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US20110047710A1 - Mattress - Google Patents

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Publication number
US20110047710A1
US20110047710A1 US12/879,114 US87911410A US2011047710A1 US 20110047710 A1 US20110047710 A1 US 20110047710A1 US 87911410 A US87911410 A US 87911410A US 2011047710 A1 US2011047710 A1 US 2011047710A1
Authority
US
United States
Prior art keywords
layer
mattress
cover
comfort
spacer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/879,114
Other languages
English (en)
Inventor
Allyn Beard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AH Beard Pty Ltd
Original Assignee
Individual
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
Priority claimed from AU2008901189A external-priority patent/AU2008901189A0/en
Application filed by Individual filed Critical Individual
Assigned to A.H. BEARD PTY LTD reassignment A.H. BEARD PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEARD, ALLYN
Publication of US20110047710A1 publication Critical patent/US20110047710A1/en
Abandoned legal-status Critical Current

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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
    • A47C21/00—Attachments for beds, e.g. sheet holders or bed-cover holders; Ventilating, cooling or heating means in connection with bedsteads or mattresses
    • A47C21/04—Devices for ventilating, cooling or heating
    • A47C21/042—Devices for ventilating, cooling or heating for ventilating or cooling
    • A47C21/046—Devices for ventilating, cooling or heating for ventilating or cooling without active means, e.g. with openings or heat conductors
    • 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
    • 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
    • A47C31/006—Use of three-dimensional fabrics
    • 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

Definitions

  • the present invention relates to a mattress, and a mattress cover therefor.
  • comfort layers in mattresses has arisen in recent years due to the comfortable support provided.
  • Such comfort layers are typically formed of latex, visco-elastic foam or other flexible high density, high resilience foams.
  • high density foams are usually regarded as those having a density of 20 to 100 kg/m 3 , with low density foams generally having a density of 10 to less than 20 kg/m 3 .
  • high density has this meaning
  • High resilience foam grades are generally high density foams in which the cell structure has been broken down to form a generally “open cell” construction which is more resilient than the closed cell structure.
  • Comfort layers are typically provided above another, typically more resilient and harder, support layer to allow a person lying on the bed to sink into the comfort layer, distributing pressure more evenly across the person's body, while still retaining support from the underlying support layer.
  • Visco-elastic foam support layers have gained particular popularity as a result of their temperature sensitivity whereby they become softer when heated by body heat and consequently generally mold to the form of the body, distributing pressure more evenly.
  • Visco-elastic foam is also referred to as “memory foam”, and is generally a form of flexible polyurethane foam.
  • Visco-elastic foam and latex support layers are generally unable to readily dissipate heat from the person's body and, given that there is generally a greater area of surface contact between the person's body and the molded upper surface of the mattress, mattresses with such comfort layers are often found to be uncomfortably hot to sleep on.
  • Mattress structures have previously been proposed that include a resilient, highly breathable spacer layer below the comfort layer to assist in dissipating heat from the comfort layer by maintaining an air space between the comfort layer and underlying support layer. Such a structure, however, relies on the heat dissipating through the thickness of the comfort layer prior to escaping via the spacer layer.
  • Mattress structures have also been proposed that utilize a spacer layer laminated to the top surface of the comfort layer in an effort to dissipate heat from the person's body prior to reaching the comfort layer.
  • Such structures do not provide for washability of the spacer layer and do not allow for retrofitting to existing mattresses with visco-elastic foam or latex comfort layers that have been found to be uncomfortable due to overheating.
  • a mattress cover which includes a sleep panel configured to cover an upper surface of a mattress body.
  • the sleep panel includes an upper cover layer formed of a breathable fabric, a lower cover layer formed of a breathable fabric, and a resilient and highly breathable three-dimensional spacer layer disposed between said upper and lower cover layers.
  • the upper cover layer, the spacer layer and the lower cover layer are secured by quilting or tufting.
  • the mattress cover further includes a peripheral skirt extending about a periphery of the sleep panel for engaging side surfaces of the mattress body.
  • the spacer layer includes a pair of spaced apart outer mesh elements interconnected by an array of spacer yarns extending between and separating the outer mesh elements.
  • the spacer layer may be formed of an open-cell reticulated foam.
  • the spacer layer is separated into multiple zones of varying resilience.
  • a mattress which includes a mattress body and a mattress cover located over the mattress body with a sleep panel covering an upper surface of the mattress body.
  • the mattress cover is constructed and arranged as described above.
  • the mattress body includes a comfort layer disposed beneath the sleep panel and a resilient support layer disposed beneath the comfort layer.
  • the comfort layer comprises a high density, high resilience foam.
  • the comfort layer is formed of visco-elastic foam.
  • the comfort layer may be formed of latex.
  • a mattress which includes a resilient support layer, a resilient and highly breathable three-dimensional lower spacer layer disposed above the support layer, a comfort layer disposed above the lower spacer layer, a resilient and highly breathable three-dimensional upper spacer layer disposed above the comfort layer, and a breathable upper cover layer disposed above the upper spacer layer.
  • the comfort layer having a plurality of perforations extending through a thickness thereof.
  • the comfort layer comprises a high density, high resilience foam.
  • the comfort layer is formed of visco-elastic foam.
  • the comfort layer may be formed of latex.
  • the spacer layers each comprise a pair of spaced apart outer mesh elements interconnected by an array of spacer yarns sitting between and separating the outer mesh elements.
  • the spacer layers may be formed of an open-cell reticulated foam.
  • the upper spacer layer is separated into multiple zones of varying resilience.
  • the lower spacer layer is laminated to the comfort layer.
  • FIG. 1 is an exploded view of a mattress.
  • FIG. 2 is a further exploded perspective view of FIG. 1 with individual layers of each panel laminated.
  • FIG. 3 is a fragmentary cross-sectional view of the mattress of FIG. 1 .
  • a mattress 1 comprises a base layer 2 , support layer 3 , intermediate panel 4 , and cover 5 .
  • the cover 5 defines the upper face of the mattress 1 forming a sleep surface.
  • the base layer 2 defines the lower face of the mattress which will typically be located on a mattress foundation.
  • the support layer 3 and intermediate panel 4 together define the mattress body 6 and are located between the cover 5 and base layer 2 .
  • the cover 5 comprises a sleep panel 7 configured to cover the upper surface of the mattress body 6 and a peripheral skirt 8 extending about a periphery of the sleep panel 7 for engaging the side surfaces of the mattress body 6 .
  • the sleep panel 7 comprises an upper cover layer 9 formed of a breathable fabric and a lower cover layer 10 also formed of a breathable fabric.
  • the breathable fabric may be either knitted or woven and may, for example, be a stretchable velour fabric.
  • a resilient and highly breathable three-dimensional upper spacer layer 12 is disposed between the upper and lower cover layers 9 , 10 .
  • the upper cover layer 9 , upper spacer layer 11 and lower cover layer 10 are secured together by quilting, so as to form a quilted sleep surface as depicted in FIG. 1 .
  • the upper cover layer 9 , upper spacer layer 11 and lower cover layer 10 might be secured by tufting.
  • the upper spacer layer 11 is typically formed of a three dimensional fabric having a pair of spaced apart outer mesh elements interconnected by an array of spacer yarns (alternatively referred to as loop piles) extending between and separating the outer mesh elements.
  • a particularly suitable three dimensional fabric for forming the spacer layer is Space Flex® spacer fabric manufactured by Pressless GmbH of Falkenau, Germany.
  • the upper spacer layer 11 will typically have a thickness of about 15 to 40 mm.
  • the upper spacer layer 11 may be separated into multiple zones of varying resilience by varying the spacing (or properties) of the spacer yarns in each zone.
  • a central zone extending laterally across the mattress may be formed of a more resilient spacer layer, whilst the opposing head and leg ends of the mattress may be formed with a spacer layer of lower resilience. Accordingly, such a central zone would provide additional support to the heavier torso of the person's body.
  • a breathable open-cell reticulated foam material may be utilized, as is available from Joyce Foam Products of Moorebank, New South Wales, Australia.
  • the peripheral skirt 8 is typically formed of a fabric material, conveniently the same material as the upper cover layer 9 .
  • the upper edge of the skirt is stitched to the sleep panel 17 .
  • the lower edge of the peripheral skirt 8 will typically be secured to the periphery of the base 2 by way of a zipper 12 .
  • the intermediate panel 4 here comprises a comfort layer 13 that is generally formed of a high density, high resilience foam.
  • the comfort layer 13 may be formed of a flexible polyurethane foam.
  • the flexible polyurethane foam may be a visco-elastic foam, typically having a density of between 40 and 100 kg/m 3 .
  • the comfort layer 13 may be formed of other types of high resilience flexible polyurethane foam having a density of between 25 and 50 kg/m 3 .
  • the comfort layer 13 may be formed of latex, which may either be Talalay or Dunlop process latex (sometimes referred to as a latex foam).
  • a series of pin hole perforations 14 may be provided, extending through the thickness of the comfort layer 13 .
  • the perforations 14 will generally be provided when the comfort layer 13 is formed of latex but they are also applicable to other compositions of comfort layer 13 .
  • the comfort layer 13 will typically have a thickness of about 50 to 100 mm.
  • the intermediate panel 4 also includes a resilient and highly breathable three-dimensional lower spacer layer 15 .
  • the lower spacer layer 15 will typically be laminated to the comfort layer 13 .
  • the lower spacer layer 15 may be formed of the same material as the upper spacer layer 11 .
  • the lower spacer layer 15 will typically have a thickness of about 10 to 30 mm.
  • the lower spacer layer 15 enables any heat that has dissipated through the comfort layer 13 to be readily dissipated by maintaining an air layer separating the comfort layer 13 from the layers lying beneath.
  • the lower spacer layer 15 may be configured as a firmer layer than the upper spacer layer 11 , so that the lower spacer layer 15 will contribute more to supporting a person lying on the mattress 1 while the upper spacer layer 11 will contribute more to comfort.
  • the firmer lower spacer layer 15 may have a compressive elastic modulus of about 11 to 15 kPa, with the upper spacer layer 11 having a compressive elastic modulus of about 2 to 10 kPa.
  • the intermediate panel 4 will typically further comprise a lower layer 16 that is laminated to the underside of the lower spacer layer 15 .
  • the lower layer 16 is typically formed of a high density flexible polyurethane foam having a density of about 25 to 50 kg/m 3 .
  • the lower layer 16 will typically have a thickness of about 20 to 40 mm.
  • the lower layer 16 provides a foundation for the lower spacer layer 15 and comfort layer 13 and adds both extra comfort and support.
  • the lower layer 16 also generally confines the lower spacer layer 15 , which when configured as a spacer fabric can be a little coarse and may have its ends otherwise sticking through the skirt 8 of the cover 5 .
  • the support layer 3 is here formed of two separate support cores 17 , 18 formed of high resilience flexible polyurethane foam having a density of about 25 to 50 kg/m 3 .
  • the support cores 17 , 18 may alternatively be formed of latex, such as Talalay process latex foam or Dunlop process latex.
  • the support cores 17 , 18 will typically each have a thickness of about 100 to 200 mm.
  • the support cores 17 , 18 may be configured with different hardness materials so as to provide different support on the two opposing sides of the mattress 1 to satisfy the desires of two individuals lying on the mattress.
  • one support core 17 may be configured with a particularly firm support core 17
  • the other support core 18 may be configured with a softer material.
  • the support cores 17 , 18 are not laminated to the lower layer 16 and as such may be readily replaced as desired if the firmness requirements of persons using the bed change over time. Forming the support cores 17 , 18 separately also enables production of mattresses with varying hardness properties merely by utilizing varying hardness support cores.
  • the side surfaces of the mattress body 6 are defined by the edges of the support layer 3 and intermediate panel 4 . So as to maintain a neat side surface in the event that there is some minor relative displacement between the support layer 3 and intermediate panel 4 , additional foam elements may be located within the skirt 8 adjacent the edges of the mattress body 6 .
  • the individual elements of the mattress body 6 being the support cores 17 , 18 and intermediate panel 4 may be covered in a dust-mite resistant barrier fabric so as to render the mattress 1 particularly suitable to asthma and other allergy sufferers.
  • the base layer 2 is typically formed of a fabric material and serves to enclose the mattress body 6 with the cover 5 that is secured to the base layer 2 by way of a zipper 12 as discussed above.
  • heat generated by the body of a person lying on the mattress may firstly be dissipated by the air layer provided by the upper spacer layer 11 , separating the person's body from the comfort layer 13 . Whilst the upper spacer layer 11 provides for dissipation of heat, some residual heat is likely to penetrate through to the comfort layer 13 .
  • the perforations 14 extending through the thickness of the comfort layer 13 provide passages for heat to dissipate through the thickness of the comfort layer 13 and then out of the mattress body 6 via the air gap provided by the lower spacer layer 15 .
  • Embodying the upper spacer layer 11 within the sleep panel 7 of the cover 5 provides for removal and washing of the upper spacer layer 11 (within the cover 5 ). This structure also allows for retrofitting of the spacer layer 11 embodied within the cover 5 , to mattresses having visco-elastic foam or latex comfort layers that have previously been purchased, typically at significant expense, without the need to discard the mattress.

Landscapes

  • Mattresses And Other Support Structures For Chairs And Beds (AREA)
US12/879,114 2008-03-11 2010-09-10 Mattress Abandoned US20110047710A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AUAU2008901189 2008-03-11
AU2008901189A AU2008901189A0 (en) 2008-03-11 A mattress
PCT/AU2009/000281 WO2009111822A1 (fr) 2008-03-11 2009-03-10 Matelas

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2009/000281 Continuation WO2009111822A1 (fr) 2008-03-11 2009-03-10 Matelas

Publications (1)

Publication Number Publication Date
US20110047710A1 true US20110047710A1 (en) 2011-03-03

Family

ID=41064660

Family Applications (1)

Application Number Title Priority Date Filing Date
US12/879,114 Abandoned US20110047710A1 (en) 2008-03-11 2010-09-10 Mattress

Country Status (4)

Country Link
US (1) US20110047710A1 (fr)
AU (1) AU2009225238A1 (fr)
NZ (1) NZ587870A (fr)
WO (1) WO2009111822A1 (fr)

Cited By (15)

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US8302229B1 (en) * 2011-06-28 2012-11-06 L&P Property Management Company Furniture cushion
US20130000044A1 (en) * 2011-06-28 2013-01-03 L&P Property Management Company Furniture Cushion
US8418297B2 (en) 2005-06-24 2013-04-16 Tempur-Pedic Management, Llc Reticulated material body support and method
US8671483B2 (en) 2011-06-28 2014-03-18 L&P Property Management Company Furniture cushion having at least one edge guard
CN104523073A (zh) * 2014-12-22 2015-04-22 天津生隆纤维制品有限公司 一种便携式椰壳纤维弹性涂胶软垫
US9138064B2 (en) 2013-01-18 2015-09-22 Fxi, Inc. Mattress with combination of pressure redistribution and internal air flow guides
US9289072B2 (en) 2013-01-18 2016-03-22 Fxi, Inc. Compressible or retractable support for air blower cavity of air flow mattress
US9392875B2 (en) 2013-01-18 2016-07-19 Fxi, Inc. Body support system with combination of pressure redistribution and internal air flow guide(s) for withdrawing heat and moisture away from body reclining on support surface of body support system
CN106724369A (zh) * 2016-12-13 2017-05-31 佛山市顺德区标越家具有限公司 一种具有多模块舒适层的床垫
US10765227B2 (en) * 2017-04-21 2020-09-08 Me. Res. S.R.L. Mattress
US20200360210A1 (en) * 2019-05-14 2020-11-19 Ige, Llc Support system including layers of spacer fabric and non-viscoelastic pressure relief material, and method for measuring pressure and pressure distribution properties of a support system
CN113662390A (zh) * 2021-08-07 2021-11-19 深圳市中深爱的寝具科技有限公司 一种具有穿梭护腰锦囊的组合式子母床垫
US11540964B2 (en) 2018-02-27 2023-01-03 Hill-Rom Services, Inc. Patient support surface control, end of life indication, and x-ray cassette sleeve
WO2024245206A1 (fr) * 2023-05-29 2024-12-05 Napnice Hk Limited Matelas
US12232624B2 (en) * 2016-06-16 2025-02-25 Ascion, Llc Mattress thermal management system

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ITVI20100306A1 (it) * 2010-11-16 2012-05-17 Cinzia Conte Cuscino
ES2486415B1 (es) * 2014-03-17 2015-05-26 New World & Sprin Company, S.L. Un colchón
WO2016172782A1 (fr) * 2015-04-29 2016-11-03 Oratex Inc. Tissu multicouche
CN113876159A (zh) * 2021-09-16 2022-01-04 金孝伟 一种乳胶蚕丝被及其制备工艺
CN115363373A (zh) * 2022-08-31 2022-11-22 佛山市惠安家居用品有限公司 一种透气海绵床垫

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