surface opposite the inner side surface and facing an exterior environment. The foam body also comprises an inner surface forming a passageway configured to exchange airflow between the inner space and the exterior environment. In this manner, the stagnant air and humidity may be removed from the interior space.
In another embodiment, side rail assembly for supporting an edge of a mattress is disclosed. The side rail assembly including layer of foam comprising at least one channel and/or a plurality of orifices. The layer is configured to be disposed about a perimeter of an inner core of the mattress. The at least one channel extends through a length of the layer and the plurality of orifices extend through a width of the layer. The at least one channel and/or the plurality of orifices are configured to permit the flow of fluid from and to the inner core through the layer. In this manner, stagnant air and humidity may be removed from the interior space.
Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description that follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description present embodiments, and are intended to provide an overview or framework for understanding the nature and character of the disclosure. The accompanying drawings are included to provide a further understanding, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments, and together with the description serve to explain the principles and operation of the concepts disclosed.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a perspective partial cutaway view of a mattress in the prior art including a mattress core of an innerspring type surrounded by an enclosure comprising at least one foam side support member and a foam base as is known in the art, illustrating the enclosure wherein stagnant air and humidity may have a tendency to collect;

FIG. 2A is a top perspective view of an exemplary mattress assembly including at least one foam side support member, a foam base, and a mattress core, illustrating one embodiment of at least one passageway to facilitate air exchange between the interior space and an exterior environment and thereby avoid or reduce stagnant air and humidity from the interior space;

FIGS. 2B and 2C are side sectional views along a width and a length, respectively, of the mattress assembly of FIG. 2A;

FIG. 2D is an exploded side sectional view of the mattress assembly of FIG. 2A including a cushion layer and the mattress core removed from an enclosure comprising the at least one side support and the foam base, illustrating an interior space with which the at least one passageway will exchange airflow to and from an exterior environment;

FIGS. 3A and 3B depict side sectional views of a mattress assembly which is a second embodiment of the mattress assembly of FIG. 2A, wherein a foam side support member allows an airflow A₁to exit from and enter into the interior space according to diffusion;

FIGS. 4A and 4B depict side sectional views of a mattress assembly which is a second embodiment of the mattress assembly of FIG. 2A, wherein a foam side support member allows an airflow A₂to exit from and enter into the interior space when the mattress assembly is subject to a weight of the user;

FIGS. 5A and 5B are a partial side view and a partial top view, respectively, of passageways through the foam side support member of FIGS. 3A-4B;

FIGS. 6A-6D are a top perspective, front side, and two right sectional views, respectively, of another embodiment of the mattress assembly including at least one side support and a foam base, illustrating at least one passageway to exchange airflow between the interior space and the exterior environment;

FIGS. 7A-7D are a top perspective, front side, and two right sectional views, respectively, of another embodiment of the mattress assembly including at least one side support and a foam base, illustrating at least one passageway to exchange airflow between the interior space and the exterior environment;

FIGS. 8A-8D are a top perspective, front side, and two right sectional views of another embodiment of the mattress assembly including at least one side support and a foam base, illustrating at least one passageway to exchange airflow between the interior space and the exterior environment;

FIG. 8E is a top perspective view of the passageways of the mattress assembly of FIG. 8A with the at least one side support member and the foam base in phantom lines;

FIG. 8F is a bottom view of the at least one side support of FIG. 8A illustrating bottom openings of inter-level channels to communicate with inner base passageways of the foam base;

FIG. 8G is a top view of the foam base of FIG. 8A illustrating top interface openings of the foam base configured to communicate with the bottom openings of the at least one side support;

FIGS. 9A-9D are a top perspective, front side, and two right sectional views of another embodiment of the mattress assembly including at least one side support and a foam base, illustrating at least one passageway to exchange airflow between the interior space and the exterior environment;

FIGS. 10A-10D are a top perspective, front side, and two right sectional views of another embodiment of the mattress assembly including at least one side support and a foam base, illustrating at least one passageway to exchange airflow with the exterior environment;

FIGS. 11A-11D are a top perspective, front side, and two right sectional views of another embodiment of the mattress assembly including at least one side support and a foam base, illustrating at least one passageway to exchange airflow with the exterior environment;

FIG. 11E is a bottom view of the at least one side support of FIG. 11A illustrating bottom openings of inter-level channels to communicate with inner base passageways of the foam base;

FIG. 11F is a top view of the foam base of FIG. 11A illustrating top interface openings of the foam base configured to communicate with the inter-level channels of the at least one side support; and

FIG. 11G is a close-up front side view of the foam base of FIG. 11B showing passageways through sidewalls of the protrusions and a foam deck of the foam base.

DETAILED DESCRIPTION

With reference now to the drawing figures, several exemplary embodiments of the present disclosure are described. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
Embodiments disclosed herein include mattress assemblies and components employing passageways for ventilation and airflow. A mattress may contain a mattress core to provide cushioning and support. For example, the mattress core may comprise an innerspring, air bladder(s), and/or foam layer(s). A mattress assembly may include a foam base and/or at least one foam side support member to at least partially surround a mattress core to provide cushioning and structure. The foam base and/or at least one foam side support member may include at least one passageway for facilitating diffusion and air exchange between an exterior environment and an interior space of the enclosure containing the mattress core. In this manner, as stagnant air and humidity developing in the mattress core may be avoided or reduced from the mattress core, which may otherwise cause unhealthy conditions or unpleasant odors for users.
In this regard, FIGS. 2A, 2B, 2C, and 2D are a top perspective view, two side sectional views, and an exploded view, respectively, of an exemplary mattress assembly 30(1). The mattress assembly 30(1) comprises at least one passageway 32A to facilitate an exchange of airflow A₁between an exterior environment 34 and an interior space 36 of the mattress assembly 30(1). The interior space 36 is disposed within an enclosure 38 comprised of at least one foam side support member 40A(1)-40A(4) supported by a foam base 42(1). The airflow A₁may occur through a force F applied by a user on the mattress assembly 30(1). It is also noted that an airflow A₂may be exchanged through the passageways 32A through diffusion in the absence of the force F. The passageways 32A may be formed by an inner surface 45 of the foam side support members 40A(1)-40A(4) connecting opposite openings 47A, 47B in the foam side support members 40A(1)-40A(4). In this manner, as a non-limiting example, stagnant air and humidity may be avoided or reduced from the interior space 36 which may otherwise cause unhealthy conditions or unpleasant odors for users.
The mattress assembly 30(1) comprises a mattress core 44, the foam base 42(1), and the foam side support members 40A(1)-40A(4). It is noted that the foam side support members 40A(1)-40A(4) may be secured to the foam base 42A with at least one first cloth member 43(1)-43(4), an adhesive, cohesive, mechanical means, or thermal bonding to form the enclosure 38. The foam base 42A and the foam side support members 40A(1)-40A(4) may be made of any polymeric foam material, for example, an extruded or molded closed-cell polyethylene foam.
The mattress core 44 is at a center of the mattress assembly 30(1) providing primary support to a user. The mattress core 44 may include a first support end 46, second support end 48, and a side periphery 50. The first support end 46 may be configured to face a user applying a weight F (or “force”) of the user to the mattress core 44. The second support end 48 may be opposite the first support end 46. The side periphery 50 may be formed by the lateral outward bounds of the mattress core 44 between the first support end 46 and the second support end 48. The mattress core 44 may further comprise at least one cushioning structure 52. Embodiments of the cushioning structure 52 may comprise, for example, a non-pocketed spring coil, a pocketed spring coil 54 (also referred to as a “Marshall coil”), or an air bladder. FIGS. 2B and 2C depict the exemplary cushioning structure 52 as a pocketed spring coil 54 in a sleeve 56.
With continuing reference to FIGS. 2A through 2C, the foam base 42(1) is a structural component which supports the mattress core 44 and also forms a portion of the enclosure 38A that surrounds the mattress core 44. The enclosure 38(1) protects the integrity of the mattress core 44 by, for example, preventing the at least one cushioning structure 52 of the mattress core 44 from separating. The mattress assembly 30(1) may include the foam base 42(1) configured to support the weight F of the user transmitted through the mattress core 44.
Next, the foam side support members 40A(1)-40A(4) provide an optional perimeter support structure around the mattress core 44 to thereby provide additional support when a user mounts or dismounts from the mattress assembly 30(1). The foam side support members 40A(1)-40A(4) also form another portion of the enclosure that surrounds the mattress core 44 and thereby may be attached to the foam base 42(1).
Each of the at least one foam side support member 40A(1)-40A(4) comprises a first surface 58(1)-58(4), a second surface 60(1)-60(4) opposite the first surface 58(1)-58(4), and an inner side surface 62(1)-62(4) facing the mattress core 44. The second surface 60(1)-60(4) of the foam side support member 40A(1)-40A(4) or any other part of the foam side support member 40A(1)-40A(4) may be attached to the first cloth member 43(1)-43(4). Further, the inner side surface 62(1)-62(4) of the foam side support member 40A(1)-40A(4) may abut the mattress core 44. This abutment enables the mattress core 44 to be vertically positioned and minimizes localized pressure experienced by the user by distributing the user's weight over a larger quantity of cushioning structures 52.
The attachments between the first cloth member 43(1)-43(4) and the foam side support member 40A(1)-40A(4) and the foam base 42(1) may be made with an adhesive or thermal bonding. The adhesive may be, for example, hot melt, a water-based adhesive, or a solvent-based adhesive. As such, the first cloth member 43(1)-43(4) may be attached in situations when thermal bonding is not available.
With continuing reference to FIGS. 2A through 2D, the mattress assembly 30(1) may further include a second cloth member 64 that may be configured to prevent the mattress core 44 from departing from an interior space 36 formed by the inner side surface 62(1)-62(4) of each of the foam side support member 40A(1)-40A(4) and a portion 66 of an inner base surface 68 of the foam base 42(1). The portion 66 of the inner base surface 68 faces the mattress core 44. The enclosure 38 forming the interior space 36 (see FIG. 2D) may comprise an opening 70. The opening 70 may be opposite the portion 66 of the inner base surface 68 to enable the mattress core 44 to abut against the inner base surface 68 when not departing the opening 70.
The second cloth member 64 may be attached to at least portions 72 (see FIG. 2A) of the foam side support member 40A(1)-40A(4) to at least partially close the opening 70 and thereby prevent the mattress core 44 from departing the interior space 36. As shown in FIG. 2A, the portions 72 may be close to the corners 74 of the mattress assembly 30(1) to enable the second cloth member 64 to more easily straddle the mattress core 44 between two portions that are relatively close together. The second cloth member 64 may be a multi-piece or single-piece structure to reduce cost.
With continuing reference to FIGS. 2B and 2C, instead of merely closing the opening 70 to prevent the mattress core 44 from departing the interior space 36, the second cloth member 64 may also be attached to the foam side support members 40A(1)-40A(4) and the mattress core 44 to prevent the mattress core 44 from departing the interior space 36.
Next, as shown in FIG. 2D, a padding material 76 may be included as part of the mattress assembly 30(1). The padding material 76 may be disposed between the user and the mattress core 44 to provide more comfort to the user. The padding material 76 may be made of a soft resilient material, for example, viscoelastic foam. Ticking 78 may be added to form an exterior surface that surrounds the other components, as well as the padding material 76 disposed between the ticking 78 and the mattress core 44. Alternatively, the mattress assembly 30(1) may optionally not include the ticking 78 and/or the padding material 76 to lower material costs and thereby enable lower prices to be provided to consumers.
Other embodiments of the mattress assembly are possible to facilitate air exchange between the exterior environment 34 and the interior space 36 and thereby avoid or reduce stagnant air and humidity within the interior space 36. FIGS. 3A-4B depict a side view of a mattress assembly 30(2) in another embodiment of the mattress assembly 30(1). The mattress assembly 30(2) may comprise a foam side support member 40B(1)-40B(4), which is another embodiment of the foam side support member 40A(1)-40A(4). The mattress assembly 30(2) may comprise the ticking 78 surrounding the foam side support member 40B(1)-40B(4), the first cloth member 43(1)-43(4), and the foam base 42(1). The ticking 78 may be configured to be permeable to the airflow A₁. The ticking 78 may be made of a strong flexible material that is permeable to the airflow A₁, A₂, for example, a woven fabric.
The foam side support member 40B(1)-40B(4) may be configured to allow the airflow A₁to exit from and enter into the interior space 36 using diffusion when the mattress assembly 30(2) is not subject to either the force F₁or the force F₂of the user as shown in FIGS. 3A-3B. The foam side support member 40B(1)-40B(4) may also be configured to allow the airflow A₂to exit from and the airflow A₂to enter into the interior space 36 when the mattress assembly 30(2) is subject to non-zero forces F₁, F₂of the user as shown in FIGS. 4A-4B. It is noted that the mattress core 44 may be disposed within the interior space 36, but the mattress core 44 is not shown in FIGS. 3A-4B to merely simplify the drawings. The airflow A₁and the airflow A₂may remove moisture and stagnant air from the interior space 36 and the mattress core 44 that may otherwise promote unhealthy conditions, for example, mold growth within the mattress.
The force F₁may be positively created directly by the user in the direction of gravity. The force F₂is a responsive force created by elements of the mattress assembly 30(2) to restore its original shape while not subject to force F₁. One or more of the foam side support members 40B(1)-40B(4) may include a first opening 80 in one or more of the inner side surfaces 62(1)-62(4). One or more of the foam side support members 40B(1)-40B(4) may also include a second opening 82 in one or more outer side surfaces 84(1)-84(4) of the foam side support members 40B(1)-40B(4) opposite the inner side surfaces 62(1)-62(4). As shown in FIGS. 5A and 5B the foam side support members 40B(1)-40B(4) may further include passageway surface 86 forming one or more passageways 32 connecting the first opening 80 to the second opening 82. The passageway 32 may be configured to allow the airflows A₁, A₂to exit from the interior space 36, and the airflows A₁, A₂to enter into the interior space 36. The passageway 32 may or may not be perpendicular to the inner side surface 62(1)-62(4), although the exemplary embodiment shown in FIG. 5B is perpendicular. Airflows A1, A2 may be directed on an angle if the passageway 32 is not perpendicular to avoid obstacles (not shown) within the interior space 36, for example, adjacent ones of the foam side support members 40B(1)-40B(4).
In order to reduce noise related to open cell foam surfaces rubbing against the ticking 78 and the mattress core 44, the inner side surface 62(1)-62(4) and the outer side surface 84(1)-84(4) may comprise mainly closed cell foam. The closed cell foam may be created, for example, through an extrusion process where the surfaces at issue are parallel to a direction of extrusion.
The passageway 32 may be non-parallel to an extrusion direction for the foam side support member 40B(1)-40B(4). In this case, the passageway 32 may be created through the foam side support member 40B(1)-40B(4) without use of extrusion, but instead by, for example, boring the passageway 32 through the foam side support member 40B(1)-40B(4). The foam side support member 40B(1)-40B(4) may comprise, for example, polyethylene to enable a boring process or other material removal process to create the passageway 32.
With reference back to FIGS. 3A-4B, at least one longitudinal passageway 88 may be created through the foam side support member 40B(1)-40B(4). The longitudinal passageway 88 may be created as part of an extrusion process, for example, and thereby may be parallel to an extrusion direction of the extrusion process. The longitudinal passageway 88 may be optionally angled to the passageway 32 and may be unconnected so as to prevent the airflow A₁, A₂from entering the longitudinal passageway 88. Preventing the airflow A₁, A₂to pass between the longitudinal passageway 88 and the passageway 32 may improve product safety by limiting oxygen flow to a localized area of the foam side support member 40B(1)-40B(4). Otherwise, a greater availability of oxygen may propagate flames in a situation known as “chimney effect” as may be measured by a product safety burn test.
It is noted that the foam side support member 40B(1)-40B(4) may be utilized in mattress assemblies 30(2) with or without flexible cloth-shaped members. This flexibility enables the airflows A₁, A₂to ventilate mattresses assemblies that utilize other attachment techniques.
Other embodiments of the mattress assembly 30 are possible to reduce stagnant air and humidity in the interior space 36. FIGS. 6A-6D are a top perspective, front side, and two right sectional views of a mattress assembly 30(3) which is another embodiment of the mattress assembly 30(2) of FIG. 3A-4B. Accordingly, only the details of differences will be discussed for clarity and conciseness.
The mattress assembly 30(3) comprises at least one foam side support member 40C(1)-40C(4) supported by the foam base 42(1). The foam side support members 40C(1)-40C(4) comprise the passageways 32 therethrough. The foam side support members 40C(1)-40C(4) also comprise at least one top groove 90 as part of the first surface 58(1)-58(4) of the foam side support members 40C(1)-40C(4). The top grooves 90 are configured pass at least a portion of the airflows A1, A2 to be exchanged between the exterior environment 34 and the interior space 36 of the mattress assembly 30(3). The top grooves 90 may be curved and up to a distance D₁deep. The distance D₁may be between 0.125 inches and 0.75 inches deep, and preferably a quarter (0.25) inches deep. The top grooves 90 may be formed with a router or other cutting tool. In this manner, stagnant air and humidity may be eliminated or reduced from the interior space 36 which may otherwise cause unhealthy conditions or unpleasant odors for users.
With continued reference to FIGS. 6A-6D, the foam base 42(1) of the mattress assembly 30(3) may include at least one inner base passageway 92 formed by at least one inner base surface 94 extending across the foam base 42(1). The at least one inner base passageway 92 may reduce stiffness of the foam base 42(1) and thereby contribute cushioning to the mattress assembly 30(3). However, the inner base passageways 92 are not connected to the passageways 32. In this manner, the mattress assembly 30(3) is less complex and easier to manufacture.
The passageways 32 of the foam side support members 40C(1)-40C(4) may also be unconnected to the longitudinal passageways 88 of the foam side support members 40C(1)-40C(4). The lack of a connection may allow the foam side support members 40C(1)-40C(4) to retain a higher level of stiffness and thereby provide more support to the mattress assembly 30(3). In this manner, the foam side support members 40C(1)-40C(4) may be made of a low density foam to save material costs yet still contribute sufficient support for the mattress assembly 30(3).
Other embodiments of the mattress assembly 30 are possible to reduce stagnant air and humidity in the interior space 36. FIGS. 7A-7D are a top perspective, front side, and two right sectional views of a mattress assembly 30(4) which is another embodiment of the mattress assembly 30(2) of FIGS. 3A-4B. Accordingly, only the details of differences will be discussed for clarity and conciseness.
The mattress assembly 30(4) comprises at least one foam side support member 40D(1)-40D(4) supported by the foam base 42(1). The foam side support members 40D(1)-40D(4) comprise the passageways 32 extending between the first openings 80 on the inner side surfaces 62(1)-62(4) and the second openings 82 on the outer side surfaces 84(1)-84(4) of the foam side support members 40D(1)-40D(4). However, the passageways 34 may be connected to a plurality of longitudinal passageways 88(1)-88(3) that extend respective lengths L_Sof the foam side support members 40D(1)-40D(4). The longitudinal passageways 88(1)-88(3) may be respectively disposed at different heights H₁, H₂, H₃of the foam side support members 40D(1)-40D(4) which may be equidistant. In this manner, the foam side support members 40D(1)-40D(4) may have reduced stiffness and thereby contribute cushioning to the mattress assembly 30(4).
For purposes of terminology it is noted, that as used herein, a hollow portion 99 (see FIG. 5B) or “hollow portion” of any foam side support member means any passageway or portion of a passageway to allow airflow to pass internally within the foam side support member and between any two openings disposed at different locations on a full periphery of the foam side support member. For example, if a foam side support member has a rectangular prism shape, then the full periphery of the foam side support member is formed by all six sides of the rectangular prism shape.
With continued reference to FIGS. 7A-7D, the mattress assembly 30(4) may also comprise at least one inter-level channel 96A connecting the longitudinal passageways 88(1)-88(3) of the foam side support members 40D(1)-40D(4). The inter-level channel 96A may be directed parallel to an axis A₃(FIGS. 7B and 7D) which may be disposed vertically. The inter-level channel 96A may allow airflow exchange between the longitudinal passageways 88(1)-88(3) and the inter-level channel 96A. In this manner, the foam side support members 40D(1)-40D(4) may have more uniform stiffness characteristics along the length L_Sof the foam side support members 40D(1)-40D(4) while providing airflow exchange throughout the side supports.
The inter-level channels 96A may also include at least one opening 98 on the first surfaces 58(1)-58(4) of the foam side support members 40D(1)-40D(4). In this manner, stagnant air and humidity may be more effectively eliminated or reduced from the interior space 36 by increasing the quantities of the possible directions the airflow could exit or enter the interior space 36.
With continued reference to FIGS. 7A-7D, the foam base 42(1) of the mattress assembly 30(3) may include the at least one inner base passageway 92 formed by the at least one inner base surface 94 extending across the foam base 42(1). The at least one inner base passageway 92 may reduce stiffness of the foam base 42(1) and thereby contribute cushioning to the mattress assembly 30(3). However, the inner base passageways 92 are not connected to the passageways 32. In this manner, the mattress assembly 30(4) is less complex and easier to manufacture.
Other embodiments are possible to reduce stagnant air and humidity in the interior space 36. FIGS. 8A-8D are a top perspective, front side, and two right sectional views of a mattress assembly 30(5) which is another embodiment of the mattress assembly 30(4) of FIG. 7A. The mattress assembly 30(5) comprises at least one side support 40E(1)-40E(4) supported by a foam base 42(2). The mattress assembly 30(5) is similar to the mattress assembly 30(4). Accordingly, only details of differences will be discussed for clarity and conciseness.
The mattress assembly 30(5) comprises at least one inter-level channel 96B connecting the longitudinal passageways 88(1)-88(3) of the foam side support members 40E(1)-40E(4), similar to the inter-level channel 96A of the mattress assembly 30(4). However, the inter-level channels 96B extend along an axis A₄to bottom openings 100 (FIG. 8F) at the second surface 60(1)-60(4) of the foam side support members 40E(1)-40E(4). The bottom openings 100 of the foam side support members 40E(1)-40E(4) connect with the inner base passageways 92 of the foam base 42(2) via top interface openings 102 on the inner base surface 68 of the foam base 42(2) (FIG. 8G). In this manner, the stagnant air and humidity may be more efficiently eliminated or reduced from the interior space 36 by exiting out the inter-level channels 96B to the foam base 42(2). It is noted that FIG. 8E is a top perspective view of the inner base passageways 92 within the mattress assembly 30(5) with outlines of the foam side support members 40E(1)-40E(4) and the foam base 42(2) in phantom lines for convenient reference.
Other embodiments are possible to reduce stagnant air and humidity in the interior space 36. FIGS. 9A-9D are a top perspective, front side, and two right sectional views of a mattress assembly 30(6) which is another embodiment of the mattress assembly 30(5) of FIG. 8A. The mattress assembly 30(6) comprises at least one foam side support member 40F(1)-40F(4) supported by the foam base 42(2) of FIG. 7A. The mattress assembly 30(5) is similar to the mattress assembly 30(4). Accordingly, only details of differences will be discussed for clarity and conciseness.
The mattress assembly 30(6) comprises at least one inter-level channel 96C connecting the longitudinal passageways 88(1)-88(3) of the foam side support members 40F(1)-40F(4) and extend to openings 98 at the first surface 58(1)-58(4), similar to the inter-level channel 96A of the mattress assembly 30(4). However, the inter-level channels 96C of the foam side support members 40F(1)-40F(4) are offset horizontally from the passageways 32. In this manner, the foam side support members 40F(1)-40F(4) are stronger because the passageways are spread more uniformly within an interior of the foam side support members 40F(1)-40F(4).
The foam side support members 40F(1)-40F(4) further comprise secondary channels 104 to connect the longitudinal passageway 88(1) with the inner base passageway 92 of the foam base 42(2) through the bottom openings 100 (FIG. 9D) of the side support and the top interface openings 102 (FIG. 8G). The secondary channels 104 are also offset horizontally from the inter-level channel 96C. In this manner, the foam side support members 40F(1)-40F(4) are made further stronger because passageways and channels are spread more uniformly within an interior of the foam side support members 40F(1)-40F(4).
Other embodiments are possible to reduce stagnant air and humidity in the interior space 36. FIGS. 10A-10D are a top perspective, front side, and two right sectional views of a mattress assembly 30(7) which is another embodiment of the mattress assembly 30(6) of FIG. 9A. The mattress assembly 30(7) comprises the foam side support members 40F(1)-40F(4) of the mattress assembly 30(6), but uses a foam base 42(3) instead. The foam base 42(3) comprises a foam deck 106 and a plurality of protrusions 108(1)-108(p). The protrusions 108(1)-108(p) comprise distal end surfaces 110(1)-110(p), respectively, which each are configured to support the second support end 48 (FIG. 2D) of the mattress core 44 and the second surface 60(1)-60(n) of the foam side support members 40F(1)-40F(4). The foam deck 106 is a connecting structure for the protrusions 108(1)-108(p) to establish spacing channels 112(1)-112(p−1) between adjacent ones of the protrusions 108(1)-108(p). The spacing channels 112(1)-112(p−1) are configured to serve as unobstructed passageways for airflow to and from the interior space 36. In this manner, stagnant air and humidity may be eliminated or reduced from the interior space 36 which may otherwise cause unhealthy conditions or unpleasant odors for users.
Moreover, the bottom openings 100 of the foam side support members 40F(1)-40F(4) are disposed above the spacing channels 112(1)-112(p−1). In this manner, stagnant air or humidity disposed within the foam side support members 40F(1)-40F(4) may be in communication with the air in the spacing channels 112(1)-112(p). Changes in either the foam side support members 40F(1)-40F(4) and/or the protrusions 108(1)-108(p) may cause airflow to increase to thereby reduce stagnant air or humidity within the interior space 36 of the mattress assembly 30(7).
Other embodiments are possible to reduce stagnant air and humidity in the interior space 36. FIGS. 11A-11D are a top perspective, front side, and two right sectional views of a mattress assembly 30(8) which is another embodiment of the mattress assembly 30(7) of FIG. 10A. The mattress assembly 30(8) comprises foam side support members 40G(1)-40G(4) and a foam base 42(4). The foam base 42(4) comprises the foam deck 106 and the protrusions 108(1)-108(p) having the distal end surfaces 110(1)-110(p). However, the protrusions 108(1)-108(p) of the foam base 42(4) may comprise the inner base surfaces 94 forming inner base passageways 92. The inner base passageways 92 may extend parallel to the foam deck 106. The inner base passageways 92 may facilitate the collapse of the distal end surfaces 110(1)-110(p) and thereby increase an amount of cushioning provided by the protrusions 108(1)-108(p). In the mattress assembly 30(8) the inner base passageways 92 exchange airflow with the foam side support members 40G(1)-40G(4) via top interface openings 102 of the foam base 42(4) and bottom openings 100 of the foam side support members 40G(1)-40G(4). The foam side support members 40G(1)-40G(4) comprise the longitudinal passageways 88(1)-88(3) connected by an inter-level channel 96D which further extends from the opening 98 at the first surface 58 of the foam side support members 40G(1)-40G(4) to the bottom openings 100 at the second surface 60. In this manner, the longitudinal passageways 88(1)-88(3) of the foam side support members 40G(1)-40G(4) may be in airflow communication with the inner base passageways 92. In this manner, any changes in the airflow of the inner base passageways 92 protrusions 108(1)-108(p) will be communicated to the longitudinal passageways 88(1)-88(3) which are in close proximity to the passageways 32. The passageways 32 are in airflow communication with the interior space 36. In this manner, airflow changes in inner base passageways 92 of the protrusions 108(1)-108(p) may cause airflow to increase to thereby reduce stagnant air or humidity within the interior space 36 of the mattress assembly 30(8).
The mattress assembly 30(8) comprises at least one inter-level channel 96D connecting the longitudinal passageways 88(1)-88(3) of the foam side support members 40E(1)-40E(4), and extend from the first surface 58 to bottom openings 100 (FIG. 11E) at the second surface 60(1)-60(4) of the foam side support members 40E(1)-40E(4). The bottom openings 100 of the foam side support members 40E(1)-40E(4) connect with the inner base passageways 92 of the foam base 42(2) via top interface openings 102 on the inner base surface 68 of the foam base 42(2) (FIG. 11F). In this manner, the stagnant air and humidity may be more efficiently eliminated or reduced from the interior space 36 by exiting out the inter-level channels 96D to the foam base 42(2).
FIG. 11F depicts a top view of the foam base 42(4). The foam deck 106 of the foam base 42(4) includes passageways 114 therethrough at the spacing channels 112(1)-112(p−1). The passageways 114 provide more opportunities for airflow exchange between the interior space 36 and the exterior environment 34 particularly when the foam base 42(4) may be supported by components allowing airflow communication between the passageways 114 and the exterior environment 34.
With continued reference to FIGS. 11A-11F and also to FIG. 11G, the foam base 42(4) also may comprise passageways 116 in opposing sidewalls 118A(1)-118A(p), 118B(1)-118B(p) of the protrusions 108(1)-108(p) to allow airflow to be exchanged between the spacing channels 112(1)-112(p−1) and the inner base passageways 92(1)-92(p). The opposing sidewalls 118A(1)-118A(p), 118B(1)-118B(p) may attach the distal end surface 110(1)-110(p) to the foam deck 106. In this manner, the passageways 116 permit airflow to be exchanged between the spacing channels 112(1)-112(p−1) and the inner base passageways 92(1)-92(p) and thereby may improve the opportunity for airflow to be exchanged between the interior space 36 and the exterior environment 34.
Embodiments disclosed herein are exemplary, and may be provided together in any combination desired. Based on this disclosure, mattress assemblies may be assembled using the foam side support members disclosed herein around any of a variety of mattress cores, including for example, air bladder mattress cores, innerspring coil mattress cores, pocketed coil spring mattress cores (e.g. Marshall coil mattress cores), and mattress cores formed from a cellular material (e.g. foam). Because each elongated edge-support member disclosed herein is adaptable to be disposed around a variety of types and dimensions of mattress cores, the embodiments disclosed herein enable mattress core manufacturers to more easily store and transport the elongated edge-support members.
Those skilled in the art will recognize improvements and modifications to the embodiments disclosed herein. Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having benefit of the teachings presented in the foregoing descriptions and the associated drawings. The materials or compositions of the aforementioned components can be varied as well, including but not limited to whether foam may be exclusively thermoset or thermoplastic materials, or a composite of both. All such improvements and modifications are considered within the scope of the concepts disclosed herein.
It is also noted that the operational steps described in any of the exemplary embodiments herein are described to provide examples and discussion. The operations described may be performed in numerous different sequences other than the illustrated sequences. Furthermore, operations described in a single operational step may actually be performed in a number of different steps. Additionally, one or more operational steps discussed in the exemplary embodiments may be combined. It is to be understood that the operational steps illustrated in the flow chart diagrams may be subject to numerous different modifications as will be readily apparent to one of skill in the art.
Further, it is to be understood that the embodiments are not limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. It is intended that the embodiments cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The previous description of the disclosure is provided to enable any person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

What is claimed is:

1. A mattress assembly, comprising:

a mattress core comprising a first support surface configured to face a user applying a weight of the user to the mattress core, a second support surface opposite the first support surface, and a side periphery extending between the first support surface and the second support surface;

a foam base configured to support the weight of the user transmitted through the mattress core; and

at least one foam side support member disposed along the side periphery,

wherein the at least one foam side support member is configured to allow an airflow to exit from and enter into an interior space formed by an inner side surface of each of the at least one foam side support member and a portion of an inner base surface of the foam base, wherein the portion of the inner base surface faces the mattress core.

2. The mattress assembly of claim 1, wherein the at least one foam side support member comprises:

a first opening in the inner side surface;

a second opening in an outer side surface of the at least one foam side support member, the outer side surface is opposite the inner side surface; and

a passageway surface surrounding a passageway coupling the first opening to the second opening,

wherein the passageway is configured to allow the airflow to exit from and enter into the interior space.

3. The mattress assembly of claim 2, wherein the passageway is not disposed perpendicular to the inner side surface.

4. The mattress assembly of claim 2, wherein the inner side surface and the outer side surface comprise mainly closed cell foam.

5. The mattress assembly of claim 2, wherein the passageway is not disposed parallel to an extrusion direction of the at least one foam side support member.

6. The mattress assembly of claim 5, wherein the at least one foam side support member comprises polyethylene.

7. A mattress assembly, comprising:

a mattress core comprising a first support surface configured to face a user applying a weight of the user to the mattress core, a second support surface opposite the first support surface, and a side periphery extends between the first support surface and the second support surface;

a foam base configured to support a weight of the mattress core, and the foam base further comprises an inner base surface facing the mattress core; and

at least one foam side support member configured to be disposed along the side periphery, the at least one foam side support member comprises an inner side surface facing the mattress core and an outer side surface opposite the inner side surface, the at least one foam side support member is configured to allow an airflow to exit from and enter into an interior space formed by the inner side surface of each of the at least one foam side support member and a portion of the inner base surface,

wherein the inner side surface and the outer side surface comprise closed cell foam.

8. The mattress assembly of claim 7, wherein the at least one foam side support member comprises:

a first opening in the inner side surface;

a second opening in the outer side surface of the at least one foam side support member opposite the inner side surface; and

a passageway surface surrounding a passageway connecting the first opening to the second opening,

9. The mattress assembly of claim 8, wherein the passageway is not perpendicular to the inner side surface.

10. The mattress assembly of claim 8, wherein the inner side surface and the outer side surface include closed cell polyethylene.

11. The mattress assembly of claim 8, wherein the passageway is not parallel to an extrusion direction of the at least one foam side support member.

12. A mattress assembly, comprising:

a mattress core comprising a cushioning structure including a first support end configured to receive a weight of a user, a second support end opposite the first support end, and a side periphery;

an enclosure forming an interior space to contain the mattress core, the enclosure comprising:

a foam base including a first surface and a second surface opposite the first surface, the first surface disposed adjacent to the second support end of the mattress core and configured to receive the weight of the user from the mattress core;

at least one foam side support member including an inner surface and an outer surface opposite the inner surface, the at least one foam side support member is disposed along the side periphery and is in communication with the foam base; and

an inner surface of the at least one foam side support member forming at least one passageway to permit an airflow between the interior space and an exterior environment.

13. The mattress assembly of claim 12, wherein the at least one passageway comprises an orifice through the foam base, the orifice including a first base opening in the first surface of the foam base and a second base opening in the second surface of the foam base and an inner base surface of the foam base connecting the first base opening and the second base opening.

14. The mattress assembly of claim 12, wherein the first surface of the foam base comprises a channel extending across the foam base, and the channel in combination with the at least one foam side support member forms a passageway of the at least one passageway.

15. The mattress assembly of claim 12, wherein the foam base comprises an inner base passageway formed from an internal base surface extending across the foam deck, the internal base surface connecting a first exterior opening to a second exterior opening, and the inner base passageway forming at least a portion of a passageway of the plurality of passageways.

16. The mattress assembly of claim 15, wherein the first surface of the foam base is partially formed by a plurality of protrusions extending from a foam deck and extending across the foam deck, the inner base passageway is at least partially disposed within at least one of the plurality of protrusions.

17. The mattress assembly of claim 15, wherein the inner base passageway exchanges airflow through the first surface with a secondary passageway, the secondary passageway extending from a secondary opening in the first surface of the foam base to a secondary opening in the internal base surface.

18. The mattress assembly of claim 16, wherein each of the plurality of protrusions comprises opposing sidewalls and a distal end, and the secondary passageway is through at least one of the opposing sidewalls.

19. The mattress assembly of claim 16, wherein each of the protrusions comprises opposing sidewalls and a distal end, and the secondary passageway is through the distal end.

20. The mattress assembly of claim 17, wherein the secondary passageway exchanges airflow with a hollow portion of the at least one foam side support member through a lower surface opening of the at least one foam side support member.

21. The mattress assembly of claim 20, wherein the hollow portion extends longitudinally across the at least one foam side support member to form at least one longitudinal side support passageway between opposite external openings of the at least one foam side support member.

22. The mattress assembly of claim 20, wherein the hollow portion traverses across a width of the at least one foam side support member to form at least one latitudinal side support passageway between opposite external openings of the at least one foam side support member.

23. The mattress assembly of claim 20, wherein the hollow portion in the at least one foam side support member further exchanges the airflow though a tertiary opening through the inner surface of the at least one foam side support member.

24. The mattress assembly of claim 20, wherein the hollow portion in the at least one foam side support member further exchanges the airflow though a tertiary opening through the outer surface of the at least one foam side support member.

25. The mattress assembly of claim 20, wherein the hollow portion in the at least one foam side support member further exchanges the airflow through a tertiary opening in an upper surface of the at least one foam side support member.

26. The mattress assembly of claim 12, wherein the at least one foam side support member comprises:

at least one hollow portion; and

a first opening in the inner side surface configured to exchange airflow between the hollow portion and the mattress core.

27. The mattress assembly of claim 26, wherein the at least one foam side support member further comprises a second opening in the outer side surface configured to exchange airflow between the at least one hollow portion and the exterior environment.

28. The mattress assembly of claim 25, wherein the at least one foam side support member further comprises an upper opening in the upper surface configured to exchange airflow between the at least one hollow portion and the exterior environment.

29. The mattress assembly of claim 26, wherein the at least one hollow portion extends longitudinally across the at least one foam side support member to form at least one longitudinal side support passageway between opposite external openings of the at least one side support.

30. A foam side support member to support a side periphery of a mattress core, comprising a foam body, the foam body comprising:

a first surface configured to receive a weight of a user, a second surface opposite the first surface to transfer the weight of the user to a foam base,

an inner side surface configured to face an inner space containing a mattress core, the inner side surface connects the first surface to the second surface,

an outer side surface opposite the inner side surface and facing an exterior environment, and

an inner surface forming a passageway configured to exchange airflow between the inner space and the exterior environment.

31. The foam side support member of claim 30, wherein the passageway extends from an opening in the inner side surface to an opening in the outer side surface.

32. The foam side support member of claim 30, wherein the passageway extends from an opening in a second side surface to an opening in the outer side surface.

33. The foam side support member of claim 30, wherein the passageway is not perpendicular to the inner side surface.

34. The foam side support member of claim 30, wherein the inner side surface and the outer side surface comprise mainly closed cell foam.

35. The foam side support member of claim 30, wherein the passageway is not parallel to an extrusion direction of the foam side support member.

36. The foam side support member of claim 30, wherein the foam side support member comprises polyethylene.

37. A side rail assembly for supporting an edge of a mattress, comprising:

a layer of foam comprising at least one channel and/or a plurality of orifices,

wherein the layer is configured to be disposed about a perimeter of an inner core of the mattress, wherein the at least one channel extends through a length of the layer and the plurality of orifices extend through a width of the layer, and wherein the at least one channel and/or the plurality of orifices are configured to permit the flow of fluid from and to the inner core through the layer.

38. The side rail assembly of claim 37, wherein the layer comprises at least one foam side support member.

39. The side rail assembly of claim 37, wherein the at least one channel comprises at least one longitudinal passage.

40. The side rail assembly of claim 37, wherein the plurality of orifices comprises at least one passageway formed by an inner surface of the at least one foam side support member to permit an air exchange between the interior space and an exterior environment.

41. The side rail assembly of claim 37, wherein the inner core comprises the mattress core.

42. The side rail assembly of claim 38, wherein the width of the layer comprises a distance between an inner side surface of the at least one foam side support member and the outer side surface of the at least one foam side support member.

43. The side rail assembly of claim 37, wherein the flow of fluid comprises an air exchange.

44. The side rail assembly of claim 39, further comprising at least one inter-level channel connecting the at least one channel.

45. The side rail assembly of claim 38, further comprising at opening at a bottom surface or a second side of the at least one foam side support member, the opening is configured to be in fluid communication with a hollow portion of the at least one foam side support member and an inner base passageway of a foam base.

46. The mattress assembly of claim 12, wherein the at least one passageway comprises a plurality of passageways which are horizontally aligned and vertically offset.