US20220287469A1

US20220287469A1 - Adjustable mattress side rails

Info

Publication number: US20220287469A1
Application number: US17/691,009
Authority: US
Inventors: Brett Pearson; Aubree Carter; Jordan Campbell
Original assignee: Purple Innovation LLC
Current assignee: Callodine Commercial Finance LLC
Priority date: 2021-03-09
Filing date: 2022-03-09
Publication date: 2022-09-15
Also published as: CA3211590A1; EP4304420A2; WO2022192458A3; WO2022192458A2

Abstract

A side rail of a mattress that may be used with an adjustable bed may include a main body that facilitate adjustment of the mattress while maximizing contact between a bottom of the mattress and an upper supporting surface of an adjustable bedframe. More specifically, the main body of the side rail may include a top edge with one or more upper recesses therein and a bottom edge with one or more lower recesses therein. An upper insert may be secured within each upper recess, while a lower insert may be secured within each lower recess. The material from which each upper insert and lower insert is formed may be more compressible than a material from which the main body of the side rail is formed to enable the side rail and the mattress to bend with the supporting surface of the adjustable bedframe.

Description

CROSS-REFERENCE TO RELATED APPLICATION

A claim for priority to the Mar. 9, 2021 filing date of U.S. Provisional Patent Application No. 63/158,753, titled ADJUSTABLE MATTRESS SIDE RAILS (“the '753 Provisional Application”), is hereby made pursuant to 35 U.S.C. § 119(e). The entire disclosure of the '753 Provisional Application is hereby incorporated herein.

TECHNICAL FIELD

This disclosure relates generally to internal side edges, or side rails, for mattresses and, more specifically, to side rails for mattresses that may be used with adjustable beds. Even more specifically, this disclosure relates to side rails with main bodies that impart lateral structure to a mattress of which they are a part and compressible inserts that facilitate adjustment of the mattress while maximizing contact between a bottom of the mattress and an upper supporting surface of an adjustable bedframe. This disclosure also relates to mattresses, to adjustable beds, and to associated methods.

RELATED ART

Adjustable beds provide for adjustment of the mattresses thereon and of each individual laying on the mattress. An adjustable bed typically bends at two or more locations across its width to provide three sections that may be oriented for a variety of purposes. By way of example, an upper, or head, section of a mattress on an adjustable bed may be oriented to position an individual's head and back in a somewhat upright orientation, in more reclined orientations, or in a substantially horizontal orientation. As another example, a lower, or foot, section of a mattress on an adjustable bed may be oriented to position an individual's feet between inclined, horizontal, and reclined orientations. An intermediate section of the mattress on an adjustable bed may provide a transition between the head section and the foot section.
Conventionally, adjustable beds have found wide use in hospitals, care centers, and at other locations where individuals may need assistance in sitting up as they convalesce, where it may be desirable to occasionally change an individual's orientation as he or she lays in bed, or for other purposes. Individuals also use adjustable beds at home, as they many people enjoy laying in non-flat orientations as they rest or sleep. In addition, many people have found adjustable mattresses to provide certain additional benefits in helping them obtain a good night's rest, as well as health benefits, including, without limitation, the ability to improve breathing during sleep (e.g., by elevating the individual's head, neck, and back, etc.).
As a mattress is adjusted, or bent, by an adjustable bedframe, the side rails of the mattress are compressed at locations where the top of the mattress is bent concavely and stretched at locations where the top of the mattress is bent convexly. Conventional mattresses, however, resist such bending, compression, and stretching somewhat. As a result, the bottom of a conventional mattress usually does not conform well to the upper supporting surface of an adjustable bedframe, particularly at corners where the upper supporting surface of the adjustable bedframe is bent concavely, where the bottom of the mattress remains suspended above the concavely bent upper supporting surface of the adjustable bedframe.
One attempted solution has been to provide mattress-retaining brackets at the head and foot ends of adjustable bedframes. Due to their locations, such brackets are unable to influence bending at intermediate locations along the length of the mattress. Other attempted solutions have been to provide weakened regions (e.g., cutouts, accordion-like features, etc.) along the internal side edges, or side rails, of the mattress. Although weakened regions reduce the mattress's resistance to bending, they also reduce the structural integrity of the side rails.

SUMMARY

In various embodiments, a side rail of an adjustable mattress according to this disclosure has a configuration that enables its bottom edge and, thus, a bottom of a mattress of which it is a part, to conform to bends in an upper supporting surface of an adjustable bedframe.
A side rail according to this disclosure may include a main body with at least one upper recess and at least one lower recess, an upper insert within the at least one upper recess, and a lower insert within the at least one lower recess. In some embodiments, the side rail may include a plurality of upper recesses and corresponding upper inserts and/or a plurality of lower recesses and corresponding lower inserts.
Each upper recess may extend downwardly into a top edge of the main body, partially into the height of the main body, and across an entirety of a width of the main body. Each lower recess may extend upwardly into a bottom edge of the main body, partially into the height of the main body, and across an entirety of a width of the main body. Without limitation, an upper recess may have the shape of a triangular prism, a substantially triangular prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), a trapezoidal prism, a substantially trapezoidal prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), or the like. A lower recess may have the shape of a triangular prism, a substantially triangular prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), a trapezoidal prism, a substantially trapezoidal prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), a rectangular prism, a substantially rectangular prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), or the like.
The shape, dimensions, and location of each upper recess and each lower recess in the main body of a side rail may enable the upper recess and/or lower recess to accommodate bending of a mattress of which the side rail is a part, as well as enable a bottom of the mattress to maintain optimal contact with an upper supporting surface of an adjustable bedframe that carries the mattress. More specifically, each upper recess may be located at a position where an upper supporting surface of the adjustable bedframe and, thus, a top of a mattress thereon are expected to be bent at a concave angle. Each lower recess may be located at a position where the upper supporting surface of the adjustable bedframe and the top of the mattress thereon are expected to be bent at a convex angle.
The main body may comprise a material having a rigidity that imparts the side rail with sufficient structural integrity to laterally support a remainder of the mattress of which the side rail is a part. The material of the main body may also be compressible to prevent it from detracting from the overall compressibility and comfort provided by the mattress of which the side rail is a part.
An upper insert may be provided in each upper recess of the side rail, while a lower insert may be provided in each lower recess of the side rail. Each upper insert may substantially fill its corresponding upper recess. Thus, each upper insert may have a shape or configuration that complements, is the same as, or is substantially the same as a shape or configuration of the upper recess in which the upper insert is positioned. Each upper insert may be secured within its corresponding upper recess in a suitable manner (e.g., with a suitable cement or other adhesive material, etc.). Each lower insert may substantially fill its corresponding lower recess. Thus, each lower insert may have a shape or configuration that complements, is the same as, or is substantially the same as a shape or configuration of the lower recess in which the lower insert is positioned. Each lower insert may be secured within its corresponding lower recess in a suitable manner (e.g., with a suitable cement or other adhesive material, etc.).
A shape of each upper insert and each lower insert and a material from which each upper insert and each lower insert is formed may enables the side rail to readily flex when the mattress of which it is a part is bent in a corresponding direction. For example, the shape and material of each upper insert may enable the side rail to readily flex when a top of the mattress is bent concavely at a location where the upper insert is located. As another example, the shape and material of each lower insert may enable the side rail to readily flex when a top of the mattress is bent convexly at a location where the lower insert is located. Without limitation, the shape of each upper insert may be a triangular prism, a substantially triangular prism, or the like, while the shape of each lower insert may be a triangular prism, a substantially triangular prism, a trapezoidal prism, a substantially trapezoidal prism, a rectangular prism, a substantially rectangular prism, or the like.
The material from which each upper insert and each lower insert is formed may be readily compressible, but have sufficient rigidity to impart the side rail with acceptable structural integrity. By way of example only, each upper insert and each lower insert may comprise a compressible, resilient material. The compressible, resilient material may comprise a foam.
In another aspect, this disclosure includes mattresses that include side rails according to this disclosure. The side rails of such a mattress may, along with a base, a head rail, and a foot rail, define a foundation for a cushioning element of the mattress. More specifically, the elements of the foundation may define a receptacle for the cushioning element. The cushioning element may comprise coil springs, pressurizable bladders, memory foam, or any other suitable cushioning element for a mattress, or a combination of cushioning elements.
Additionally, such a mattress may include a gel cushion, such as those disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750, the entire disclosures of which are hereby incorporated herein. Such a gel cushion may include a plurality of resiliently compressible interconnected or intersecting walls defining an array of interconnected, resiliently buckling columns, with a void in each column. Stated another way, the interconnected or intersecting walls may define an array of hollow columns, or voids. Such a gel cushion may be formed from any of a variety of compressible, resilient materials, including cushioning foams and elastomeric materials, such as the extended A B A triblock copolymers disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein.
In addition, the mattress may include a cover over the foundation, cushioning element, and any gel cushion over the foundation and cushioning element.
As another aspect, adjustable beds are disclosed. An adjustable bed of this disclosure includes an adjustable bedframe and a mattress that includes side rails according to this disclosure.
Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosure, should be apparent to those of ordinary skill in the art through consideration of the preceding disclosure, the description that follows, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a side view of an embodiment of a side rail that may be included in an adjustable mattress;

FIG. 2 is an enlarged view of the upper recesses and upper inserts of the embodiment of the side rail shown in FIG. 1;

FIG. 3 is a side view of the embodiment of the side rail shown in FIG. 1, with the top edge of the side rail bent concavely between the two upper recesses and upper inserts shown in FIG. 2;

FIG. 4A is a perspective view another embodiment of a side rail that may be included in an adjustable mattress;

FIG. 4B is a top view of the embodiment of the side rail shown in FIG. 4A;

FIG. 4C is a side view of the embodiment of the side rail shown in FIG. 4A;

FIG. 4D is an end view of the embodiment of the side rail shown in FIG. 4A;

FIG. 5A is a perspective view of yet another embodiment of a side rail that may be included in an adjustable mattress;

FIG. 5B is a top view of the embodiment of the side rail shown in FIG. 5A;

FIG. 5C is a side view of the embodiment of the side rail shown in FIG. 5A;

FIG. 5D is a bottom view of the embodiment of the side rail shown in FIG. 5A; and

FIG. 6 is a perspective view of the interior of an embodiment of a mattress that includes the embodiment of the side rail shown in FIGS. 4A-4D.

DETAILED DESCRIPTION

With reference to FIGS. 1 and 2, an embodiment of a side rail 10 for an adjustable mattress (not shown in FIG. 1 or FIG. 2) is depicted. The side rail 10 includes a main body 20 with a top edge 22, a bottom edge 24, a head end 26, and a foot end 28. One or more upper recesses 30 may open to the top edge 22 of the main body 20 and extend toward the bottom edge 24 of the main body 20. One or more lower recesses 40 may open to the bottom edge 24 of the main body 20 and extend toward the top edge 22 of the main body 20. An upper insert 60 may be provided in each upper recess 30. A lower insert 70 may be provided in each lower recess 40.
A height of the main body 20 and, thus, of the side rail 10 extends between the top edge 22 and bottom edge 24 of the main body 20. The main body 20 also includes an interior surface 21, which faces an interior of a mattress (not shown in FIG. 1 or FIG. 2) of which the side rail 10 is a part, as well as an exterior surface 29, which is opposite from the interior surface 21 and faces outwardly when the side rail 10 is assembled with other components of the mattress. Both the interior surface 21 and the exterior surface 29 extend between the top edge 22 and the bottom edge 24 of the side rail 20. A width of the main body 20 and, thus, of the side rail 10 extends between the interior surface 21 and exterior surface 29 of the main body 20.
The main body 20 may be formed from a material having a rigidity that imparts the side rail 10 with sufficient structural integrity to laterally support a remainder of the mattress (not shown in FIG. 1 or FIG. 2) of which the side rail 10 is a part. The material of the main body 20 may also be compressible to prevent it from detracting from the overall compressibility and comfort provided by the mattress of which the side rail 10 is a part. In a specific embodiment, the main body 20 may comprise a so-called “structured foam,” which may comprise a compressible foam material with an indentation load deflection (ILD) rating of about 35 to about 65 (e.g., 40, 45, 50, 55, 60, 65, etc.). An ILD rating is the amount of pressure, converted to weight in pounds, it takes to indent a circular area of 50 square inches (i.e., lbs/50 in²) over a four inch thick piece of the structured foam by 25% (i.e., one inch). In a specific embodiment, the main body 20 may comprise a high density polyethylene (HDPE) foam.
Each upper recess 30 may extend downwardly into the top edge 22 of the main body 20, partially into the height of the main body 20, and across an entirety of the width of the main body 20. Each upper recess 30 may include: a base 32 adjacent to but spaced apart from the bottom edge 24 of the main body 20; a head surface 34 extending at a non-perpendicular angle to the top edge 22, from the top edge 22 to the base 32 and toward the foot end 28 of the main body 20; and a foot surface 36 extending at a non-perpendicular angle to the top edge 22, from the top edge 22 to the base 32 and toward the head end 26 of the main body 20. The base 32 of the upper recess 30 may be defined by a junction between the head surface 34 and the foot surface 36 of the upper recess 30. In some embodiments, that junction may be radiused (e.g., it may comprise an arc of a circle, etc.) or otherwise rounded. Alternatively, the base 32 of the upper recess 30 may be elongated. An elongated base 32 may be substantially parallel to the bottom edge 24 of the main body 20.
Each upper recess 30 may be positioned at a location along the length of the main body 20 of the side rail 10 where the top of the mattress (not shown in FIG. 1 or FIG. 2) is expected to be bent concavely. For example, each upper recess 30 may be positioned at a location that will be superimposed over a joint between a head section and an intermediate section of an adjustable bedframe (not shown in FIG. 1 or FIG. 2). Alternatively, a plurality of upper recesses 30 may be positioned locations that will be superimposed with an area on both sides of a joint between the head section and the intermediate section of the adjustable bedframe. As illustrated by FIGS. 1 and 2, the upper recesses 30 are positioned between or at a transition between a head portion 12 of the side rail 10 and an intermediate portion 14 of the side rail 10.
The side rail 10 may include a main body 20 with a plurality of upper recesses 30. In the embodiment shown in FIGS. 1 and 2, the side rail 10 may include two upper recesses 30. In the embodiment of side rail 10′ shown in FIGS. 4A-4D, the main body 20′ may include four upper recesses 30′. Regardless of how many upper recesses 30 are included, they may be grouped together.
With continued reference to FIGS. 1 and 2, each lower recess 40 in the bottom edge 24 of the main body 20 of the side rail 10 extends upwardly from the bottom edge 24 into the main body 20, partially into the height of the main body 20, and across an entirety of the width of the main body 20. Each lower recess 40 may include: a top 42 adjacent to but spaced apart from the top edge 22 of the main body 20; a head surface 44 extending at an angle (e.g., a non-perpendicular angle, a perpendicular angle, etc.) to the bottom edge 24, from the bottom edge 24 to the top 42 of the main body 20 and, in embodiments where the angle is a non-perpendicular angle, toward the foot end 28 of the main body 20; and a foot surface 46 extending at an angle (e.g., a non-perpendicular angle, a perpendicular angle, etc.) to the bottom edge 24, from the bottom edge 24 to the top 42 and, in embodiments where the angle is a non-perpendicular angle, toward the head end 26 of the main body 20. The top 42 of the lower recess 40 may be defined by a junction between the head surface 44 and the foot surface 46 of the upper recess 40. In some embodiments, that junction may be radiused or otherwise rounded. Alternatively, the top 42 of the lower recess 40 may be elongated. An elongated top 42 may be substantially parallel to the top edge 22 of the main body 20.
Each lower recess 40 may be positioned at a location along the length of the main body 20 of the side rail 10 where the top of the mattress (not shown in FIG. 1 or FIG. 2) is expected to be bent convexly. For example, each lower recess 40 may be positioned at a location that will be superimposed over a joint between an intermediate section and a foot section of an adjustable bedframe (not shown in FIG. 1 or FIG. 2). Alternatively, a plurality of lower recesses 40 may be positioned at locations that will be superimposed with an area on both sides of a joint between the intermediate section and the foot section of the adjustable bedframe. As illustrated by FIG. 1, the lower recess 40 is positioned between or at a transition between the intermediate portion 14 of the side rail 10 and a foot portion 16 of the side rail 10.
The side rail 10 may include one or more lower recesses 40. In the embodiment depicted by FIGS. 1 and 2, the side rail 10 may include a single lower recess 40. In the embodiment of side rail 10′ shown in FIGS. 4A-4D, the main body 20′ may include two lower recesses 40′. Regardless of how many lower recesses 40 are included, they may be grouped together.
An upper insert 60 may be provided in each upper recess 30 of the main body 20 of the side rail 10. Each upper insert 60 may substantially fill its corresponding upper recess 30 and include a top edge 62 that is coplanar or substantially coplanar with the top edge 22 of the main body 20, a base 64 adjacent to the base 32 of the corresponding upper recess 30, a head surface 66 adjacent to the head surface 34 of the corresponding upper recess 30, and a foot surface 68 adjacent to the foot surface 36 of the corresponding upper recess 30. An entirety of each of the base 64, head surface 66, and foot surface 68 of the upper insert 60 may contact and be secured to (e.g., with a suitable cement or other adhesive material, etc.) its corresponding base 32, head surface 34, and foot surface 36 of the corresponding upper recess 30. Thus, a shape or configuration of each upper insert 60 may complement, be the same as, or be substantially the same as a shape or configuration of the upper recess 30 in which the upper insert 60 is positioned.
A lower insert 70 may be provided in each lower recess 40 of the main body 20 of the side rail 10. Each lower insert 70 may substantially fill its corresponding lower recess 40 and include a bottom edge 72 that is coplanar or substantially coplanar with the bottom edge 24 of the main body 20 of the side rail 10, a top 74 adjacent to the top 42 of the corresponding lower recess 40, a head surface 76 adjacent to the head surface 44 of the corresponding lower recess 40, and a foot surface 78 adjacent to the foot surface 46 of the corresponding lower recess 40. An entirety of each of the top 74, head surface 76, and foot surface 78 of the lower insert 70 may contact and be secured to (e.g., with a suitable cement or other adhesive material, etc.) its corresponding top 42, head surface 44, and foot surface 46 of the corresponding lower recess 40. Thus, a shape or configuration of each lower insert 70 may complement, be the same as, or be substantially the same as a shape or configuration of the lower recess 40 in which the lower insert 70 is positioned.
A shape of each upper insert 60 and each lower insert 70 and a material from which each upper insert 60 and each lower insert 70 is formed may enable the side rail 10 to readily flex when the mattress (not shown in FIG. 1 or FIG. 2) of which it is a part is bent in a corresponding direction. For example, the shape and material of each upper insert 60 may enable the side rail 10 to readily flex when a top of the mattress is bent concavely at a location where the upper insert 60 is located. As another example, the shape and material of each lower insert 70 may enable the side rail 10 to readily flex when a top of the mattress is bent convexly at a location where the lower insert 70 is located.
The material from which each upper insert 60 and each lower insert 70 is formed may be readily compressible, but have sufficient rigidity to impart the side rail 10 with acceptable structural integrity. By way of example only, each upper insert 60 and each lower insert 70 may comprise a compressible, resilient material. The compressible, resilient material may comprise a foam. The compressible, resilient material of each upper insert 60 and each lower insert 70 may be more readily compressible than the compressible, resilient material of the main body 20 to which the upper insert 60 and lower insert 70 are secured. For example, an ILD rating of the compressible, resilient material of each upper insert 60 and each lower insert 70 of a side rail 10 may be less than an ILD rating of the compressible, resilient material from which the main body 20 of the side rail 10 is formed. An ILD rating of the compressible resilient material may be 18 to about 24 (e.g., 18, 20, 22, 24, etc.). In a specific embodiment, each upper insert 60 and/or each lower insert 70 may be formed from a medium density polyethylene (MDPE) foam.
While FIGS. 1 and 2 show each upper recess 30 with an upper insert 60 therein and each lower recess 40 with a lower insert 70 therein, one, more than one, or all of the upper recesses 30 and/or lower recesses 40 may lack a corresponding upper insert 60 or lower insert 70 and, thus, remain open, comprising a relief cut in the main body 20 of the side rail 10.
FIG. 3 shows how the upper inserts 60 of an embodiment of a side rail 10 may compress and, thus, give way more readily than the main body 20 of the side rail 10. As illustrated, the top edge 22 of the main body 20 of the side rail 10 is bent concavely at a location where two upper recesses 30 and their corresponding upper inserts 60 are located. While the upper inserts 60 compress from between their head surfaces 66 and their foot surfaces 68, shortening their top edges 62, the top edge 22 of the main body 20 remains substantially unbent and otherwise unaffected. Moreover, the upper recesses 30 and the upper inserts 60 therein control the location at which the bottom edge 24 of the main body 20 bends and limits the distance along a length of the bottom edge 24 along which bending occurs.
The embodiment of side rail 10′ depicted by FIGS. 4A-4D includes a main body 20′ with four upper recesses 30 a′, 30 b′, 30 c′, 30 d′ (each also referred to as an upper recess 30′) and two lower recesses 40 a′ and 40 b′ (each also referred to as a lower recess 40′). An upper insert 60 a′, 60 b′, 60 c′, 60 d′ (each also referred to as an upper insert 60′) is secured in place within a corresponding upper recess 30 a′, 30 b′, 30 c′, 30 d′. A lower insert 70 a′, 70 b′ (each also referred to as a lower insert 70′) is secured in place within a corresponding lower recess 40 a′, 40 b′.
The four upper recesses 30′ and corresponding upper inserts 60′ are grouped together at a location where a top of a mattress (not shown in FIGS. 4A-4D) of which the side rail 10′ is a part will be bent concavely (e.g., between or at a transition between a head region and an intermediate region along the length, or height, of the mattress, etc.). For example, the upper recesses 30′ may be positioned between or at a transition between a head portion 12′ of the side rail 10′ and an intermediate portion 14′ of the side rail 10′. The two lower recesses 40′ and corresponding lower inserts 70′ are grouped together at a location where a top of the mattress of which the side rail 10′ is a part will be bent convexly (e.g., between or at a transition between an intermediate region and a foot region along the length, or height, of the mattress, etc.). For example, the lower recesses 40′ may be positioned between or at a transition between the intermediate portion 14′ of the side rail 10′ and a foot portion 16′ of the side rail 10′.
While FIGS. 4A-4D show a side rail 10′ with each upper recess 30′ including an upper insert 60′ therein and each lower recess 40′ including a lower insert 70′ therein, one, more than one, or all of the upper recesses 30′ and/or lower recesses 40′ may lack a corresponding upper insert 60′ or lower insert 70′ and, thus, remain open, comprising a relief cut in the main body 20′ of the side rail 10′.
FIGS. 5A-D depict yet another embodiment of a side rail 10″. The side rail 10″ includes a main body 20″ with at least one upper recess 30″ (five upper recesses 30 a″, 30 b″, 30 c″, 30 d″, 30 e″ are depicted) in the top edge 22″ of the main body 20″. In addition, the side rail 10″ includes at least one lower recess 40″ (a single lower recess 40″is depicted) in a bottom edge 24″ of the main body 20″. As depicted, each upper recess 30″ and lower recess 40″ may have the same or substantially the same dimensions. Alternatively, the dimensions of the upper recess(es) 30″ and lower recess(es) 40″ may differ from each other.
The upper recesses 30″ and/or lower recesses 40″ of the side rail 10″ may be grouped. As shown in FIGS. 5A-5D, a first group 31A″ of upper recesses 30 a″, 30 b″, 30 c″ may be located between or at a transition between a head region 12″ and an intermediate region 14″ of the side rail 10″. A second group 31B″ of upper recesses 30 d″, 30 e″ may be positioned between or at a transition between the intermediate region 14″ of the side rail 10″ and a foot region 16″ of the side rail 10″. The lower recess 40″ may also be positioned between or at a transition between the intermediate region 14″ and the foot region 16″, closer to the foot end 28″ of the main body 12″ of the side rail 10″ than the second group 31B″ of upper recesses 30 d″, 30 e″. Alternatively, the lower recess 40″ may be positioned at an intermediate location along the length of the foot portion 16″ of the side rail 10″.
While FIGS. 5A-5D show a side rail 10″ with each upper recess 30″ and lower recess 40″lacking an insert and, thus, remaining open, comprising a relief cut in the main body 20″ of the side rail 10″, one, more than one, or all of the upper recesses 30″ and/or lower recesses 40″ may include an insert.
FIGS. 4A-4D and FIGS. 5A-5D illustrate specific shapes and dimensions for the embodiments of side rails 10′ and 10″ depicted thereby and the elements of the depicted embodiments of the side rails 10′ and 10″, including the main body 20′, 20″, each upper recess 30′, 30″, upper insert 60′, 60″, lower, recess 40′, 40″, and lower insert 70′, 70″. Although FIGS. 4A-4D and FIGS. 5A-5D provide specific shapes and dimensions for each of the features of the illustrated side rails 10′ and 10″, the details provided by FIGS. 4A-4D and FIGS. 5A-5D are merely representative.
Turning now to FIG. 6, an embodiment of a mattress 100 is depicted with a side rails 10′ (see also FIGS. 4A-4D) positioned along each side 102 of the mattress 100. The side rails 10′, along with a base (not shown), a head rail (not shown), and a foot rail (not shown), may define at least part of a foundation 110 of the mattress 100. The foundation 110 may define a receptacle (not shown) for at least one cushioning element (not shown) of the mattress.
The cushioning element (not shown) of the mattress 100 may comprise coil springs (not shown) (see, e.g., U.S. Patent Application Publication US 2019/0150632 A1, the entire disclosure of which is hereby incorporated herein), one or more pressurizable bladders (see, e.g., U.S. Pat. No. 11,213,139, the entire disclosure of which is hereby incorporated herein), memory foam, and/or any other suitable cushioning element for a mattress, or a combination of cushioning elements.
An intermediate layer 120 may be positioned over the foundation 110. A top cushioning element 130 may be positioned over the intermediate layer 120. The top cushioning element 130 may comprise a gel cushion (not shown). The gel cushion of the top cushioning element 130 may include a plurality of resiliently compressible intersecting or interconnected walls defining an array of interconnected, resiliently buckling columns, with a void in each column, as described by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750. Stated another way, the interconnected or intersecting walls may define an array of hollow columns, or voids. Such a gel cushion may be formed from any of a variety of compressible, resilient materials, including cushioning foams and elastomeric materials, such as the extended A-B-A triblock copolymers described by U.S. Pat. Nos. 6,413,458, 6,797,765, and 7,964,664. While such a gel cushion may extend to the periphery of the inner assembly of the mattress 100, such a gel cushion may be surrounded by foam edge pieces 135. Although not shown in FIG. 6, the depicted inner assembly of the mattress 100 may be enclosed within a mattress cover.
In FIG. 6, a side rail 10′ of the mattress 100 is shown in a bent arrangement, in which a top 104 of the mattress 100 and the top edge 22′ (FIGS. 4A-4C) of the main body 20′ of the side rail 10′ are bent concavely at a location between a head region 106 of the mattress 100 and an intermediate region 107 of the mattress 100. The upper inserts 60′ of the side rail 10′, especially upper inserts 60 a′ and 60 b′, are shown in compressed states. In addition, the top 104 of the mattress 100 and the top edge 22′ of the main body 20′ of the side rail 10′ are bent convexly at a location between the intermediate region 107 and a foot region 108 of the mattress 100. The lower inserts 70′ of the side rail 10′, particularly the lower insert 70 a′, is in a compressed state.
In addition to illustrating an embodiment of a side rail 10′ and an embodiment of a mattress 100, FIG. 6 depicts an embodiment of an adjustable bed 200, with the mattress 100 resting upon an adjustable bedframe 210. The adjustable bedframe 210 may include a support surface 212 that includes a plurality of support elements 214, 216, and 218. More specifically, the support surface 212 may include a head support element 212, an intermediate support element 214, and a foot support element 216. As illustrated, at least one concavely bending joint 215 may be located between the head support element 212 and the intermediate support element 216. At least one convexly bending joint 217 may be located between the intermediate support element 216 and the foot support element 218. Specifically, the adjustable bedframe 210 may comprise the PURPLE POWERBASE adjustable bedframe available from Purple Innovation, LLC, of Lehi, Utah. See, e.g., U.S. Patent Application Publication US 2018/0168359 A1, the entire disclosure of which is hereby incorporated herein. Of course, a bed according to this disclosure may include any other embodiment of adjustable bedframe with support elements and joints that differ from those (in number, location, etc.) shown in FIG. 6, as well as a mattress with side rails that include upper and lower recesses and upper and lower inserts that are positioned for use with the arrangement of support elements and joints of the adjustable bedframe.
Although the preceding disclosure provides many specifics, these should not be construed as limiting the scope of any of the claims that follow, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, and of their elements and features, may be devised which do not depart from the spirit or scope of any of the claims. Features from different embodiments may be employed in combination. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.

Claims

What is claimed:

1. A side rail for a mattress for an adjustable bed, comprising:

a main body comprising a first material having a first rigidity and a first compressibility;

at least one upper recess extending into a top edge of the main body, partially into a height of the main body, and across an entirety of a width of the main body, the at least one upper recess including:

a base adjacent to but spaced apart from a bottom edge of the main body;

a head surface extending at a non-perpendicular angle to the top edge, to the base and toward a foot end of the main body; and

a foot surface extending at a non-perpendicular angle to the top edge, to the base and toward a head end of the main body;

at least one upper insert substantially filling the at least one upper recess, the at least one upper insert comprising a second material and including a top edge coplanar with the top edge of the main body, a base adjacent to the base of the at least one upper recess, a head surface adjacent to the head surface of the at least one upper recess, and a foot surface adjacent to the foot surface of the at least one upper recess;

at least one lower recess extending into the bottom edge of the main body, partially into the height of the main body, and across the entirety of the width of the main body, the at least one lower recess including:

a top adjacent to but spaced apart from the top edge of the main body;

a head surface extending at an angle to the bottom surface, to the top; and

a foot surface extending at an angle to the bottom surface, to the top; and

at least one lower insert substantially filling the at least one lower recess, the at least one lower insert comprising a third material and including a bottom edge coplanar with the bottom edge of the main body, a top adjacent to the top of the at least one lower recess, a head surface adjacent to the head surface of the at least one lower recess, and a foot surface adjacent to the foot surface of the at least one lower recess.

2. The side rail of claim 1, wherein the at least one upper recess is positioned at a location where an upper surface of the mattress is expected to bend concavely.

3. The side rail of claim 1, wherein the at least one lower recess is positioned at a location where the upper surface of the mattress is expected to bend convexly.

4. The side rail of claim 1, comprising a plurality of upper recesses, a plurality of upper inserts, a plurality of lower recesses, and a plurality of lower inserts.

5. The side rail of claim 4, wherein the plurality of upper recesses and the plurality of upper inserts are grouped together.

6. The side rail of claim 4, wherein the plurality of lower recesses and the plurality of lower inserts are grouped together.

7. The side rail of claim 1, wherein the base of the at least one upper recess is defined by a junction between the head surface and the foot surface of the at least one upper recess.

8. The side rail of claim 1, wherein the base of the at least one upper recess is elongated.

9. The side rail of claim 8, wherein the base of the at least one upper recess is substantially parallel to the bottom edge of the main body.

10. The side rail of claim 1, wherein the top of the at least one lower recess is defined by a junction between the head surface and the foot surface of the at least one lower recess.

11. The side rail of claim 1, wherein the top of the at least one lower recess is elongated.

12. The side rail of claim 11, wherein the top of the at least one lower recess is substantially parallel to the top edge of the main body.

13. The side rail of claim 1, wherein the second material and the third material are less rigid and more compressible than the first material.

14. A mattress for an adjustable bed, comprising:

a foundation including a base, a head rail, a foot rail, and a pair of side rails defining a receptacle, each side rail including:

a main body formed from a first compressible material and including a top edge with at least one upper recess therein and a bottom edge with at least one lower recess therein;

at least one upper insert formed from a second compressible material secured within the at least one upper recess;

at least one lower insert formed from a third compressible material secured within the at least one lower recess;

a cushioning element within the receptacle defined by the foundation; and

a cover over the cushioning element, the head rail, the foot rail, and the pair of side rails of the foundation.

15. The mattress of claim 14, wherein the at least one upper recess and the at least one upper insert has a shape of a triangular prism.

16. The mattress of claim 15, wherein the at least one lower recess and the at least one lower insert has a shape of a triangular prism, a trapezoidal prism, or a rectangular prism.

17. The mattress of claim 14, wherein the second compressible material and the third compressible material are more compressible than the first material.

18. The mattress of claim 14, further comprising:

a gel cushion over the cushioning element and comprising interconnected walls formed from an elastomeric material and defining an array of columnar voids.

19. The mattress of claim 14, wherein the cushioning element comprises an array of coils and/or at least one pressurizable bladder.

20. An adjustable bed, comprising:

an adjustable frame including:

a support surface including a plurality of support elements;

at least one concavely bending joint between a head support element and an intermediate support element of the plurality of support elements; and

at least one convexly bending joint between the intermediate support element and a foot support element of the plurality of support elements; and

a mattress on a support surface of the adjustable frame and including:

a main body formed from a first compressible material and including a top edge with at least one upper recess therein, the upper recess positioned over the at least one concavely bending joint of the adjustable frame, and a bottom edge with at least one lower recess therein, the at least one lower recess positioned over the at least one convexly bending joint of the adjustable frame;

a cushioning element within the receptacle defined by the foundation; and