US20120284927A1 - Tension relief foam and mattress constructions - Google Patents
Tension relief foam and mattress constructions Download PDFInfo
- Publication number
- US20120284927A1 US20120284927A1 US13/470,903 US201213470903A US2012284927A1 US 20120284927 A1 US20120284927 A1 US 20120284927A1 US 201213470903 A US201213470903 A US 201213470903A US 2012284927 A1 US2012284927 A1 US 2012284927A1
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- US
- United States
- Prior art keywords
- tension relief
- pad
- foam
- mattress system
- tension
- 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
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Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—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
-
- 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
Abstract
Description
- This application claims priority to U.S. Provisional Patent Application No. 61/485,364, filed on May 12, 2011, which is incorporated herein by reference in its entirety.
- The present invention is in the field of reflexive support systems including support systems for humans such as bedding or seating.
- The present invention incorporates surface or structurally modified foam into a mattress for highly localized deformation and support, independent movement and reduced tension in the horizontal plane, an improvement in conformance and motion separation characteristics of the support system. In a representative embodiment, a tension relief foam pad is a generally rectangular piece of foam having a top surface and a bottom surface opposite and parallel to the top surface with four side wall which are perpendicular to and extend between the top and bottom surface. The length and width measurements of the pad are substantially equal to that of a mattress with which it is to be used. Depending on the arrangement of the tension relief foam pad within a mattress construction, discussed in greater detail below, either the top or bottom surface contains a plurality of cuts arranged in a checkerboard or other pattern, while the opposite surface is substantially planar. The cuts create a plurality of square or rectangular blocks on the surface of the pad and independent modules which have independent support characteristics, and which may be coupled with other support elements such as springs.
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FIG. 1A is a perspective view of a preferred placement of a tension relief foam topper among other foam layers in a mattress system. -
FIG. 1B is a perspective view of an alternate placement of a tension relief foam pad among other foam layers in a mattress system. -
FIG. 2 is a side view of one embodiment of tension relief foam pad and innerspring. -
FIG. 3 is a side view of an alternate embodiment of tension relief foam pad and innerspring. -
FIG. 4 is a chart showing the surface deflection on a tension relief foam pad in various locations among other foam layers in a mattress system. -
FIG. 5 is a chart showing the surface strain on a tension relief foam pad in various locations among other foam layers in a mattress system. -
FIG. 6A is a perspective view showing the stress distribution across a tension relief foam pad when the pad is used as a top layer of a mattress system. -
FIG. 6B is a perspective view showing the stress distribution across a tension relief foam pad when the pad is used as a bottom layer of a mattress system. -
FIG. 7 is a side view of an alternate embodiment of tension relief foam pad and innerspring. -
FIG. 8 is a top view of a tension relief foam pad with non-uniform sized blocks. -
FIG. 9 is a side view of one embodiment of tension relief foam pad with non-uniform sized blocks. -
FIG. 10 is a side view of an alternate embodiment of tension relief foam pad with non-uniform sized blocks. -
FIG. 11 is a side view of an alternate embodiment of tension relief foam pad with non-uniform sized blocks. - The tension relief foam pads, mattresses and support systems of the present disclosure and related inventions utilize surface modified foams to achieve independent and localized deformation, support and movement and reduced tension or shear forces in the horizontal plane, benefitting the conformance and motion separation characteristics of the system. The various forms of tension relief foam pieces and pads described herein (also referred to herein as “pad” or “foam pad” or “topper”) 10 are generally in the form of rectangular block planar shapes having a top surface and a bottom surface opposite and parallel to the top surface. For example, the length and width measurements of the
pad 10 are substantially equal to that of a mattress with which it is to be used. Although described with reference to particular representative embodiments, it is understood that the concepts of the present disclosure can be applied and implemented in other physical forms of foam. As used herein, the term “tension relief foam” refers generally to each of the various described foam configurations and constructs, and more generally to foam body configurations which reduce or eliminate stress forces within the cellular structure of a body of foam. The design concepts and configurations are equally applicable to any type of foam from which such shapes and configurations can be manufactured, including open cell and closed cell type foams. Depending on the arrangement of the tensionrelief foam pad 10 within the mattress construction, set forth in greater detail below, either the top or bottom surface contains a plurality ofcontinuous cuts 18 arranged in a checkerboard or other pattern, while the opposite surface is substantially planar and generally without cuts. Thecuts 18 create a plurality of square orrectangular blocks 16 on one surface of thepad 10. - A typical mattress system includes a foundation or box spring, a support unit and optionally, a comfort unit. The foundation can be of conventional internal design and construction, having a rectangular frame on which are mounted a plurality of spring elements or modules to provide flexible support for an overlying grid, which defines the foundation surface. The spring modules in the foundation may be formed of wire or made of a composite material, or be entirely without individual spring modules and rather in the form of a flexible support surface. Foundation units are typically supported by a bed frame which may further include side boards, a head board and foot board. The support unit or innerspring of the mattresses of the disclosure are dimensioned to fit upon the foundation surface and be fully supported thereby. The support unit or innerspring may be of conventional design, containing a plurality of interconnected spring coils. The support unit may alternatively be a high performance foam core structure without any internal wire or spring elements. The support surface has relatively few layers of material, which cover the innerspring, such as one or more layers of mat or foam or other sheet-like fabric or non-woven material. The primary purpose of layers is to provide a smooth surface over the ends of the coils of the innerspring. A comfort unit is dimensioned to fit upon the support unit. It has a generally horizontal top and bottom and generally vertical or tapered sides extending between the top and bottom to define a central space containing supporting and cushioning components. The comfort unit contains additional layers of compressible, conformable internal layers of materials. A comfort unit may contain one or more foam core layers and intermediate and outer layers made of matted material, synthetic or organic, such as cotton or wool fibers, polyester, or hybrid material mats. Extra material layers may also be used, such as woven cotton, wool or synthetic cloths or hybrids thereof, or sheet materials such as plastic films, solid or perforated, which may serve as moisture barriers, aeration promoters, liners or flame or heat retardants. The feel of the comfort unit may be adjusted by using different insert materials such as polyurethane foams, visco-elastic foams, latex foams, fibers, gels or various combinations thereof. The comfort unit materials are encapsulated by upholstery, which may include ticking, for example foam or padding backed woven or embroidered material, side wall material or ticking, tape edges, and a gusset which extends from the pillowtop to the top of the support unit. The upholstery of the comfort unit may be a combination of materials.
- In a preferred embodiment, the top surface of the
tension relief pad 10 is generally planar while the bottom surface contains a plurality ofcuts 18 arranged in a checkerboard or other pattern. The cuts orvoids 18 between discrete islands of foam can be uniform in size and spacing or not, generally linear or not, and dimensioned uniformly or not. Thefoam structures 16 can be formed by molding, cutting, water-jet forming or by any other suitable process. When used in combination with aninnerspring 15 or spring unit, thetension relief foam 10 pad is generally placed directly above theinnerspring 15 and below anyother foam layers 12 of the mattress or comfort unit, as shown inFIGS. 1A , 2 and 3. A thin fabric or fiber layer or insulation layer may be located between the tensionrelief foam pad 10 and theinnerspring 15. Theindividual blocks 16 on the bottom surface of thepad 10 may be aligned with or correspond in location to the positions of the upper terminal convolutions of thecoils 14 of themattress innerspring 15, as shown inFIGS. 2 and 3 . Depending on the size of theblocks 16, each block may correspond and work in combination with two or more springs orcoils 14 of theinnerspring 15 to provide improved independent movement of thefoam 10 andcoils 14 accentuating the feel of thecoils 14. Each of theindividual blocks 16, in combination with theinnerspring 15, is separately compressible in response to the weight placed directly thereon. Placing thetension relief pad 10 directly on top of theinnerspring 15, belowother foam layers 12, is shown to provide more local compliance, a lower surface strain and a lower complex stress state, as shown in the charts ofFIGS. 4 and 5 and on the stress state mapping shown inFIG. 6B . - Representative and non-limiting examples of springs which can be used in the tension relief foam mattress system of the present invention include those disclosed in the commonly assigned U.S. Pat. Nos. 4,535,978; 4,726,572; 5,558,315; 6,134,729; 6,354,577; 6,406,009; 8,178,187; 7,404,223; 7,908,693 and any other spring or reflexive device or devices which could be mounted upon a frame or platform and support a grid or other mattress support structure over the frame or platform. The springs may be individually pocketed or Marshall-type coils or the coils may be without a pocket or encasement. Each of the individual foam blocks 16 may be associated with one or more
corresponding spring 14 of aspring unit 15, as shown inFIGS. 2 , 3 and 7. Having an axial upper end of eachcoil 14 in direct or indirect physical contact with an opposing face of afoam block 16 provides a hybrid spring combination by which a force applied to the area of aparticular foam block 16 is transferred in whole or in part to thecorresponding spring 14, and the matchedspring 14 or springs andfoam block 16 respond together to applied forces. The size of eachblock 16 in the pattern may be uniform, such as, for example, thepad 10 shown inFIG. 7 wherein each uniformlysized foam block 16 corresponds to asingle coil unit 14 of the innerspring 15. Also,FIG. 3 shows apad 10 with uniformly sized foam blocks 16 correspond to every twocoil units 14 of the innerspring 15. Alternatively, the size of the foam blocks 16 in the pattern may be non-uniform, such as, for example, thepad 10 shown inFIG. 2 , wherein blocks 16 having a first size, which corresponds to threecoil units 14 of the innerspring 15, are interspersed betweenblocks 16 having a second size which corresponds to twocoil units 14 of the innerspring 15. The individual blocks 16 may be zoned such that theblocks 16 vary in number or size. For example, theblocks 16 located along the short edges of thepad 10 may have a larger width while the remainder of theblocks 16 located therebetween may have a uniform width, which is less than the width of theblocks 16 along the short edges of thepad 10. Any pattern of uniform or non-uniformsized blocks 16, which correspond to any number ofcoils 14 may be used to create different zones in the tensionrelief foam pad 10 and mattress system of the present invention. - In an alternate embodiment, the bottom surface of the tension
relief foam pad 10 is generally planar while the top surface contains a plurality ofcuts 18 arranged in a checkerboard or other uniform or non-uniform pattern. In this configuration, shown inFIG. 1B , the tensionrelief foam pad 10 is typically placed between additional foam layers 12 of the mattress construction. To prevent bunching or sticking between theblocks 16 on the top surface of the tensionrelief foam pad 10 and the bottom surface of anadjacent foam pad 12, which may result in body impressions, thetension relief pad 10 may be laminated. Thecuts 18 may be of any width or opening (or no opening, such as in the form of a slit) or any size width from 1 mm to 10 mm or greater. Also, thecuts 18 may have generally planar and parallel walls or tapered or other shape, and may be formed in straight and orthogonal lines as shown or in other arrangements which have the similar result of relieving tension in the foam piece. - The tension
relief foam pad 10 dimensions, block cut and geometry affect the surface deformation, surface strain, stress state upon the layer and deformation modes of thepad 10. For example, if the height of theblocks 16 is too great, it may cause weak points between eachblock 16, which may be subject to tearing when a force is applied thereto. If the width of thecuts 18 or the gap between eachblock 16 is too wide, it may cause local depressions on the top surface of the mattress. If thegap 18 is too narrow, there may be too much contact betweenadjacent blocks 16 preventing independent movement. Also, if the height of theblocks 16 is too high, it may cause bending or deformation of theblocks 16. Therefore, as general overall design considerations, the thickness of thefoam pad 10 or the overall solid height of thefoam pad 1—must be greater than or equal to 1 inch; theblock 16 width must be greater than or equal to theblock 16 height or greater than or equal to 2.5 inches; the gap width must be 15% of thesmallest block 16 width or less than 0.75 inches. - As an example, a tension
relief foam pad 10 may be approximately 3 inches thick withcuts 18 between eachblock 16 being approximately 2 inches deep or extending approximately 2/3 of the way into thefoam pad 10. The individual blocks 16 may have a uniform size, such as 3.75 inches wide by 3.75 inches long with the width of the cut orgap 18 betweenblocks 16 being approximately 0.25 inch wide. Alternatively, the individual blocks 16 may vary in size such that theblocks 16 located at the short edges are larger than theblocks 16 located therebetween, wherein theblocks 16 located at the short edges of thepad 10 are approximately 7.35 inches wide and theblocks 16 located therebetween are approximately 5.2 inches wide. This example tensionrelief foam pad 10 enables a zoned mattress construction wherein blocks 16 of different sizes can be formed and located in particular zones or regions where different support characteristics are desired, such as the shoulder or lumbar areas of the mattress where blocks 16 of a relatively larger size may have a relatively greater density and relatively less freedom of individual movement or deformation to provide firmer support which still has the enhanced conformance of the structurally modified foam and a corresponding spring or core unit support. Tensionrelief foam pads 10 having various thickness measurements are shown inFIGS. 9 , 10 and 11. - It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Other features and aspects of this invention will be appreciated by those skilled in the art upon reading and comprehending this disclosure. Such features, aspects, and expected variations and modifications of the reported results and examples are clearly within the scope of the invention where the invention is limited solely by the scope of the following claims.
Claims (20)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US13/470,903 US20120284927A1 (en) | 2011-05-12 | 2012-05-14 | Tension relief foam and mattress constructions |
Applications Claiming Priority (2)
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US201161485364P | 2011-05-12 | 2011-05-12 | |
US13/470,903 US20120284927A1 (en) | 2011-05-12 | 2012-05-14 | Tension relief foam and mattress constructions |
Publications (1)
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US20120284927A1 true US20120284927A1 (en) | 2012-11-15 |
Family
ID=47139724
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US13/470,903 Abandoned US20120284927A1 (en) | 2011-05-12 | 2012-05-14 | Tension relief foam and mattress constructions |
Country Status (6)
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US (1) | US20120284927A1 (en) |
EP (1) | EP2706888A4 (en) |
JP (1) | JP2014512936A (en) |
CN (1) | CN103702591A (en) |
CA (1) | CA2835841A1 (en) |
WO (1) | WO2012155132A1 (en) |
Cited By (3)
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US20120284926A1 (en) * | 2011-05-12 | 2012-11-15 | Tyree Steven | Low shear mattress topper constructions |
USD738644S1 (en) | 2013-09-20 | 2015-09-15 | Future Foam, Inc. | Pillow |
US20150289669A1 (en) * | 2014-04-10 | 2015-10-15 | Randy A. Reynolds | Independent foam spring mattress |
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US20130081209A1 (en) | 2011-09-30 | 2013-04-04 | Nomaco Inc. | Cellular mattress assemblies and related methods |
US8356373B2 (en) | 2009-03-06 | 2013-01-22 | Noel Group Llc | Unitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s) |
US20120272457A1 (en) | 2011-04-29 | 2012-11-01 | Nomaco Inc. | Unitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s) and related methods |
USD693144S1 (en) | 2010-03-03 | 2013-11-12 | Noel Group Llc | Mattress bed cushion |
USD693145S1 (en) | 2010-03-03 | 2013-11-12 | Noel Group Llc | Mattress bed cushion |
USD694553S1 (en) | 2010-03-03 | 2013-12-03 | Noel Group Llc | Mattress bed cushion |
USD688492S1 (en) | 2010-03-03 | 2013-08-27 | Noel Group Llc | Mattress bed cushion |
USD693148S1 (en) | 2010-03-03 | 2013-11-12 | Noel Group Llc | Mattress bed cushion |
USD691400S1 (en) | 2012-02-10 | 2013-10-15 | Nomaco Inc. | Stackable base for mattress assembly |
USD693149S1 (en) | 2012-04-27 | 2013-11-12 | Noel Group Llc | Mattress bed cushion |
USD694552S1 (en) | 2012-04-27 | 2013-12-03 | Noel Group Llc | Mattress bed cushion |
USD693147S1 (en) | 2012-04-27 | 2013-11-12 | Noel Group Llc | Mattress bed cushion |
USD693146S1 (en) | 2012-04-27 | 2013-11-12 | Noel Group Llc | Mattress bed cushion |
USD692693S1 (en) | 2012-04-27 | 2013-11-05 | Noel Group Llc | Mattress bed cushion |
USD697337S1 (en) | 2012-07-03 | 2014-01-14 | Nomaco, Inc. | Stackable base for mattress assembly |
USD690536S1 (en) | 2012-07-26 | 2013-10-01 | Nomaco Inc. | Motion isolation insulator pad |
USD694041S1 (en) | 2012-09-28 | 2013-11-26 | Noel Group Llc | Mattress bed cushion |
USD692694S1 (en) | 2012-09-28 | 2013-11-05 | Noel Group Llc | Mattress bed cushion |
USD688069S1 (en) | 2012-09-28 | 2013-08-20 | Noel Group Llc | Mattress bed cushion |
USD701713S1 (en) | 2012-11-09 | 2014-04-01 | Noel Group, Llc | Mattress bed cushion |
USD709301S1 (en) | 2012-11-09 | 2014-07-22 | Noel Group Llc | Mattress bed cushion |
USD707467S1 (en) | 2012-11-09 | 2014-06-24 | Noel Group Llc | Mattress bed cushion |
USD707468S1 (en) | 2012-11-09 | 2014-06-24 | Noel Group Llc | Mattress bed cushion |
WO2014176400A1 (en) | 2013-04-26 | 2014-10-30 | Noel Group Llc | Cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow, and related methods |
USD704962S1 (en) | 2013-09-09 | 2014-05-20 | Noel Group Llc | Mattress bed cushion |
WO2016195700A1 (en) | 2015-06-05 | 2016-12-08 | Sealy Technology, Llc | Non-linear springs and mattresses including the same |
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US20120284926A1 (en) * | 2011-05-12 | 2012-11-15 | Tyree Steven | Low shear mattress topper constructions |
USD738644S1 (en) | 2013-09-20 | 2015-09-15 | Future Foam, Inc. | Pillow |
USD751322S1 (en) | 2013-09-20 | 2016-03-15 | Future Foam, Inc. | Pillow |
US20150289669A1 (en) * | 2014-04-10 | 2015-10-15 | Randy A. Reynolds | Independent foam spring mattress |
Also Published As
Publication number | Publication date |
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WO2012155132A1 (en) | 2012-11-15 |
EP2706888A4 (en) | 2014-10-01 |
EP2706888A1 (en) | 2014-03-19 |
JP2014512936A (en) | 2014-05-29 |
CN103702591A (en) | 2014-04-02 |
CA2835841A1 (en) | 2012-11-15 |
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