WO2023004154A1 - Matelas quatre-en-un pourvu de paramètres personnalisables de confort de sommeil - Google Patents

Matelas quatre-en-un pourvu de paramètres personnalisables de confort de sommeil Download PDF

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Publication number
WO2023004154A1
WO2023004154A1 PCT/US2022/038075 US2022038075W WO2023004154A1 WO 2023004154 A1 WO2023004154 A1 WO 2023004154A1 US 2022038075 W US2022038075 W US 2022038075W WO 2023004154 A1 WO2023004154 A1 WO 2023004154A1
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WO
WIPO (PCT)
Prior art keywords
layer
foam
mattress
outer layer
sleeping
Prior art date
Application number
PCT/US2022/038075
Other languages
English (en)
Inventor
Matt Smith
Original Assignee
Matt Smith
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Matt Smith filed Critical Matt Smith
Publication of WO2023004154A1 publication Critical patent/WO2023004154A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/10—Loose or removable furniture covers
    • A47C31/105—Loose or removable furniture covers for mattresses

Definitions

  • the present disclosure relates to the field of bed mattresses, and more specifically to mattresses having multiple layers of different types of materials.
  • a wide variety of bed mattresses are generally well-known in the art that allow users to sleep comfortably.
  • Mattresses may broadly include wire spring based mattresses, foam based mattresses, and inflatable mattresses.
  • Many modern beds use a foam based mattress that does not include any springs, but instead may be made up of one or more layers of foam substrate.
  • Multiple layer foam mattresses come in a variety of forms. The type of material, the thickness of each layer, and the density of each layer in a multi-layer foam mattress can all be varied to provide a mattress with different characteristics.
  • mattress customers may also change their preferences in mattress characteristics over time. Such changes may be the result of changes in environment such as moving to a new home, or changes in the weather across seasons. Alternatively, such changes in customer preference may be caused by a life event such as a medical condition that may temporarily or permanently change their needs with respect to mattress characteristics.
  • the disclosure provides a multi-layer foam mattress comprising: a foam pad, the foam pad including a first foam layer, the first foam layer have a first firmness; a second foam layer, a third foam layer, the third foam layer having a second firmness, the second firmness being greater than the first firmness; wherein the second foam layer is disposed between the first foam layer and the second foam layer; and an removable outer layer, the removable outer layer completely surrounding the foam pad on all sides; the removable outer layer having a first side being made of a material having a first heat transference; the removable outer layer having a second side, the second side being configured to cover an opposite sleeping side of the mattress from the first side of the removable outer layer, the second side being made of a material having a second heat transference that transfers heat away from a user when sleeping such that a temperature observed by the user when sleeping is at least 3° F less than a temperature observed by the user when sleeping on the first side; the removable outer layer including a means for reversibly opening the outer layer such
  • this disclosure provides a method of customizing a multi-layer foam mattress comprising: receiving a mattress comprising a foam pad and a removable outer layer; the foam pad including a first foam layer, the first foam layer have a first firmness; a second foam layer, the second foam layer a third foam layer, the third foam layer having a second firmness, the second firmness being greater than the first firmness; wherein the second foam layer is disposed between the first foam layer and the second foam layer; the removable outer layer including a first side being made of a material having a first heat transference; the removable outer layer having a second side, the second side being configured to cover an opposite sleeping side of the mattress from the first side of the removable outer layer, the second side being made of a material having a second heat transference that transfers heat away from a user when sleeping such that a temperature observed by the user when sleeping is at least 3° F less than a temperature observed by the user when sleeping on the first side; removing the removable outer layer from the foam pad; flipping
  • FIG. 1 is cross-sectional view of a first embodiment of a mattress in accordance with this disclosure
  • FIG. 2 is cross-sectional view of a second embodiment of a mattress in accordance with this disclosure.
  • FIG. 3 is a photograph of a flat-on view of a first lateral side of an embodiment of a mattress in accordance with this disclosure showing the multi-layer foam pad therein.
  • FIG. 4 is a top isometric view of an embodiment of a multi-zone support layer in the multi-layer foam pad
  • FIG. 5 is a photograph of a flat-on view of a first lateral side of an embodiment of a mattress showing several vents into the multi-zone support layer;
  • FIG. 6 is an isometric view photograph of an embodiment of a mattress with the removable outer layer partially opened;
  • FIG. 7 is a photograph of a temperature indicator on the removable outer layer
  • FIG. 8 is a photograph of another temperature indicate on the removable outer layer
  • FIG. 9 is a table showing a matrix of the four configurations the mattress may be customized into by changing the orientation of the foam pad and changing the orientation of the removable outer layer;
  • FIG. 10 is a flowchart showing a method of customizing a mattress. DETAILED DESCRIPTION
  • mattresses that may be customized with respect to one or more aspects in order to achieve a desired comfort profile.
  • a mattress may be a multi-layer foam based mattress.
  • Such a customizable mattress may allow a customer to change the parameters of their mattress, so as to e.g. avoid needing to purchase a new mattress when their sleep comfort preferences or needs change.
  • a mattress may broadly refer to a structure suitable for human beings to sleep on.
  • mattresses generally come in standardized sizes such as twin, twin extra-long, queen, king, “California” king, and others.
  • this disclosure is directed to a multi-layer foam mattress having a removable outer layer that allows for customization of at least two sleep characteristics of the mattress.
  • the mattress in accordance with this disclosure may be referred to as a “four in one” mattress, because it may offer at least two degrees of freedom with respect to a first sleep characteristic and at least two degrees of freedom with respect to a second sleep characteristics. Therefore, there may be a total of four different combinations across the two sleep characteristics.
  • FIG. 1 shows a first embodiment of a mattress in accordance with this disclosure.
  • a mattress may have a removable outer layer, that surrounds a foam pad.
  • Foam pad may include a first layer that has a first firmness, i.e. first layer may be a softer layer.
  • Foam pad may then include a second layer the is a lumbar support core layer.
  • foam pad may include a third layer that has a second firmness. The second firmness may be greater than the first firmness, i.e. third layer may be a firmer layer.
  • the lumbar support core layer may be disposed between the first softer layer and the third firmer layer.
  • FIG. 1 shows a cross-sectional view, as taken from one lateral side to a second lateral side.
  • outer layer may have a first side made of a material having a first heat transference.
  • outer layer may have a second side made of a material having a second heat transference.
  • the second side being configured to cover an opposite sleeping side of the mattress from the first side of the removable outer layer.
  • the second heat transference being such that the outer layer transfers heat away from a user when sleeping such that a temperature observed by the user when sleeping is at least 3° F less than a temperature observed by the user when sleeping on the first side. In some embodiments, this difference may be at least 4° F less, or may be at least 5° F less.
  • the outer layer may also have an opening mechanism (such as a zipper) that allows the outer layer to be fully opened and removed from the foam pad. Because the outer layer may be removed in this way, a user may selected which side of the outer layer serves as the top sleeping surface.
  • an opening mechanism such as a zipper
  • a user may select the warmer side or the cooler side of the outer layer in order to best fit the user’s preferences and needs with regards to temperature while sleeping.
  • FIG. 2 shows a cross-sectional view of a second embodiment of a mattress in accordance with this disclosure.
  • foam pad may include a first layer that is the softer layer.
  • foam pay may include a multi-zone support layer adjacent to the softer layer.
  • the multi-zone support layer may serve as lumbar support, and is described in further detail below with respect to FIG. 4.
  • the foam pad shown in FIG. 2 may include a lumbar support core layer that is adjacent to the multi-zone support layer.
  • Lumber support core layer may serve to provide structure and rigidity to the center of the foam multi-layer pad.
  • foam pad may include firmer layer adjacent to the lumbar support core layer.
  • either of these layers may serve as the sleeping surface by flipping the foam pad. In this way, a user may customize the firmness level of the mattress by selecting either the softer layer or the firmer layer.
  • softer layer may have a height that (as is generally known in the art of mattresses) affects its properties and the overall feel of the mattress. Height of softer layer may, in some embodiments, be approximately three inches - or approximately one third of the total height of the foam pad.
  • multi-zone support layer may have a height that may be, in some embodiments, approximately 2 inches or 2/9ths of the total height of the foam pad.
  • Lumbar support core layer may have a height of approximately 4 inches or 4/9 th of the total height of the foam pad.
  • firmer layer may have a height that may be approximately three inches or 1/3 of the total height of the foam pad.
  • the softer layer may, in some embodiments, be a viscoelastic polyurethane foam.
  • This viscoelastic polyurethane may also be a gel viscoelastic mixture, that includes a gel swirl throughout the foam mixture.
  • the gel mixture may help with temperature management, as viscoelastic foams may otherwise retain heat.
  • the gel viscoelastic polyurethane mixture foam may have a density of about 3 lbs per cubic foot.
  • the gel viscoelastic polyurethan foam may have a firmness rating of 10 lb ILD.
  • the ILD is generally known in the art as the indentation load deflection (also referred to as IFD, indentation force-deflection value), and may be tested according to ASTM D3574.
  • the multi-zone support layer may be a polyurethane foam.
  • This layer polyurethane foam may have a density of about 1.5 lbs per cubic foot.
  • This layer may also have a firmness rating of 35 lb ILD. The firmness value of 35 lb ILD in this layer may help ensure that the multi-zone support layer provides lumbar support throughout the mattress.
  • the lumbar support layer may also be a polyurethane foam.
  • This layer of polyurethane foam may have a density of about 1.8 lbs per cubic foot.
  • This layer may also have a firmness rating of 30 lb ILD.
  • the firmer layer may be a “latex like” polyurethane foam.
  • this foam may also be made from polyurethane it may nonetheless have several characteristics that are designed to mimic the characteristics of a latex foam. This may allow the foam to achieve favorable properties associated with latex at a fraction of the cost.
  • This layer may have a density of 3 lbs per cubic foot.
  • This layer may have a firmness rating of 23 lb ILD. In one particular embodiment, the 23 lb ILD rating of the firmer “latex like” layer is therefore a higher firmness than the 10 lb ILD firmness rating of the softer gel viscoelastic layer.
  • FIG. 3 shows a photograph of a lateral side of the foam pad, including all the layers as discussed above.
  • FIG. 3 also shows a vent in the multi- zone support layer.
  • FIG. 3 also shows the thin fire barrier layer that directly surrounds the foam pad, as well.
  • a fire barrier layer may be required by various governmental regulations concerning mattresses.
  • the gel swirl in the softer layer is also shown in FIG. 3.
  • FIG. 4 shows one particular embodiment of a multi-zone support layer that may be used in a mattress in accordance with this disclosure.
  • multi-zone support layer may change in thickness so as to provide additional support where it is most needed due to the location of a person’s body weight.
  • Multi-zone support layer may be roughly divided into a first zone having a first height, and then a second zone of height greater than the first height, and third zone having a height that maybe the same as the height in the first zone. In particular, in the second zone the height may gradually increase until it reaches a peak height where a person’s body weight would likely lie when sleeping.
  • This configuration may provide additional lumbar support so as to properly conform to a person’s body, even when the person’s body otherwise sinks into the softer layer (to which the multi-zone support layer is adjacent).
  • the multi-zone support layer may therefore have a “hump” in the middle in order to provide additional structure where needed to most comfortably conform to a user’s body while sleeping.
  • FIG. 4 shows how multi-zone support layer may also have venting therein.
  • multi-zone support layer may therefore include temperature management structures therein so as to allow venting of the adjacent gel viscoelastic foam layer.
  • multi-zone support layer may include a first vent that includes a first vent channel and a second vent channel.
  • Each of the vent channels may extend laterally across the width of the mattress from one lateral side to the other side. In between the first vent channel and the second vent channel may be a support column structure.
  • the support column structure may provide the firmness and support to ensure proper lumbar support and body posture when sleeping, even though adjacent gel viscoelastic layer may itself be rather soft.
  • multi-zone support layer may also include “egg crate” venting throughout the first zone and the third zone.
  • FIG. 5 shows first vent in the second zone of the multi-zone support layer. Also shown is the egg crate venting in the first zone. FIG. 5 also shows how the height of multi-zone support layer may change from the first zone to the second zone. As discussed above, this change in height may provide additional structure and lumbar support where needed by a user’s torso (where most body weight is located, as opposed to head / shoulders and legs / feet).
  • FIG. 6 shows a mattress in accordance with this disclosure with the removable outer cover thereon.
  • the removable outer cover includes a warmer side, which is acting as the sleeping surface by facing upward in FIG. 6.
  • the warmer side includes the entire top surface as well as half of the lateral sides.
  • the cooler side in this view is facing downward not being used as the sleeping surface at this time.
  • the opening mechanism is partial opened in FIG. 6, in this embodiment the opening mechanism being a zipper.
  • the opening mechanism may run around substantially an entire perimeter of the lateral sides of the mattress so that a user may entirely remove the foam pad from therein.
  • the warmer side of the removable outer layer may be made from 100% polyester.
  • the cooler side of the removable outer layer may be made from 70% polyester and 30% polyethylene. This difference in composition may result in a difference in sleeping temperature of at least about 3° F, or at least about 4° F, or at least about 5 ° F, or at least about 6° F between the two sides.
  • FIG. 7 shows a temperature indicator on the removable outer layer.
  • the temperature indicate may be orientated such that a user may clearly understand which side of the outer cover (warmer or cooler) will be orientated on the sleeping surface for use while sleeping.
  • the temperature indicator shown in FIG. 7 is for the warmer side of the removable outer layer.
  • FIG. 8 shows another temperature indicator on the removable outer layer. This temperature indicator corresponds to the cooler side of the removable outer layer.
  • FIG. 9 shows a chart of all the four options for sleep characteristics that a mattress in accordance with this disclosure may achieve. Namely, there are four possible combinations across two factors that each have two degrees of freedom. Namely, the mattress may achieve softer and cooler, firmer and cooler, softer and warmer, and firmer and warmer.
  • FIG. 10 shows a method of customizing a multi-layer foam mattress. Namely, first an end user customer may receive the four-in-one mattress from a manufacturer. The customer may then remove the removable outer layer from the foam pad. The customer may then select their preferred hardness level, whether softer or firmer. The customer may then flip the foam pad so that either the softer layer or the firmer layer is facing upward to act as the sleeping surface. Next, the customer may select their desired temperature level, whether cooler or warmer. The customer may then re-enclose the removable outer layer around the foam pad in an orientation such that the preferred side of the removable outer layer is facing upward to correspond to the sleeping surface. Optionally, if necessary, the customer may then install the mattress on a platform or other furniture.

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  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

La présente invention concerne un matelas en mousse multicouche qui est personnalisable en ce qui concerne au moins deux paramètres de sommeil. Notamment, le matelas en mousse multicouche peut comprendre une couche plus molle à l'intérieur d'un rembourrage en mousse et une couche plus ferme à l'intérieur du rembourrage en mousse et peut également comprendre une couche externe présentant un côté plus froid et un côté plus chaud. Les deux options pour le niveau de fermeté et la température peuvent donc se combiner en quatre options distinctes pour la personnalisation des caractéristiques de sommeil du matelas. Ceci peut aider les clients à personnaliser leur matelas en fonction des besoins changeants dans le temps.
PCT/US2022/038075 2021-07-23 2022-07-22 Matelas quatre-en-un pourvu de paramètres personnalisables de confort de sommeil WO2023004154A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202163225390P 2021-07-23 2021-07-23
US63/225,390 2021-07-23

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WO2023004154A1 true WO2023004154A1 (fr) 2023-01-26

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140090178A1 (en) * 2012-09-28 2014-04-03 Direct Supply, Inc. Medical Mattress With Firmness Adjustment
US20150067967A1 (en) * 2012-01-25 2015-03-12 Sealy Technology Llc Engineered foams and foam mattress constructions
US20170325597A1 (en) * 2016-05-13 2017-11-16 Stuart Carlitz Reversible mattress with varying firmness
US20190320808A1 (en) * 2018-04-23 2019-10-24 Casper Sleep Inc. Temperature-Regulating Mattress
US20190365117A1 (en) * 2018-06-05 2019-12-05 E & E Co., Ltd. Reversible multi-layer mattress pad

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150067967A1 (en) * 2012-01-25 2015-03-12 Sealy Technology Llc Engineered foams and foam mattress constructions
US20140090178A1 (en) * 2012-09-28 2014-04-03 Direct Supply, Inc. Medical Mattress With Firmness Adjustment
US20170325597A1 (en) * 2016-05-13 2017-11-16 Stuart Carlitz Reversible mattress with varying firmness
US20190320808A1 (en) * 2018-04-23 2019-10-24 Casper Sleep Inc. Temperature-Regulating Mattress
US20190365117A1 (en) * 2018-06-05 2019-12-05 E & E Co., Ltd. Reversible multi-layer mattress pad

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