US20110191962A1 - Mattress having a foam panel which interlocks a spring assembly and a quilted assembly - Google Patents
Mattress having a foam panel which interlocks a spring assembly and a quilted assembly Download PDFInfo
- Publication number
- US20110191962A1 US20110191962A1 US12/966,631 US96663110A US2011191962A1 US 20110191962 A1 US20110191962 A1 US 20110191962A1 US 96663110 A US96663110 A US 96663110A US 2011191962 A1 US2011191962 A1 US 2011191962A1
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- United States
- Prior art keywords
- coils
- mattress
- panel
- receptacle
- foam
- 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
Links
- 239000006260 foam Substances 0.000 title claims abstract description 66
- 239000004744 fabric Substances 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 8
- 239000006261 foam material Substances 0.000 claims description 4
- 230000006835 compression Effects 0.000 claims description 3
- 238000007906 compression Methods 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 6
- 239000003292 glue Substances 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 239000002184 metal Substances 0.000 description 2
- 229920005830 Polyurethane Foam Polymers 0.000 description 1
- 229920001870 copolymer plastic Polymers 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 238000009732 tufting Methods 0.000 description 1
Images
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
- A47C27/04—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
-
- 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
- A47C27/06—Spring inlays
- A47C27/062—Spring inlays of different resiliencies
-
- 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
- A47C27/06—Spring inlays
- A47C27/063—Spring inlays wrapped or otherwise protected
- A47C27/064—Pocketed springs
Definitions
- This application discloses an invention which is related, generally and in various embodiments, to a mattress having a foam panel which interlocks a spring assembly and a quilted assembly.
- Conventional mattresses are constructed in many different ways to provide uniform or varied firmness along their lengths, such as conventional coil spring mattresses or synthetic foam mattresses.
- Other mattresses include housings made of synthetic polymer/copolymer plastic material generally formed by upper and lower layers or panels and a peripheral border therebetween.
- a spring unit or series of springs are housed within the chamber of the mattress housing.
- Conventional mattresses utilizing springs can be zoned to provide varying firmness. Typical zoned mattresses are divided into at least three longitudinal zones of differing firmnesses.
- FIG. 1 illustrates various embodiments of a mattress
- FIG. 2 illustrates various embodiments of a housing of the mattress of FIG. 1 ;
- FIGS. 3 and 4 illustrate various embodiments of a spring assembly of the mattress of FIG. 1 ;
- FIGS. 5-9 illustrate different arrangements of first and second coils for different embodiments of the mattress of FIG. 1 ;
- FIG. 10 illustrates various embodiments of a foam panel of the mattress of FIG. 1 ;
- FIG. 11 illustrates other embodiments of the mattress of FIG. 1 .
- FIG. 1 illustrates various embodiments of a mattress 10 .
- the mattress 10 includes a housing 12 , a spring assembly 14 , a quilted assembly 16 , and a foam panel 18 which interlocks the spring assembly 14 and the quilted assembly 16 .
- FIG. 2 illustrates various embodiments of the housing 12 of the mattress 10 of FIG. 1 .
- the housing 12 is substantially rectangular in shape, defines a receptacle 20 that is substantially rectangular in shape, having first and second ends, and also defining first and second lengths L 1 , L 2 , first and second widths W 1 , W 2 , and first and second heights H 1 , H 2 .
- the first length L 1 , the first width W 1 , and the first height H 1 define the respective “outer” dimensions of the housing 12 .
- the second length L 2 , the second width W 2 , and the second height H 2 define the respective “outer” dimensions of the receptacle 20 . It will be appreciated that any of the first and second lengths L 1 and L 2 , the first and second widths W 1 and W 2 , and the first and second heights H 1 and H 2 can be different for different embodiments.
- the housing 12 includes a panel 22 and a border 24 connected to the panel 22 .
- the panel 22 may be fabricated from any suitable foam material.
- the panel 22 is substantially rectangular in shape, is fabricated to substantially the same length and width as the first length L 1 and the first width W 1 , and has a substantially uniform thickness. The difference between the first height H 1 and the second height H 2 is the thickness of the panel 22 .
- the border 24 may be connected to the panel 22 in any suitable manner.
- the border 24 is connected to the panel 22 with an adhesive (e.g., a glue).
- the border 24 may be fabricated from any suitable foam material, and is generally fabricated from the same foam material that the panel 22 is fabricated from.
- the border 24 is substantially uniform in cross-section also and is substantially rectangular in shape, and defines a first surface 26 and a second surface 28 .
- the first surface 26 may be considered the “outer” surface of the border 24 and the second surface 28 may be considered the “inner” surface of the border 24 .
- the border 24 is connected to the panel 22 such that the “outer” surface 26 of the border 24 is substantially aligned with the perimeter of the panel 22 , and the “inner” surface 28 of the border 24 defines the respective “outer” dimensions of the receptacle 20 , and thus defines the perimeter of the receptacle 20 .
- the border 24 includes a plurality of individual border members (e.g., one for each of the four sides of the rectangular shape) which are adhered together to form the entirety of the border 24 .
- the border 24 is fabricated as a single molded component substantially rectangular in shape.
- the border 22 is fabricated as a single piece of material having a first end and a second end. The single piece of material is subsequently bent to form three corners, then the first end and the second end are adhered together to form the fourth corner of the substantially rectangular shape.
- FIG. 3 illustrates various embodiments of the spring assembly 14 of the mattress 10 of FIG. 1 .
- the spring assembly 14 is positioned on the panel 22 and within the receptacle 20 , and includes a plurality of first coils 30 and a plurality of second coils 32 arranged in rows extending continuously from the first end to the second end of the receptacle.
- the panel 22 is not shown in FIG. 3 .
- the first and second coils 30 , 32 may be any suitable type of coils (e.g., bonnell coils, coil springs, etc.), and are collectively arranged to substantially cover the entire length L 2 and width W 2 of the receptacle 20 as shown in FIG. 4 .
- the plurality of first and second coils 30 , 32 may be arranged in any manner to substantially cover the entire length L 2 and width W 2 of the receptacle 20 , and the respective first and second coils 30 , 32 may be of any suitable size, height, shape (rectangular, cylindrical, etc.), wire gauge, composition, etc. According to various embodiments, each individual coil is positioned in a fabric pocket. All of the fabric pockets for a given “row” may be fabricated as a single “row” of pockets, and the fabric of each “row” may be connected to the fabric of adjacent “rows” by an adhesive (e.g., glue).
- an adhesive e.g., glue
- different embodiments of the spring assembly 14 may include different arrangements of the first and second coils 30 , 32 , different numbers of first coils 30 , different numbers of second coils 32 , different sizes (e.g., heights, wire gauges, diameters, etc.) of the first and second coils 30 , 32 , etc.
- first and second coils 30 , 32 are shown in FIG. 4 as arranged in straight lines, it will be appreciated that according to other embodiments, a “row” of either first coils 30 or second coils 32 may be arranged in a staggered or other type of configuration.
- the first coils 30 are of a first height and the second coils 32 are of a second height, but the first and second coils 30 , 32 are otherwise identical regarding the diameter, style, metal composition, wire gauge, etc. It will be appreciated that according to other embodiments, the first and second coils 30 , 32 may have different resistances to compression by being different in size, shape, style, metal composition, wire gauge, etc. In the illustrated embodiment, the first coils 30 are less resistant to compression than the second coils 32 due to the greater height of the first coils 30 .
- a first group of the first coils 30 collectively define a first zone 34
- a first group of the second coils 32 collectively define a second zone 36 .
- the first zone 34 is smaller than either the length L 2 or the width W 2 of the receptacle 20
- the second zone 36 is smaller than either the length L 2 or the width W 2 of the receptacle 20
- the first zone 34 may be positioned anywhere on the panel 22 and within the receptacle 20
- the second zone 36 may similarly be positioned anywhere on the panel 22 and within the receptacle 20
- each of the first and second coils 30 , 32 includes a first end and a second end; and wherein the first ends of the first and second coils 30 , 32 are disposed adjacent the housing panel 22 and lie in a first plane parallel to the housing panel 22 .
- the second ends of the first coils 30 lie in a second plane and the second ends of the second coils 32 lie in a third plane, and wherein the second plane is parallel to and spaced from the third plane.
- additional groups of the first coils 30 may respectively define additional first zones 34
- additional groups of the second coils 32 may respectively define additional second zones 36 .
- the one in the center may be considered a torso or lumber zone 36
- the one to the left may be considered a head zone 36
- the one to the right may be considered a foot or leg zone 36 .
- the first zones 34 are more firm than the second zones 36 due to the first coils 30 having greater respective heights than the second coils 32
- the second zones 36 are more yielding than the first zones 34 due to the second coils 32 having lesser respective heights than the first coils 30 .
- the number of first coils 30 which collectively define a given first zone 34 can be different than the number of first coils 30 which collectively define another first zone 34 .
- the length of a given first zone 34 can be different than the length of another first zone 34 .
- the number of second coils 32 which collectively define a given second zone 36 can be different than the number of second coils 32 which collectively define another second zone 36 .
- the length of a given second zone 36 can be different than the length of another second zone 36 .
- different embodiments of the mattress 10 having substantially the same size may include different arrangements of second coils 32 .
- a first embodiment of the mattress 10 as shown in FIG. 5 may utilize five “rows” of second coils 32 to collectively define a second zone 36 A (e.g., a head zone), seven “rows” of second coils 32 to collectively define another second zone 36 B (e.g., a torso or lumbar zone), and five “rows” of second coils 32 to collectively define yet another second zone 36 C (e.g., a foot or leg zone), a second embodiment of the mattress 10 as shown in FIG.
- second coils 32 may utilize four “rows” of second coils 32 to collectively define a corresponding head zone 36 A, nine “rows” of second coils 32 to collectively define a corresponding torso or lumbar zone 36 B, and four “rows” of second coils 36 to collectively define a corresponding foot or leg zone 36 C.
- first and second coils 30 , 32 may include different sizes and arrangements of first and second coils 30 , 32 .
- a first embodiment of the mattress 10 as shown in FIG. 7 utilizes two “rows” of first coils 30 having respective first diameters at the two ends of the spring assembly 14
- a second embodiment of the mattress 10 as shown in FIG. 8 also utilizes two “rows” of first coils 30 having respective second diameters at the two ends of the spring assembly 14
- a third embodiment of the mattress 10 as shown in FIG. 9 utilizes three “rows” of first coils 30 having respective third diameters at the two ends of the spring assembly 14 .
- the first embodiment of the mattress 10 as shown in FIG. 7 utilizes four “rows” of second coils 32 having respective first diameters to collectively define a second zone 36 A (e.g., a head zone), nine “rows” of second coils 32 having respective first diameters to collectively define a second zone 36 B (e.g., a torso or lumbar zone), and four “rows” of second coils 32 having respective first diameters to collectively define a second zone 36 C (e.g., a foot or leg zone), the second embodiment of the mattress 10 as shown in FIG.
- a second zone 36 A e.g., a head zone
- nine “rows” of second coils 32 having respective first diameters to collectively define a second zone 36 B e.g., a torso or lumbar zone
- a second zone 36 C e.g., a foot or leg zone
- first and second coils 30 , 32 are coil springs, although each of the first and second coils 30 , 32 in a given embodiment had the same respective diameter, it will be appreciated that the first coils 30 of a given embodiment may include any number of different coil diameters, the second coils 32 of a given embodiment may include any number of different coil diameters, and a given embodiment may include any number of different first coil diameters and different second coil diameters.
- the respective heights of the first coils 30 are substantially the same as the second height H 2 . Therefore, it will be appreciated that the portions of the receptacle 20 which are aligned with the first zones 34 are substantially filled by the first coils 30 . As the respective heights of the second coils 32 are less than the respective heights of the first coils 30 , and thus are less than the second height H 2 , it will be appreciated that the portions of the receptacle 20 which are aligned with the second zones 36 are not substantially filled by the second coils 32 .
- the resulting unfilled volumes or voids 38 are positioned directly above the second firmness zones and are collectively defined by the border 24 and the second coils 32 .
- FIG. 10 illustrates various embodiments of the foam panel 18 of the mattress 10 of FIG. 1 .
- the foam panel 18 is substantially rectangular in shape, may be fabricated from any suitable material, is fabricated to substantially the same length and width as the first length L 1 and the first width W 1 , and includes projections 40 configured to substantially fill any voids 38 (the number of projections 40 corresponds to the number of voids 38 ).
- the projections 40 are substantially rectangular in shape, are smaller than either the length L 2 or the width W 2 of the receptacle 20 , and provide for an increased level of comfort “above” the second zones 36 . Due to the projections 40 , different portions of the foam assembly 18 have different respective heights.
- the projections 40 are connected to the spring assembly 14 and may be connected in any suitable manner.
- the projections 40 are connected to the fabric which surrounds the second coils 32 with an adhesive (e.g., a glue).
- the projections 40 are connected to the fabric which surrounds the second coils 32 with a tufting.
- the foam panel 18 is also connected to the housing 12 , and may be connected in any suitable manner.
- the foam panel 18 may be connected to the border 24 with an adhesive (e.g., a glue).
- the foam panel 18 may be fabricated from any suitable material, and may be fabricated in any suitable manner. According to various embodiments, the foam panel 18 is fabricated from a slab of foam having a thickness equal to the largest height of the foam panel 18 . Portions of the foam panel 18 which are aligned with the first zones 34 are removed from the slab to define the projections 40 . According to other embodiments, the foam panel 18 is fabricated by connecting (e.g., adhering) individual foam panels which are the same size as the projections 40 to a slab of foam substantially the same length and width as the first length L 1 and the first width W 1 to form the foam panel 18 .
- different individual foam panels may be fabricated from different foams, and the slab of foam may be the same foam or a different foam than any one of the individual foam panels.
- the foam panel 18 may be convoluted cut to produce a plurality of “peaks” and “valleys” on a surface of the foam panel 18 (e.g., on the “upper” surface).
- the quilted assembly 16 is substantially rectangular in shape, and is fabricated to substantially the same length and width as the first length L 1 and the first width W 1 .
- the quilted assembly 16 may include a foam panel 42 substantially the same length and width as the first length L 1 and the first width W 1 , and a quilt top 44 which covers the foam panel 42 .
- the foam panel 42 may be fabricated from any suitable foam.
- the foam panel is fabricated from a polyurethane foam.
- the foam panel 42 may include a plant based mix such as, for example, a mix which includes a soy component. It will be appreciated that the quilted assembly 16 may include any number of foam panels 42 , and the respective foam panels 42 may be fabricated from the same foam or different foams.
- the quilted assembly 16 is connected to the foam panel 18 , and may be connected in any suitable manner.
- the foam panel 42 is connected to the foam panel 18 with an adhesive (e.g., a glue). Due to its connection to the foam panel 18 , and the connection of the foam panel 18 to the spring assembly 14 , it will be appreciated that the foam panel 18 also functions to interlock the spring assembly 14 and the quilted assembly 16 .
- FIG. 11 illustrates other embodiments of the mattress 10 of FIG. 1 .
- the mattress 10 also includes a foam panel 46 positioned between and connected to the quilted assembly 16 and the foam panel 18 .
- the foam panel 46 is substantially rectangular in shape, is fabricated to substantially the same length and width as the first length L 1 and the first width W 1 , may be fabricated from any suitable foam, and may be connected to the quilted assembly 16 and the foam panel 18 in any suitable manner.
- the foam panel 46 may be connected to the foam panel 18 and the foam panel 42 with an adhesive (e.g., a glue).
- the mattress 10 of FIG. 1 or the mattress 10 of FIG. 11 does not include the housing 12 .
- the length and width of the foam panel 18 is substantially the same as the overall length and width of the coil assembly 14
- the length and width of the quilted assembly 16 is substantially the same as the length and width of the foam panel 18 .
- the length and width of the foam panel 46 is substantially the same as the respective lengths and widths of the foam panel 18 and the quilted assembly 16 .
- a fabric may be utilized to encapsulate the entirety of the mattress 10 .
- a fabric may be utilized to encapsulate the entirety of the mattress 10 for embodiments which do include the housing 12 .
Abstract
A mattress including a housing having a panel forming a base and a border connected to the panel, wherein the panel and border define a receptacle having a first end and a second end. The mattress further includes a spring assembly positioned on the panel and within the receptacle, wherein the spring assembly comprises a plurality of first and second coils arranged in rows extending continuously from the first end to the second end of the receptacle, wherein the first coils are different in size from the second coils; wherein groups of one or more of the first coils and groups of one or more of the second coils define at least three zones of firmness between the first end and the second end of the receptacle, wherein each of the first and second coils includes a first end and a second end; and wherein the first ends of the first and second coils are disposed adjacent the housing panel and lie in a first plane parallel to the housing panel. The mattress further includes a quilted assembly; and a foam panel disposed between the quilted assembly and the second ends of the first and second coils.
Description
- This application claims the benefit under 35 U.S.C. §119(e) of the earlier filing date of U.S. Provisional Application Ser. No. 61/285,649 filed on Dec. 11, 2009, the contents of which are hereby incorporated by reference.
- This application discloses an invention which is related, generally and in various embodiments, to a mattress having a foam panel which interlocks a spring assembly and a quilted assembly.
- Conventional mattresses are constructed in many different ways to provide uniform or varied firmness along their lengths, such as conventional coil spring mattresses or synthetic foam mattresses. Other mattresses include housings made of synthetic polymer/copolymer plastic material generally formed by upper and lower layers or panels and a peripheral border therebetween. In one type of mattress a spring unit or series of springs are housed within the chamber of the mattress housing. Conventional mattresses utilizing springs can be zoned to provide varying firmness. Typical zoned mattresses are divided into at least three longitudinal zones of differing firmnesses.
- Various embodiments of the invention are described herein in by way of example in conjunction with the following figures, wherein like reference characters designate the same or similar elements.
-
FIG. 1 illustrates various embodiments of a mattress; -
FIG. 2 illustrates various embodiments of a housing of the mattress ofFIG. 1 ; -
FIGS. 3 and 4 illustrate various embodiments of a spring assembly of the mattress ofFIG. 1 ; -
FIGS. 5-9 illustrate different arrangements of first and second coils for different embodiments of the mattress ofFIG. 1 ; -
FIG. 10 illustrates various embodiments of a foam panel of the mattress ofFIG. 1 ; and -
FIG. 11 illustrates other embodiments of the mattress ofFIG. 1 . - It is to be understood that at least some of the figures and descriptions of the invention have been simplified to illustrate elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the invention, a description of such elements is not provided herein.
-
FIG. 1 illustrates various embodiments of amattress 10. For purposes of clarity, a partially exploded view of themattress 10 is shown inFIG. 1 . Themattress 10 includes ahousing 12, aspring assembly 14, aquilted assembly 16, and afoam panel 18 which interlocks thespring assembly 14 and thequilted assembly 16. -
FIG. 2 illustrates various embodiments of thehousing 12 of themattress 10 ofFIG. 1 . Thehousing 12 is substantially rectangular in shape, defines areceptacle 20 that is substantially rectangular in shape, having first and second ends, and also defining first and second lengths L1, L2, first and second widths W1, W2, and first and second heights H1, H2. The first length L1, the first width W1 , and the first height H1 define the respective “outer” dimensions of thehousing 12. The second length L2, the second width W2, and the second height H2 define the respective “outer” dimensions of thereceptacle 20. It will be appreciated that any of the first and second lengths L1 and L2, the first and second widths W1 and W2, and the first and second heights H1 and H2 can be different for different embodiments. - The
housing 12 includes apanel 22 and aborder 24 connected to thepanel 22. Thepanel 22 may be fabricated from any suitable foam material. Thepanel 22 is substantially rectangular in shape, is fabricated to substantially the same length and width as the first length L1 and the first width W1, and has a substantially uniform thickness. The difference between the first height H1 and the second height H2 is the thickness of thepanel 22. - The
border 24 may be connected to thepanel 22 in any suitable manner. For example, according to various embodiments, theborder 24 is connected to thepanel 22 with an adhesive (e.g., a glue). Theborder 24 may be fabricated from any suitable foam material, and is generally fabricated from the same foam material that thepanel 22 is fabricated from. Theborder 24 is substantially uniform in cross-section also and is substantially rectangular in shape, and defines afirst surface 26 and asecond surface 28. Thefirst surface 26 may be considered the “outer” surface of theborder 24 and thesecond surface 28 may be considered the “inner” surface of theborder 24. Theborder 24 is connected to thepanel 22 such that the “outer”surface 26 of theborder 24 is substantially aligned with the perimeter of thepanel 22, and the “inner”surface 28 of theborder 24 defines the respective “outer” dimensions of thereceptacle 20, and thus defines the perimeter of thereceptacle 20. - According to various embodiments, the
border 24 includes a plurality of individual border members (e.g., one for each of the four sides of the rectangular shape) which are adhered together to form the entirety of theborder 24. According to other embodiments, theborder 24 is fabricated as a single molded component substantially rectangular in shape. According to yet other embodiments, theborder 22 is fabricated as a single piece of material having a first end and a second end. The single piece of material is subsequently bent to form three corners, then the first end and the second end are adhered together to form the fourth corner of the substantially rectangular shape. -
FIG. 3 illustrates various embodiments of thespring assembly 14 of themattress 10 ofFIG. 1 . Thespring assembly 14 is positioned on thepanel 22 and within thereceptacle 20, and includes a plurality offirst coils 30 and a plurality ofsecond coils 32 arranged in rows extending continuously from the first end to the second end of the receptacle. For purposes of simplicity, thepanel 22 is not shown inFIG. 3 . The first andsecond coils receptacle 20 as shown inFIG. 4 . The plurality of first andsecond coils receptacle 20, and the respective first andsecond coils - It will be appreciated that different embodiments of the
spring assembly 14 may include different arrangements of the first andsecond coils first coils 30, different numbers ofsecond coils 32, different sizes (e.g., heights, wire gauges, diameters, etc.) of the first andsecond coils second coils FIG. 4 as arranged in straight lines, it will be appreciated that according to other embodiments, a “row” of eitherfirst coils 30 orsecond coils 32 may be arranged in a staggered or other type of configuration. - As shown in
FIG. 3 , thefirst coils 30 are of a first height and thesecond coils 32 are of a second height, but the first andsecond coils second coils first coils 30 are less resistant to compression than thesecond coils 32 due to the greater height of thefirst coils 30. A first group of thefirst coils 30 collectively define afirst zone 34, and a first group of thesecond coils 32 collectively define asecond zone 36. Thefirst zone 34 is smaller than either the length L2 or the width W2 of thereceptacle 20, and thesecond zone 36 is smaller than either the length L2 or the width W2 of thereceptacle 20. Thefirst zone 34 may be positioned anywhere on thepanel 22 and within thereceptacle 20, and thesecond zone 36 may similarly be positioned anywhere on thepanel 22 and within thereceptacle 20. Also, as shown inFIG. 3 , each of the first andsecond coils second coils housing panel 22 and lie in a first plane parallel to thehousing panel 22. Furthermore, as shown inFIG. 3 , the second ends of thefirst coils 30 lie in a second plane and the second ends of thesecond coils 32 lie in a third plane, and wherein the second plane is parallel to and spaced from the third plane. - As shown in
FIG. 3 , additional groups of thefirst coils 30 may respectively define additionalfirst zones 34, and additional groups of thesecond coils 32 may respectively define additionalsecond zones 36. For the plurality ofsecond zones 36 shown inFIG. 3 , the one in the center may be considered a torso orlumber zone 36, the one to the left may be considered ahead zone 36, and the one to the right may be considered a foot orleg zone 36. In general, thefirst zones 34 are more firm than thesecond zones 36 due to thefirst coils 30 having greater respective heights than thesecond coils 32. Stated differently, thesecond zones 36 are more yielding than thefirst zones 34 due to thesecond coils 32 having lesser respective heights than thefirst coils 30. - For a given
mattress 10, the number offirst coils 30 which collectively define a givenfirst zone 34 can be different than the number offirst coils 30 which collectively define anotherfirst zone 34. Stated differently, the length of a givenfirst zone 34 can be different than the length of anotherfirst zone 34. Similarly, the number ofsecond coils 32 which collectively define a givensecond zone 36 can be different than the number ofsecond coils 32 which collectively define anothersecond zone 36. Stated differently, the length of a givensecond zone 36 can be different than the length of anothersecond zone 36. - It will be appreciated that different embodiments of the
mattress 10 having substantially the same size may include different arrangements ofsecond coils 32. For example, whereas a first embodiment of themattress 10 as shown inFIG. 5 may utilize five “rows” ofsecond coils 32 to collectively define asecond zone 36A (e.g., a head zone), seven “rows” ofsecond coils 32 to collectively define anothersecond zone 36B (e.g., a torso or lumbar zone), and five “rows” ofsecond coils 32 to collectively define yet anothersecond zone 36C (e.g., a foot or leg zone), a second embodiment of themattress 10 as shown inFIG. 6 may utilize four “rows” ofsecond coils 32 to collectively define a correspondinghead zone 36A, nine “rows” ofsecond coils 32 to collectively define a corresponding torso orlumbar zone 36B, and four “rows” ofsecond coils 36 to collectively define a corresponding foot orleg zone 36C. - It will also be appreciated that different embodiments of the
mattress 10 having substantially the same size may include different sizes and arrangements of first andsecond coils mattress 10 as shown inFIG. 7 utilizes two “rows” offirst coils 30 having respective first diameters at the two ends of thespring assembly 14, a second embodiment of themattress 10 as shown inFIG. 8 also utilizes two “rows” offirst coils 30 having respective second diameters at the two ends of thespring assembly 14, and a third embodiment of themattress 10 as shown inFIG. 9 utilizes three “rows” offirst coils 30 having respective third diameters at the two ends of thespring assembly 14. - For this example, with respect to the second coils 32, the first embodiment of the mattress 10 as shown in
FIG. 7 utilizes four “rows” of second coils 32 having respective first diameters to collectively define a second zone 36A (e.g., a head zone), nine “rows” of second coils 32 having respective first diameters to collectively define a second zone 36B (e.g., a torso or lumbar zone), and four “rows” of second coils 32 having respective first diameters to collectively define a second zone 36C (e.g., a foot or leg zone), the second embodiment of the mattress 10 as shown inFIG. 8 utilizes five “rows” of second coils 32 having respective second diameters to collectively define a corresponding head zone 36A, nine “rows” of the second coils 32 having respective second diameters to collectively define a corresponding torso or lumbar zone 36B, and five “rows” of second coils 32 having respective second diameters to collectively define a corresponding foot or leg zone 36C, and the third embodiment of the mattress 10 as shown inFIG. 9 utilizes five “rows” of second coils 32 having respective third diameters to collectively define a corresponding head zone 36A, eleven “rows” of second coils 32 having respective third diameters to collectively define a corresponding torso or lumbar zone 36B, and five “rows” of second coils 32 having respective third diameters to collectively define a corresponding foot or leg zone 36C. - For embodiments where the first and
second coils second coils first coils 30 of a given embodiment may include any number of different coil diameters, the second coils 32 of a given embodiment may include any number of different coil diameters, and a given embodiment may include any number of different first coil diameters and different second coil diameters. - The respective heights of the
first coils 30 are substantially the same as the second height H2. Therefore, it will be appreciated that the portions of thereceptacle 20 which are aligned with thefirst zones 34 are substantially filled by the first coils 30. As the respective heights of the second coils 32 are less than the respective heights of the first coils 30, and thus are less than the second height H2, it will be appreciated that the portions of thereceptacle 20 which are aligned with thesecond zones 36 are not substantially filled by the second coils 32. The resulting unfilled volumes or voids 38 (seeFIG. 3 ) are positioned directly above the second firmness zones and are collectively defined by theborder 24 and the second coils 32. -
FIG. 10 illustrates various embodiments of thefoam panel 18 of themattress 10 ofFIG. 1 . Thefoam panel 18 is substantially rectangular in shape, may be fabricated from any suitable material, is fabricated to substantially the same length and width as the first length L1 and the first width W1, and includesprojections 40 configured to substantially fill any voids 38 (the number ofprojections 40 corresponds to the number of voids 38). Theprojections 40 are substantially rectangular in shape, are smaller than either the length L2 or the width W2 of thereceptacle 20, and provide for an increased level of comfort “above” thesecond zones 36. Due to theprojections 40, different portions of thefoam assembly 18 have different respective heights. Theprojections 40 are connected to thespring assembly 14 and may be connected in any suitable manner. For example, according to various embodiments, theprojections 40 are connected to the fabric which surrounds thesecond coils 32 with an adhesive (e.g., a glue). According to other embodiments, theprojections 40 are connected to the fabric which surrounds thesecond coils 32 with a tufting. Thefoam panel 18 is also connected to thehousing 12, and may be connected in any suitable manner. According to various embodiments, thefoam panel 18 may be connected to theborder 24 with an adhesive (e.g., a glue). - The
foam panel 18 may be fabricated from any suitable material, and may be fabricated in any suitable manner. According to various embodiments, thefoam panel 18 is fabricated from a slab of foam having a thickness equal to the largest height of thefoam panel 18. Portions of thefoam panel 18 which are aligned with thefirst zones 34 are removed from the slab to define theprojections 40. According to other embodiments, thefoam panel 18 is fabricated by connecting (e.g., adhering) individual foam panels which are the same size as theprojections 40 to a slab of foam substantially the same length and width as the first length L1 and the first width W1 to form thefoam panel 18. For such embodiments, different individual foam panels may be fabricated from different foams, and the slab of foam may be the same foam or a different foam than any one of the individual foam panels. According to yet other embodiments, thefoam panel 18 may be convoluted cut to produce a plurality of “peaks” and “valleys” on a surface of the foam panel 18 (e.g., on the “upper” surface). - Returning to
FIG. 1 , thequilted assembly 16 is substantially rectangular in shape, and is fabricated to substantially the same length and width as the first length L1 and the first width W1. For example, thequilted assembly 16 may include afoam panel 42 substantially the same length and width as the first length L1 and the first width W1, and aquilt top 44 which covers thefoam panel 42. Thefoam panel 42 may be fabricated from any suitable foam. For example, according to various embodiments, the foam panel is fabricated from a polyurethane foam. According to other embodiments, thefoam panel 42 may include a plant based mix such as, for example, a mix which includes a soy component. It will be appreciated that thequilted assembly 16 may include any number offoam panels 42, and therespective foam panels 42 may be fabricated from the same foam or different foams. - The
quilted assembly 16 is connected to thefoam panel 18, and may be connected in any suitable manner. For example, according to various embodiments, thefoam panel 42 is connected to thefoam panel 18 with an adhesive (e.g., a glue). Due to its connection to thefoam panel 18, and the connection of thefoam panel 18 to thespring assembly 14, it will be appreciated that thefoam panel 18 also functions to interlock thespring assembly 14 and thequilted assembly 16. -
FIG. 11 illustrates other embodiments of themattress 10 ofFIG. 1 . For purposes of clarity, an exploded view of themattress 10 is shown inFIG. 11 . For these embodiments, themattress 10 also includes afoam panel 46 positioned between and connected to thequilted assembly 16 and thefoam panel 18. Thefoam panel 46 is substantially rectangular in shape, is fabricated to substantially the same length and width as the first length L1 and the first width W1, may be fabricated from any suitable foam, and may be connected to thequilted assembly 16 and thefoam panel 18 in any suitable manner. For example, according to various embodiments, thefoam panel 46 may be connected to thefoam panel 18 and thefoam panel 42 with an adhesive (e.g., a glue). - According to other embodiments, the
mattress 10 ofFIG. 1 or themattress 10 ofFIG. 11 does not include thehousing 12. For such embodiments, the length and width of thefoam panel 18 is substantially the same as the overall length and width of thecoil assembly 14, and the length and width of thequilted assembly 16 is substantially the same as the length and width of thefoam panel 18. For embodiments which also include thefoam panel 46, the length and width of thefoam panel 46 is substantially the same as the respective lengths and widths of thefoam panel 18 and thequilted assembly 16. For embodiments which do not include thehousing 12, it will be appreciated that a fabric may be utilized to encapsulate the entirety of themattress 10. It will also be appreciated that a fabric may be utilized to encapsulate the entirety of themattress 10 for embodiments which do include thehousing 12. - Nothing in the above description is meant to limit the invention to any specific materials, geometry, or orientation of elements. Many part/orientation substitutions are contemplated within the scope of the invention and will be apparent to those skilled in the art. The embodiments described herein were presented by way of example only and should not be used to limit the scope of the invention.
- Although the invention has been described in terms of particular embodiments in this application, one of ordinary skill in the art, in light of the teachings herein, can generate additional embodiments and modifications without departing from the spirit of, or exceeding the scope of, the claimed invention. Accordingly, it is understood that the drawings and the descriptions herein are proffered only to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
Claims (19)
1. A mattress, comprising:
a housing, wherein the housing comprises:
a panel forming a base; and
a border connected to the panel, wherein the panel and border collectively define a receptacle having a first end and a second end;
a spring assembly positioned on the panel and within the receptacle, wherein the spring assembly extends continuously from the first end of the receptacle to the second end of the receptacle, the spring assembly comprising a plurality of first coils and a plurality of second coils, wherein:
each of the first and second coils is disposed adjacent the panel and has a first end which lies in a first plane parallel to the panel;
the first coils are less resistant to compression than are the second coils; and
the spring assembly defines at least three zones of firmness between the first end of the receptacle and the second end of the receptacle;
a quilted assembly; and
at least one foam panel disposed between the quilted assembly and the spring assembly.
2. The mattress of claim 1 , wherein the border comprises a foam material.
3. The mattress of claim 1 , wherein the border is substantially uniform in cross-section.
4. The mattress of claim 1 , wherein:
the first coils are arranged in rows; and
the second coils are arranged in rows.
5. The mattress of claim 4 , wherein:
a first row of the first coils is positioned within the receptacle and between the first and second ends of the receptacle;
a first row of the second coils is positioned within the receptacle and between the first row of the first coils and the second end of the receptacle; and
a second row of the first coils is positioned within the receptacle and between the first row of the second coils and the second end of the receptacle.
6. The mattress of claim 5 , wherein a second row of the second coils is positioned between the second row of the first coils and the second end of the receptacle.
7. The mattress of claim 1 , wherein a wire gauge of the first coils is different than a wire gauge of the second coils.
8. The mattress of claim 1 , wherein a height of the first coils is greater than a height of the second coils.
9. The mattress of claim 1 , wherein a material which comprises the first coils is different from a material which comprises the second coils.
10. The mattress of claim 1 , wherein a shape of the first coils is different from a shape of the second coils.
11. The mattress of claim 1 , wherein:
each of the first coils has a second end which lies in a second plane parallel to the housing panel; and
each of the second coils has a second end which lies in a third plane parallel to the housing panel, wherein the second plane is parallel to and spaced from the third plane.
12. The mattress of claim 1 , wherein at least some of the second coils define at least one of the at least three zones of firmness.
13. The mattress of claim 1 , wherein the at least three zones of firmness comprise:
a head firmness zone;
a leg firmness zone; and
a torso firmness zone between the head and leg firmness zones.
14. The mattress of claim 1 , wherein the at least one foam panel comprises a first foam panel having:
a first surface adjacent a second end of the second coils; and
a substantially planar second surface which lies in a second plane parallel to the housing panel.
15. The mattress of claim 14 , wherein the first foam panel is substantially uniform in cross-section.
16. The mattress of claim 14 , wherein the at least one foam panel further comprises a second foam panel disposed between the first foam panel and the quilted assembly.
17. The mattress of claim 16 , wherein the second foam panel is substantially uniform in cross-section:
18. The mattress of claim 1 , wherein the at least one foam panel has:
a first surface adjacent a second end of the second coils;
a second surface adjacent a second end of the first coils; and
a substantially planar third surface which lies in a second plane parallel to the housing panel.
19. The mattress of claim 1 , further comprising:
a first fabric pocket which surrounds one of the first coils; and
a second fabric pocket which surrounds one of the second coils.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/966,631 US20110191962A1 (en) | 2009-12-11 | 2010-12-13 | Mattress having a foam panel which interlocks a spring assembly and a quilted assembly |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US28564909P | 2009-12-11 | 2009-12-11 | |
US12/966,631 US20110191962A1 (en) | 2009-12-11 | 2010-12-13 | Mattress having a foam panel which interlocks a spring assembly and a quilted assembly |
Publications (1)
Publication Number | Publication Date |
---|---|
US20110191962A1 true US20110191962A1 (en) | 2011-08-11 |
Family
ID=44145952
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/966,631 Abandoned US20110191962A1 (en) | 2009-12-11 | 2010-12-13 | Mattress having a foam panel which interlocks a spring assembly and a quilted assembly |
Country Status (2)
Country | Link |
---|---|
US (1) | US20110191962A1 (en) |
WO (1) | WO2011072294A1 (en) |
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WO2014113737A1 (en) | 2013-01-19 | 2014-07-24 | Wolfson Martin | No-glue pocketed spring unit construction |
US20140283307A1 (en) * | 2013-03-22 | 2014-09-25 | Comfort Revolution, LLC | Mattress toppers combining foam and pocket coil layers |
US8955182B1 (en) | 2011-11-15 | 2015-02-17 | Pranasleep, LLC | Perimeter-wrapped mattress and method of manufacture |
US20150082549A1 (en) * | 2012-05-03 | 2015-03-26 | Simon Cairns | Bedding systems |
US9179782B2 (en) | 2012-04-27 | 2015-11-10 | Stephen J. SCHILLER | Perimeter-wrapped mattress and method of manufacture |
US20150335163A1 (en) * | 2012-12-28 | 2015-11-26 | Tempur-Pedic Management, Llc | Mattress assembly |
US10206515B1 (en) * | 2017-09-20 | 2019-02-19 | L&P Property Management Company | Pocketed spring assembly |
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US10820716B1 (en) * | 2016-12-20 | 2020-11-03 | Steven J. Antinori | Dual sided innerspring mattress |
US11013340B2 (en) * | 2018-05-23 | 2021-05-25 | L&P Property Management Company | Pocketed spring assembly having dimensionally stabilizing substrate |
US11583098B2 (en) * | 2018-11-26 | 2023-02-21 | L&P Swiss Holding Gmbh | Pocket spring core |
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Cited By (14)
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---|---|---|---|---|
US8955182B1 (en) | 2011-11-15 | 2015-02-17 | Pranasleep, LLC | Perimeter-wrapped mattress and method of manufacture |
US9179782B2 (en) | 2012-04-27 | 2015-11-10 | Stephen J. SCHILLER | Perimeter-wrapped mattress and method of manufacture |
US20150082549A1 (en) * | 2012-05-03 | 2015-03-26 | Simon Cairns | Bedding systems |
US20150335163A1 (en) * | 2012-12-28 | 2015-11-26 | Tempur-Pedic Management, Llc | Mattress assembly |
US9848711B2 (en) * | 2012-12-28 | 2017-12-26 | Tempur-Pedic Management, Llc | Mattress assembly |
EP3184001A1 (en) | 2013-01-19 | 2017-06-28 | Wolfson, Martin | Glueless pocketed spring unit construction |
WO2014113737A1 (en) | 2013-01-19 | 2014-07-24 | Wolfson Martin | No-glue pocketed spring unit construction |
US20140283307A1 (en) * | 2013-03-22 | 2014-09-25 | Comfort Revolution, LLC | Mattress toppers combining foam and pocket coil layers |
US9861206B2 (en) * | 2013-03-22 | 2018-01-09 | Comfort Revolution, LLC | Mattress toppers combining foam and pocket coil layers |
US10820716B1 (en) * | 2016-12-20 | 2020-11-03 | Steven J. Antinori | Dual sided innerspring mattress |
JP2019025129A (en) * | 2017-08-01 | 2019-02-21 | 株式会社ルービックJp | mattress |
US10206515B1 (en) * | 2017-09-20 | 2019-02-19 | L&P Property Management Company | Pocketed spring assembly |
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