US20070044245A1 - Mattress with triple zone topper - Google Patents
Mattress with triple zone topper Download PDFInfo
- Publication number
- US20070044245A1 US20070044245A1 US11/218,230 US21823005A US2007044245A1 US 20070044245 A1 US20070044245 A1 US 20070044245A1 US 21823005 A US21823005 A US 21823005A US 2007044245 A1 US2007044245 A1 US 2007044245A1
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- topper
- mattress
- zones
- base unit
- convoluted
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- 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
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
- A47C27/056—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers with different layers of foamed material
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- 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
- A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
- A47C27/144—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities inside the mattress or cushion
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- 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
- A47C27/142—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
- A47C27/146—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
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- 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
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- 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
Definitions
- This invention relates to an elongate topper or cushion in a mattress for supporting a recumbent human body and, more particularly, to a triple zone topper.
- a mattress in its most basic form, comprises a base unit surrounded by a cover fabric layer.
- the base unit may be a conventional spring assembly having open coils secured internally and by upper and lower border wires.
- the spring assembly could alternatively include individual fabric pocketed coils and could eliminate the border wire.
- Another type of mattress, known as foam encased includes a bottom foam layer.
- Four foam side walls are adhered to an upper surface of the bottom foam layer at its peripheral edges to provide a rectangular frame or box section.
- a support component such as a spring assembly, foam, or the like, is loosely positioned in the box section.
- a top foam layer, pad or fiber may be adhered to the tops of the side walls.
- various layers of foam and/or upholstery fabrics may be included between the cover fabric layer and the base unit to provide varying degrees of comfort.
- Firmness of the mattress is generally determined by firmness of the base unit.
- toppers Various forms of foam cushions or pad, also known as toppers, have been integrated into mattress designs.
- Conventional mattress toppers may be traditional flat foam or may comprise convoluted cushions which reduces pressure points.
- An example of a convoluted foam cushion is shown in Nunez et al. U.S. Pat. No. 6,041,459, assigned to the assignee of the present application.
- the convoluted foam cushion described therein comprises an elongate rectangular body of uniform firmness and density including distinct comfort and support zones using different patterns of convolution.
- the present invention is directed to further improvements in mattress design.
- a mattress including a topper having multiple zones of density and/or firmness.
- a mattress comprising a base unit.
- a topper is supported above the base unit.
- the topper comprises an elongate rectangular body having a center zone joined between opposite end zones.
- the topper is of a select foam material of substantially uniform firmness and the center zone has a density greater than density of the end zones.
- a cover fabric layer surrounds the base unit and the topper.
- the topper is of polyethylene foam construction.
- the topper has a planar bottom surface engaging the base unit and a convoluted upper surface.
- the convoluted upper surface has alternating peaks and valleys arranged in a checkerboard configuration.
- the convoluted upper surface has a plurality of convolution zones providing different amounts of support.
- the convoluted upper surface has a different convolution pattern in the center zone than in the end zones to providing different amounts of support.
- convoluted upper surface has at least five convolution zones providing different amounts of support.
- the convoluted upper surface has seven convolution zones providing highest support in a central area and gradually decreasing support at longitudinal ends of the topper.
- the topper has a planar bottom surface engaging the base unit and a planar upper surface having a plurality of upwardly opening slots in a grid pattern of a first size in the central zone and a second size in the end zones.
- the center zone has a density at least 25% greater than density of the end zones.
- a mattress comprising a base unit.
- a topper is supported above the base unit.
- the topper comprises an elongate rectangular body having a center zone joined between opposite end zones.
- the topper has a planar bottom surface engaging the base unit and a patterned upper surface.
- the center zone has a density greater than density of the end zones.
- a cover fabric layer surrounds the base unit and the topper.
- FIG. 1 is an exploded, partial perspective view, with parts removed for clarity, of a mattress including a triple zone topper according to the invention
- FIG. 2 is a plan view of the topper of the mattress of FIG. 1 ;
- FIG. 3 is a sectional view taken along a line 3 - 3 of FIG. 2 ;
- FIG. 4 is a plan view of a mattress topper according to a first alternative embodiment of the invention.
- FIG. 5 is a sectional view taken along the line 5 - 5 of FIG. 4 ;
- FIG. 6 is a plan view of a mattress topper according to a second alternative embodiment of the invention.
- FIG. 7 is a sectional view taken along the line 7 - 7 of FIG. 6 ;
- FIG. 8 is a plan view of a mattress topper according to a third alternative embodiment of the invention.
- FIG. 9 is a sectional view taken along the line 9 - 9 of FIG. 8 .
- the mattress 10 is generally conventional in construction and includes a base unit 14 .
- the base unit 14 comprises a conventional spring assembly having open coils secured internally and by upper and lower border wires.
- the base unit 14 could alternatively include individual fabric pocketed coils and could eliminate the border wire or comprise a foam encased mattress unit.
- the invention is not intended to be limited to any particular construction for the base unit.
- a plurality of lower fiber layers 16 rest on the base unit 14 .
- the topper 12 sits on the lower fiber layers 16 .
- Several additional upper fiber layers 18 are disposed between the topper 12 and a cover fabric layer 20 . As is apparent, the cover fabric layer 20 surrounds the entire mattress 10 .
- the topper 12 can be used in various mattress configurations.
- the particular configuration illustrated in FIG. 1 is but one example of such a mattress.
- the topper 12 could be provided as a separate unit which can be selectively placed atop a mattress.
- the topper 12 could also be used as an insert layer in a quilt top mattress, such as a replacement for the insert layer shown in Nunez et al. U.S. Pat. No. 5,974,609, assigned to the assignee of the present application, the specification of which is incorporated by reference herein.
- the topper 12 is configured to provide comfort and support to a human body, represented at B. As is apparent, different levels of comfort and support are advantageously provided for different portions of the body B. In accordance with the invention, the topper 12 is provided with three distinct zones providing different firmness and/or density and/or support.
- the topper 12 has a length L and width W.
- the length L is typically on the order of 79′′.
- the width W varies according to the mattress size, such as twin, double, full, queen or king size.
- the topper 12 includes a first end zone 22 and a second end zone 24 on opposite ends of a center zone 26 .
- Each zone 22 , 24 and 26 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam.
- Each zone 22 , 24 and 26 is made separately and then laminated together. Particularly, the first end zone 22 and center zone 26 are laminated together at a first joint 28 . Similarly, the second end zone 24 and the center zone 26 are laminated together at a second joint 30 .
- each zone 22 , 24 and 26 has a similar firmness with the center zone 26 being of a higher density.
- the topper 12 may have a firmness of 10 ILD (initial load deflection).
- the end zones 22 and 24 may have a density of about 1.2 lbs. per cubic foot, while the center zone 26 may have a density of about 3 lbs. per cubic foot. This provides greater cushioning durability in the center zone 26 .
- each end zone 22 and 24 may have a length of about 24′′, with the center zone 26 having a length of about 31′′.
- the topper 12 includes a planar top surface 32 and an opposite planar bottom surface 34 .
- the topper 12 may have a thickness on the order of about 1′′.
- the end zones 22 and 24 being of identical construction, allows the mattress 10 to be turned so that either end zone 22 or 24 can be used as the head end or the foot end.
- the relative lengths of the zones 22 , 24 and 26 could be varied to provide greater or lesser amounts of enhanced cushioning durability, as is apparent.
- the firmness in the end zones 22 and 24 could be different from that in the center zone 26 .
- the density in each zone 22 , 24 and 26 could be of a different amount from that mentioned above.
- a topper 112 according to a first alternative embodiment of the invention is illustrated.
- the topper 112 will be described using reference numerals 100 higher than corresponding elements in the topper 12 of FIGS. 2 and 3 .
- the topper 112 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam, and includes a first end zone 122 and a second end zone 124 longitudinally separated by a center zone 126 .
- the first end zone 122 is joined to the center zone 126 at a joint 128 .
- the second end zone 124 is joined to the center zone 126 at a joint 130 .
- the length and width of each zone 122 , 124 and 126 is similar to those discussed with respect to the topper 12 discussed above.
- the topper 112 includes a generally planar top surface 132 and a generally planar bottom surface 134 .
- the topper 112 has a thickness on the order of 21 ⁇ 4′′.
- the firmness is substantially similar in each zone 122 , 124 and 126 , while the density in the center zone 126 is substantially greater than in the end zones 122 and 124 .
- the end zones 122 and 124 have a firmness of 21 ILD and a density of 1.2 lbs. per cubic foot.
- the center zone 126 has a firmness of about 23 ILD and a density of about 1.65 lbs. per cubic foot.
- other firmness and densities could be used, including those discussed above relative to the topper 12 .
- the top surface 132 includes surface treatment in the form of a plurality of slots 140 cut through the top surface 132 in a grid pattern.
- a different set of slots 142 is cut through the top surface 132 of the center zone 126 , also in a grid pattern.
- the slots 140 and 142 are about 1 ⁇ 2′′ in depth.
- Grid spacing of the slots 140 in the end zones 122 and 124 is about 3′′.
- Grid spacing of the slots 142 in the center zone 126 is about 6′′. This provides greater cushioning support in the center zone 126 .
- a topper 212 according to a second alternative embodiment of the invention is illustrated. Again, for simplicity, the topper 212 uses reference numerals similar to those with respect to the embodiments of FIGS. 2 and 3 and 4 and 5 , except being in the 200 number series.
- the topper 212 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam, and includes first and second end zones 222 and 224 longitudinally separated from a center zone 226 by respective joints 228 and 230 .
- the topper 212 includes a top surface 232 and a bottom surface 234 .
- the bottom surface 234 is planar.
- the topper 212 differs in that the top surface 232 comprises a surface treatment in the form of a patterned convoluted surface.
- the top surface 232 includes what is known as “egg crate” convolutions throughout.
- the convoluted top surface 232 has alternating peaks 240 and valleys 242 arranged in a checkerboard configuration.
- each of the zones 222 , 224 and 226 include a similar pattern of convolutions throughout.
- the mattress topper 212 could include different convolution patterns in each of the zones, 222 , 224 and 226 .
- the convolution patterns could be the same in the end zones 222 and 224 , but different in the center zone 226 .
- the convolutions could be zoned independently of the three different foam zones.
- the top surface 232 could include seven zones of convolution as shown in U.S. Pat. No. 5,974,609, incorporated by reference above.
- a topper 312 according to a third alternative embodiment of the invention is illustrated. Again, for simplicity, the topper 312 uses reference numerals similar to those with respect to the previous embodiments, except being in the 300 number series.
- a top surface 332 includes seven different zones of convolution.
- the convolutions are formed by alternating peaks 340 and valleys 342 .
- the peaks 340 and valleys 342 are arranged in rows, with adjacent rows being staggered to form a checkerboard pattern, as is apparent.
- the topper 312 can be manufactured using conventional processes for convoluted foam cushions.
- the peaks 340 have flat top surfaces.
- the topper 312 has a height of about 2′′ measured from the planar bottom surface 334 to the top of the peaks 340 .
- the topper 312 has a base thickness of about 11 ⁇ 2′′ measured from the planar bottom surface 334 to the base of the valleys 342 .
- the peaks 340 and valleys 342 are generally rectangular in shape, albeit having rounded edges, as is well known.
- the top surface 332 includes seven zones of convolution numbered 351 , 352 , 353 , 354 , 355 , 356 and 357 .
- the outermost zones 351 and 357 are similar.
- the next innermost zones 352 and 356 are similar.
- the next innermost zones 353 and 355 are similar.
- the peaks and valleys have a lateral dimension of about 1′′.
- the peaks and valleys have a longitudinal dimension of about 2′′.
- the peaks and valleys have a longitudinal dimension of about 3′′.
- Innermost zone 354 has peaks and valleys with a longitudinal dimension of about 5′′ in length.
- the center most convolution zone 354 provides the greatest amount of support, with support gradually decreasing moving longitudinally from the center convolution zone 354 to either end most convolution zone 351 or 357 .
- the convolution zones do not and need not correspond to the three foam zones.
- the topper 312 could alternatively be provided with a different number of convolution zones such as, for example, three zones or five zones.
- the borders of the convolution zones need not match up with the borders of the foam zones.
- the invention is not limited to a particular type of surface treatment.
- the surface treatment could be applied to the bottom surface.
- the surface treatment could be, for example, contoured, such as body contouring.
- Each topper described herein can be constructed of polyurethane foam or of latex. Also, it could be formed of a visco-elastic memory foam.
- a triple zone mattress topper providing greater durability and support in a center zone compared to end zone.
Abstract
Description
- This invention relates to an elongate topper or cushion in a mattress for supporting a recumbent human body and, more particularly, to a triple zone topper.
- A mattress, in its most basic form, comprises a base unit surrounded by a cover fabric layer. The base unit may be a conventional spring assembly having open coils secured internally and by upper and lower border wires. The spring assembly could alternatively include individual fabric pocketed coils and could eliminate the border wire. Another type of mattress, known as foam encased, includes a bottom foam layer. Four foam side walls are adhered to an upper surface of the bottom foam layer at its peripheral edges to provide a rectangular frame or box section. A support component, such as a spring assembly, foam, or the like, is loosely positioned in the box section. A top foam layer, pad or fiber, may be adhered to the tops of the side walls. With any of these designs, various layers of foam and/or upholstery fabrics may be included between the cover fabric layer and the base unit to provide varying degrees of comfort. Firmness of the mattress is generally determined by firmness of the base unit.
- Various forms of foam cushions or pad, also known as toppers, have been integrated into mattress designs. Conventional mattress toppers may be traditional flat foam or may comprise convoluted cushions which reduces pressure points. An example of a convoluted foam cushion is shown in Nunez et al. U.S. Pat. No. 6,041,459, assigned to the assignee of the present application. The convoluted foam cushion described therein comprises an elongate rectangular body of uniform firmness and density including distinct comfort and support zones using different patterns of convolution.
- The present invention is directed to further improvements in mattress design.
- In accordance with the invention, there is provided a mattress including a topper having multiple zones of density and/or firmness.
- There is disclosed in accordance with one aspect of the invention a mattress comprising a base unit. A topper is supported above the base unit. The topper comprises an elongate rectangular body having a center zone joined between opposite end zones. The topper is of a select foam material of substantially uniform firmness and the center zone has a density greater than density of the end zones. A cover fabric layer surrounds the base unit and the topper.
- It is a feature of the invention that the topper is of polyethylene foam construction.
- It is another feature of the invention that the topper has a planar bottom surface engaging the base unit and a convoluted upper surface.
- It is a further feature of the invention that the convoluted upper surface has alternating peaks and valleys arranged in a checkerboard configuration.
- It is yet another feature of the invention that the convoluted upper surface has a plurality of convolution zones providing different amounts of support.
- It is still a further feature of the invention that the convoluted upper surface has a different convolution pattern in the center zone than in the end zones to providing different amounts of support.
- It is yet a further feature of the invention that convoluted upper surface has at least five convolution zones providing different amounts of support.
- It is an additional feature of the invention that the convoluted upper surface has seven convolution zones providing highest support in a central area and gradually decreasing support at longitudinal ends of the topper.
- It is yet another feature of the invention that the topper has a planar bottom surface engaging the base unit and a planar upper surface having a plurality of upwardly opening slots in a grid pattern of a first size in the central zone and a second size in the end zones.
- It is still another feature of the invention that the center zone has a density at least 25% greater than density of the end zones.
- There is disclosed in accordance with another aspect of the invention a mattress comprising a base unit. A topper is supported above the base unit. The topper comprises an elongate rectangular body having a center zone joined between opposite end zones. The topper has a planar bottom surface engaging the base unit and a patterned upper surface. The center zone has a density greater than density of the end zones. A cover fabric layer surrounds the base unit and the topper.
- Further features and advantages of the invention will be readily apparent from the specification and the drawings.
-
FIG. 1 is an exploded, partial perspective view, with parts removed for clarity, of a mattress including a triple zone topper according to the invention; -
FIG. 2 is a plan view of the topper of the mattress ofFIG. 1 ; -
FIG. 3 is a sectional view taken along a line 3-3 ofFIG. 2 ; -
FIG. 4 is a plan view of a mattress topper according to a first alternative embodiment of the invention; -
FIG. 5 is a sectional view taken along the line 5-5 ofFIG. 4 ; -
FIG. 6 is a plan view of a mattress topper according to a second alternative embodiment of the invention; -
FIG. 7 is a sectional view taken along the line 7-7 ofFIG. 6 ; and -
FIG. 8 is a plan view of a mattress topper according to a third alternative embodiment of the invention; -
FIG. 9 is a sectional view taken along the line 9-9 ofFIG. 8 . - Referring initially to
FIG. 1 , there is illustrated amattress 10 including a foam pad or cushion, referred to herein as a topper, 12 according to the invention. Overall, themattress 10 is generally conventional in construction and includes a base unit 14. In the illustrated embodiment of the invention, the base unit 14 comprises a conventional spring assembly having open coils secured internally and by upper and lower border wires. The base unit 14 could alternatively include individual fabric pocketed coils and could eliminate the border wire or comprise a foam encased mattress unit. The invention is not intended to be limited to any particular construction for the base unit. A plurality oflower fiber layers 16 rest on the base unit 14. Thetopper 12 sits on thelower fiber layers 16. Several additionalupper fiber layers 18 are disposed between thetopper 12 and acover fabric layer 20. As is apparent, thecover fabric layer 20 surrounds theentire mattress 10. - As is apparent, the
topper 12 can be used in various mattress configurations. The particular configuration illustrated inFIG. 1 is but one example of such a mattress. Also, thetopper 12 could be provided as a separate unit which can be selectively placed atop a mattress. Moreover, thetopper 12 could also be used as an insert layer in a quilt top mattress, such as a replacement for the insert layer shown in Nunez et al. U.S. Pat. No. 5,974,609, assigned to the assignee of the present application, the specification of which is incorporated by reference herein. - The
topper 12 is configured to provide comfort and support to a human body, represented at B. As is apparent, different levels of comfort and support are advantageously provided for different portions of the body B. In accordance with the invention, thetopper 12 is provided with three distinct zones providing different firmness and/or density and/or support. - Referring to
FIG. 2 , thetopper 12 has a length L and width W. The length L is typically on the order of 79″. The width W varies according to the mattress size, such as twin, double, full, queen or king size. Thetopper 12 includes afirst end zone 22 and asecond end zone 24 on opposite ends of acenter zone 26. Eachzone zone first end zone 22 andcenter zone 26 are laminated together at a first joint 28. Similarly, thesecond end zone 24 and thecenter zone 26 are laminated together at a second joint 30. Thejoints zone center zone 26 being of a higher density. For example, thetopper 12 may have a firmness of 10 ILD (initial load deflection). Theend zones center zone 26 may have a density of about 3 lbs. per cubic foot. This provides greater cushioning durability in thecenter zone 26. - In an illustrated embodiment of the invention, each
end zone center zone 26 having a length of about 31″. Thetopper 12 includes a planartop surface 32 and an opposite planarbottom surface 34. Thetopper 12 may have a thickness on the order of about 1″. Theend zones mattress 10 to be turned so that eitherend zone zones end zones center zone 26. Likewise, the density in eachzone - Referring to
FIGS. 4 and 5 , atopper 112 according to a first alternative embodiment of the invention is illustrated. For simplicity, thetopper 112 will be described usingreference numerals 100 higher than corresponding elements in thetopper 12 ofFIGS. 2 and 3 . - The
topper 112 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam, and includes afirst end zone 122 and asecond end zone 124 longitudinally separated by acenter zone 126. Thefirst end zone 122 is joined to thecenter zone 126 at a joint 128. Thesecond end zone 124 is joined to thecenter zone 126 at a joint 130. The length and width of eachzone topper 12 discussed above. Thetopper 112 includes a generally planartop surface 132 and a generally planarbottom surface 134. Thetopper 112 has a thickness on the order of 2¼″. The firmness is substantially similar in eachzone center zone 126 is substantially greater than in theend zones end zones center zone 126 has a firmness of about 23 ILD and a density of about 1.65 lbs. per cubic foot. As is apparent, other firmness and densities could be used, including those discussed above relative to thetopper 12. - The
top surface 132 includes surface treatment in the form of a plurality ofslots 140 cut through thetop surface 132 in a grid pattern. A different set ofslots 142 is cut through thetop surface 132 of thecenter zone 126, also in a grid pattern. Theslots slots 140 in theend zones slots 142 in thecenter zone 126 is about 6″. This provides greater cushioning support in thecenter zone 126. - Referring to
FIGS. 6 and 7 , atopper 212 according to a second alternative embodiment of the invention is illustrated. Again, for simplicity, thetopper 212 uses reference numerals similar to those with respect to the embodiments ofFIGS. 2 and 3 and 4 and 5, except being in the 200 number series. - The
topper 212 is made of polyurethane foam, but could be of latex foam or visco-elastic memory foam, and includes first andsecond end zones center zone 226 byrespective joints 228 and 230. Thetopper 212 includes atop surface 232 and abottom surface 234. Thebottom surface 234 is planar. Thetopper 212 differs in that thetop surface 232 comprises a surface treatment in the form of a patterned convoluted surface. Thetop surface 232 includes what is known as “egg crate” convolutions throughout. Particularly, the convolutedtop surface 232 has alternating peaks 240 and valleys 242 arranged in a checkerboard configuration. In this embodiment, each of thezones - Alternatively, the
mattress topper 212 could include different convolution patterns in each of the zones, 222, 224 and 226. Indeed, the convolution patterns could be the same in theend zones center zone 226. Alternatively, the convolutions could be zoned independently of the three different foam zones. For example, thetop surface 232 could include seven zones of convolution as shown in U.S. Pat. No. 5,974,609, incorporated by reference above. - Referring to
FIGS. 8 and 9 , atopper 312 according to a third alternative embodiment of the invention is illustrated. Again, for simplicity, thetopper 312 uses reference numerals similar to those with respect to the previous embodiments, except being in the 300 number series. - The principal difference between the
topper 212 and thetopper 312 is that atop surface 332 includes seven different zones of convolution. The convolutions are formed by alternatingpeaks 340 andvalleys 342. Thepeaks 340 andvalleys 342 are arranged in rows, with adjacent rows being staggered to form a checkerboard pattern, as is apparent. Thetopper 312 can be manufactured using conventional processes for convoluted foam cushions. In the illustrated embodiment of the invention, thepeaks 340 have flat top surfaces. In an illustrative embodiment of the invention, thetopper 312 has a height of about 2″ measured from the planarbottom surface 334 to the top of thepeaks 340. Thetopper 312 has a base thickness of about 1½″ measured from the planarbottom surface 334 to the base of thevalleys 342. Thepeaks 340 andvalleys 342 are generally rectangular in shape, albeit having rounded edges, as is well known. Thetop surface 332 includes seven zones of convolution numbered 351, 352, 353, 354, 355, 356 and 357. Theoutermost zones innermost zones innermost zones zones zones zones Innermost zone 354 has peaks and valleys with a longitudinal dimension of about 5″ in length. As such, the centermost convolution zone 354 provides the greatest amount of support, with support gradually decreasing moving longitudinally from thecenter convolution zone 354 to either endmost convolution zone - The
topper 312 could alternatively be provided with a different number of convolution zones such as, for example, three zones or five zones. The borders of the convolution zones need not match up with the borders of the foam zones. - The invention is not limited to a particular type of surface treatment. Also, the surface treatment could be applied to the bottom surface. The surface treatment could be, for example, contoured, such as body contouring.
- Each topper described herein can be constructed of polyurethane foam or of latex. Also, it could be formed of a visco-elastic memory foam.
- Thus, in accordance with the invention, there is provided a triple zone mattress topper providing greater durability and support in a center zone compared to end zone.
Claims (20)
Priority Applications (1)
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US11/218,230 US20070044245A1 (en) | 2005-09-01 | 2005-09-01 | Mattress with triple zone topper |
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US11/218,230 US20070044245A1 (en) | 2005-09-01 | 2005-09-01 | Mattress with triple zone topper |
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Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090089933A1 (en) * | 2007-10-09 | 2009-04-09 | Sealy Technology, Llc | Pressure dispersion support systems |
US20100325806A1 (en) * | 2007-10-09 | 2010-12-30 | Sealy Technology, Llc | Pressure dispersion support systems |
US20110067183A1 (en) * | 2009-09-18 | 2011-03-24 | Hawkins Steven D | Cushioning device and method of manufacturing |
EP2706888A1 (en) * | 2011-05-12 | 2014-03-19 | Sealy Technology LLC | Tension relief foam and mattress constructions |
US20160270546A1 (en) * | 2015-03-17 | 2016-09-22 | Richard Codos | Mattress |
US9504334B2 (en) | 2014-05-19 | 2016-11-29 | Welspun India Limited | Ergonomic mattress pad with polyester fill |
US9661932B2 (en) * | 2015-03-17 | 2017-05-30 | Richard Codos | Mattress |
US20170258242A1 (en) * | 2015-03-17 | 2017-09-14 | Richard Codos | Spring Unit for a Mattress |
WO2020069447A1 (en) * | 2018-09-28 | 2020-04-02 | Dyob, Llc | Modular and adjustable mattress |
US10617224B2 (en) | 2015-03-17 | 2020-04-14 | Sleepovation Llc | Mattress |
US10624468B2 (en) | 2015-03-17 | 2020-04-21 | Sleepovation Llc | Pillow |
US20200237109A1 (en) * | 2015-03-17 | 2020-07-30 | Richard Codos | Mattress |
US10835051B2 (en) * | 2016-12-15 | 2020-11-17 | Stryker Corporation | Person support |
US11122910B2 (en) | 2012-10-22 | 2021-09-21 | Dreamwell, Ltd. | Multi-layered convoluted foam layer |
US20220202196A1 (en) * | 2020-12-31 | 2022-06-30 | DrRest Pty Ltd | Mattress |
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US20090089933A1 (en) * | 2007-10-09 | 2009-04-09 | Sealy Technology, Llc | Pressure dispersion support systems |
US7845035B2 (en) | 2007-10-09 | 2010-12-07 | Sealy Technology Llc | Pressure dispersion support systems |
US20100325806A1 (en) * | 2007-10-09 | 2010-12-30 | Sealy Technology, Llc | Pressure dispersion support systems |
US20110067183A1 (en) * | 2009-09-18 | 2011-03-24 | Hawkins Steven D | Cushioning device and method of manufacturing |
US8613120B2 (en) * | 2009-09-18 | 2013-12-24 | Carpenter Co. | Cushioning device and method of manufacturing |
EP2706888A1 (en) * | 2011-05-12 | 2014-03-19 | Sealy Technology LLC | Tension relief foam and mattress constructions |
EP2706888A4 (en) * | 2011-05-12 | 2014-10-01 | Sealy Technology Llc | Tension relief foam and mattress constructions |
US11122910B2 (en) | 2012-10-22 | 2021-09-21 | Dreamwell, Ltd. | Multi-layered convoluted foam layer |
US9504334B2 (en) | 2014-05-19 | 2016-11-29 | Welspun India Limited | Ergonomic mattress pad with polyester fill |
US20170258242A1 (en) * | 2015-03-17 | 2017-09-14 | Richard Codos | Spring Unit for a Mattress |
US9661932B2 (en) * | 2015-03-17 | 2017-05-30 | Richard Codos | Mattress |
US9949571B2 (en) * | 2015-03-17 | 2018-04-24 | Richard Codos | Spring unit for a mattress |
US10188219B2 (en) * | 2015-03-17 | 2019-01-29 | Richard Codos | Mattress |
US10368655B2 (en) | 2015-03-17 | 2019-08-06 | Richard Codos | Mattress |
US10617224B2 (en) | 2015-03-17 | 2020-04-14 | Sleepovation Llc | Mattress |
US10624468B2 (en) | 2015-03-17 | 2020-04-21 | Sleepovation Llc | Pillow |
US20200237109A1 (en) * | 2015-03-17 | 2020-07-30 | Richard Codos | Mattress |
US20160270546A1 (en) * | 2015-03-17 | 2016-09-22 | Richard Codos | Mattress |
US11324334B2 (en) * | 2015-03-17 | 2022-05-10 | Sleepovation Llc | Mattress |
US10835051B2 (en) * | 2016-12-15 | 2020-11-17 | Stryker Corporation | Person support |
WO2020069447A1 (en) * | 2018-09-28 | 2020-04-02 | Dyob, Llc | Modular and adjustable mattress |
US20220202196A1 (en) * | 2020-12-31 | 2022-06-30 | DrRest Pty Ltd | Mattress |
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