WO1995022272A1

WO1995022272A1 - Mattress system

Info

Publication number: WO1995022272A1
Application number: PCT/CA1995/000087
Authority: WO
Inventors: Jack Schwartz
Original assignee: Jack Schwartz
Priority date: 1991-08-20
Filing date: 1995-02-17
Publication date: 1995-08-24
Also published as: WO1993003654A1; CA2112895A1; DE69208364T2; ATE134114T1; AU2438692A; NO950430D0; US5819349A; AU690889B2; US5513402A; EP0599922A1; CA2112895C; GB2313051B; BR9207151A; CA2117000A1; ES2086133T3; JPH07509376A; EP0599922B1; NO950430L; GB2313051A; DE69208364D1

Abstract

In a mattress system having side-by-side sleeping zones (190, 191) for two individuals, movement of a person resting on one side is suppressed from inducing movement in another side of the mattress system by providing a sectional spring base having a panel (196) for each sleeping zone and a middle panel (196) to support a boundary area of the two sleeping zones. To prevent side-by-side foam mattresses from sticking as they flex and compress independently, an edge separation is provided to reduce the foam-to-foam friction.

Description

MATTRESS SYSTEM

Field of the Invention

This invention is concerned with a mattress system. In particular, the invention relates to a mattress system in which movement of a person resting on one side is suppressed from inducing movement in another side of the mattress system.

Background of the Invention

A multilayer mattress system is disclosed in PCT patent application PCT/CA92/00348 published on March 3, 1993 under the No. WO 93/03654. Such a mattress system provides adjustability for individuals. A stack of individual mattress elements includes separation sheets to allow the mattress elements to flex and compress separately. A containment means is provided to keep the stack of mattress elements aligned in a vertical stack. When there are two vertical stacks of mattress elements, containment means are provided around the two stacks to keep them together.

The prior art mattress system provides a conveniently adjustable sleeping surface for two individuals sleeping side-by-side. However, loss of flexibility and softness can arise as a result of placing the two mattress stacks side-by-side in close connection while maintaining independent movement between the two sides.

Summary of the Invention

The present invention provides a mattress system comprising: a first mattress, a second mattress adjacent the first mattress to provide two contiguous sleeping zones having a border therebetween extending from head to toe; and a sectional spring base having first and a second vertically mobile, resilient, substantially horizontal panels supporting each of the sleeping zones of the mattress system, and a third narrow vertically mobile, resilient, substantially horizontal panel extending from head to toe for supporting independently an area of the first and the second mattress near the border.

According to the invention, there is provided a mattress comprising a first foam mattress, edge separation means provided on a longitudinal side edge of the first mattress, and a second mattress longitudinally adjacent the first mattress. The edge separation means allows the first mattress to compress and move vertically with reduced friction while in contact with said second mattress. According to a further aspect of the invention, there is provided a multilayer mattress comprising at least two mattress elements, at least one of which being made of foam and having a different hardness from the others, open top containment means adapted and constructed to ensure that the mattress elements remain situated in their chosen order in a substantially vertical stack, and to subject the mattress elements to slight lateral compression, the containment means allowing the elements to be removed from the stack vertically, and edge separation means for allowing the elements to flex and move vertically with reduced friction between the elements and the containment means.

Brief Description of the Drawings

The invention will now be described by way of reference to the attached Figures, in which:

Figure 1 shows a double mattress and a cradle; Figure 2 shows a detail of the cradle;

Figure 3 shows a mattress set for a double bed;

Figure 4 shows a detailed end view of the attachment straps between two adjacent stacks of mattress elements; Figure 5 shows a side view of the sectional spring support base according to the preferred embodiment;

Figure 6 shows a detailed sectional view of adjacent foam mattresses provided with edge separation means with one mattress undergoing independent compression,-

Figure 7 shows a transverse sectional view of two side by side mattresses provided with single fitted sheets for edge separation means and a single king size fitted sheet over both mattresses as containment means;

Figure 8 shows a detailed end view of the movement block located between two stacks of mattress elements, provided with straps connecting the elements to the block;

Figure 9 shows a transverse sectional view of three mattress elements in a vertical stack each having at least partial foam contact between adjacent mattress elements or the support base; Figure 10 shows a detailed sectional view of the open top containment means provided with interior edge separation means and exterior slits for receiving a mattress cover and the fitted sheet;

Figure 11 shows a plan view of two mattresses held together by four L-shaped containment members interconnected at their ends by straps;

Figure 12 shows an end view of a sectional spring support base according to the preferred embodiment; and Figure 13 shows a perspective view of a base frame having removable edge containment members. Detailed Description of the Preferred Embodiments

In Figure 1, a prior art system is shown representing a double bed mattress. The mattress shown generally at 11 comprises two sets of mattress elements 12, 13, 14, 15, 16, and 22, 23, 24, 25, and 26, and two rigid core elements 17 and 27. As shown, these are not in the same place. When both sets are assembled into the cradle 21 with the overall fitted sheet 8 (shown cut away for clarity), the top surface of the sheet 8 is substantially flat.

Figure 1 also shows some further details concerning various options in the separation means and the containment means. The purpose of the separation means is to allow each foam mattress element to compress and to flex under the load imposed by the user. If no separation is provided, it appears that foam-to-foam friction relatively rapidly degrades the foam elements, especially in the main load areas, which are usually substantially along the center of the mattress. To eliminate this friction and to ensure that the mattress elements are free to compress and to flex independently, the simple way is to encase each mattress element, the core element, and a torso board, as discussed below, in an individual fabric case, as at 20 for the element 12. A mattress pad as at 19 can be provided within such a case, or it can be incorporated into the case. If such a pad is used, it is preferred that it is included on both sides of the mattress, thus avoiding the mattress elements becoming one-sided. Alternatively, the separation means can comprise a sheet of fabric as at 29 glued or otherwise attached to at least one face of each mattress element, to the core element, and, if required, to a torso board. Again, to avoid the elements becoming one-sided, it is preferred to provide such a sheet on both faces of each mattress element, of the core element, and of the torso board. If such an attached sheet is used, it need not be the full size of the mattress, and an edge border as at 29A, can be left uncovered. The separation sheet can even comprise a regular fitted sheet or fitted mattress pad, and for the purposes of providing a separation sheet on both sides of the foam mattress element, two fitted sheets applied to both sides of the foam mattress element can be used. It appears that leaving this edge area open to foam-to- foam friction is beneficial, particularly in a double bed having two mattress sets, as it helps in eliminating any separation between the two sets along the mattress centerline. Further, it is also possible to include a mattress pad, as at 19, either with and as part of the sheet 29, or in conjunction with it, so that the pad is somewhat smaller than the mattress element with which it is associated. In that case, it has been found beneficial to provide a shallow recess in the mattress element to receive the pad, so that the mattress element retains an essentially flat surface.

The separation means may comprise a single sheet of material provided between two foam elements provided that the sheet has a sufficiently low coefficient of friction with the foam to allow the foam surface to move with respect to the sheet. Certain plastic sheets provide a suitable reduced friction with conventional bedding foam. In the preferred embodiment, a fabric covering on each foam surface where there is to be separation works well because each fabric sheet adheres to its respective foam element with reduced friction between the sheets.

For such a double bed, it is also possible to use one, or more, mattress elements which are the full size of the bed.

There are several choices for the containment for a double bed, which are much the same as those discussed above for Figure 1. If a cradle is used, as is discussed below, then the overall sheet 8 may be omitted, and each mattress contained in its own sheet, as at 33 on the element 12.

It is also possible to include a mattress pad into the separation means, especially when this is an attached sheet, such as 29 in Figure 1.

The containment means, in addition to the overall fitted sheet 8, and the pad 9, may include a cradle. One possible cradle arrangement, 21, shown in Figures 1 and 2, comprises a base 18, and corner elements 28. These corners include a flex niche 28A allowing the corner to deflect, for example, when sat upon, as can be seen from Figure 3. The corners 28 are so spaced that when all of the mattress elements are stacked into the cradle, the two sets will be under some slight lateral compression, in addition to any provided by a fitted sheet, such as 8. As a consequence of the lateral compression, the corner elements also serve to substantially eliminate centerline separation. If a cradle is used, as is preferred for a double bed, then although a sheet will be needed usually, it does not have to be a fitted one forming part of the containment. The manner of construction of the cradle depends upon the nature of the base to be used underneath it. If it is to be used on top of an existing box spring base to replace an existing mattress, then the base 18 of the cradle can be relatively light material, for example the 3mm. thick hardboard known as masonite, and perhaps need not be continuous covering the whole area of the bed. It is also advantageous to provide some anchoring of the cradle 18 to a box spring base. Conveniently, this can be done by the use of cooperating hook and loop type fastener patches (e.g. Velcro brand), as at 18A in Figure 3. Alternatively, if the cradle is to be placed on a base, which provides adequate support only at the edges together with one or two cross-beams, such as a steel bed frame, then a much heavier material for the base 18 will be needed. For example, for a single bed it could be a sheet of 20mm. plywood of suitable size.

As shown, the double bed of Figure 1 uses two sets of mattress elements. This is not necessary, as a perfectly usable bed can be made in the same way as in Figure 1, by using adequately sized elements. However, in such an arrangement, individual choice for each user is lost. Alternatively, a mix of full width and half width mattress elements could be used, but again, the level of personal choice is diminished, as shown in Figure 3. In Figure 3 an end view is shown much the same as Figure 2, from which the containment, such as 8 in Figure 1, is omitted for clarity. The double bed mattress can be seen to be assembled from three sets of mattress elements, as follows: (i) a first group of one person wide elements 14, 15, 16 and 17, in which the core element 17 is roughly midway; (ii) a second group of one person wide elements 23, 24, 26 and 27, in which the core element 27 is near the bottom; and (iii) two full width elements 44 and 45, one at the top and the other lower down.

Thus, the firmness of each of the user surfaces will depend to a degree on the firmnesses of the elements 44, 45 and the order in which both they and the remaining elements are assembled.

In foam mattress construction, the inherent "firmness" of the foam material used is important. Unfortunately, commercial foam makers do not have a uniform standard used in describing this attribute of a given foam. The following information is given as a guide to the various levels of firmness used. Table 1

Foam Characteristic (1) Compression (2) VS Very Soft 1.82 S Soft 2.27

M Medium 22.7

H Hard 27.3

(1) VS, S, and M are open cell foams; H may be open or closed cell foam. (2) The compression is measured by determining the weight, in kg, required to compress a 305mm square piece of foam from a thickness of 102mm down to 76mm; hence, a hard, stiff, foam has a high compression, and a soft foam, a low compression. Whilst often quoted, foam density is not overly important, as it is not directly related to foam firmness. Generally, foams with a density of greater than 32 kg/cubic metre are used. Density is more an indication of foam quality and longevity, as low density foams are generally structurally weaker materials. These tend to fail under repeated compression. A higher density foam is generally more resilient to impact, is structurally stronger, and retains its properties better. In the preceding discussion the mattress elements, and the core element, are referred to as being made from, or incorporate, "foam". This term is well understood in the upholstery art. It is used to refer to foam rubber, but latterly refers to foam materials made from synthetic polymers, including synthetic rubbers and other polymers. In modern practice, polyurethane materials are commonly used. These can be either open cell or closed cell materials. Further, it is also known to control the firmness of a foam material by including deliberate voids within it, and to contour its surface. The voids commonly are deliberately shaped holes, such as cylindrical ones . The use of such procedures is within the concepts of this invention.

As shown in Figure 4, the containment means can also be provided by attachment straps 102. The straps 102 interconnect corresponding mattress elements 100 and 100' directly in the embodiment shown. Preferably, the straps 102 are releasably attachable to either mattress element and fasteners 104 and 104' are provided which act between the mattress elements and the straps. Suitable fasteners are snaps, Velcro or even hooks, the latter being more effective when the straps are elastic. As can be appreciated, the centerline gap between the stacks is securely minimized by the use of straps 102. Alternatively, a full height strap could interconnect all mattress elements together.

Figure 5 illustrates a sectional spring base 120 having three vertically mobile panels 124, 124' and 124" which are mounted on springs 122, 122* and 122" respectively. The tension of the springs are selected to provide a suitable resilient base support at the head zone, H, the torso zone, T, and the leg zone, L. The spring base gives a soft and lively feel to the mattress. The section panels 124 may be wholly independent as illustrated or interconnected by hinges or even articulated springs.

Figure 6 shows two foam mattresses 134 and 134 ' arranged side by side and provided with edge separation fabric strips 132. When a pressure is exerted on one mattress 134' in the direction 136, the compression results in movement between the two mattresses at the centerline. Foam to foam contact could result in wear due to friction. The edge separation means also prevents that when the compression is released, the returning movement of mattress 134' has less ability to lift adjacent mattress 134. The strips 132 can be made of fabric, in which case the fabric is preferably glued to the lengthwise edges of both mattresses. As shown, the strip 132 on mattress 134' has return portions covering the upper and the lower edges of the mattress to prevent any catching of the edge on the adjacent mattress. If the strip is made of a material having a low coefficient of friction with foam, such as a plastic film, then a single sheet arranged between the mattresses may provide ample separation between the mattresses 134 and 134'. As shown in Figure 7, the edge separation means can also be provided by placing a fitted sheet 142 and 142' around each respective mattress 140 and 140'. To make a single sleeping surface and to contain the mattresses 140 and 140', a larger fitted sheet 144 or a mattress pad can be placed around both fitted sheets 142. In the arrangement shown, mattresses 140 are single mattresses which are half of the width of a king mattress. The fitted sheets 142 are standard single bed fitted sheets. The fitted sheet 144 is then a standard king size fitted sheet. The sheet 144 may be store bought with the user's choice of color and pattern. If the same arrangement is applied to a queen size mattress system, the single fitted sheets 142 could be custom made to be of the right size to fit mattresses 140, whose length would be the same as a standard queen bed and whose width would be one half that of a standard queen bed. Then, the user may choose any commercially available fitted queen sheet for sheet 144. To provide a stronger containment means, in particular a greater force holding mattresses 140 and 140' together, a surrounding band 146 can be provided, as part of the mattress pad or sheet 144 which holds the mattresses together with a given resilient force.

Figure 8 shows a detailed end view of the movement block 150. The block 150 helps to reduce deflection transmission sideways across a bed, especially if one user is of significantly different weight to the other. The foam block 151 can absorb small sideways movements of either mattress set 157 or 156. The block 151 includes a semi- rigid core panel 152 for dispersing evenly a sideways movement from one set of mattress elements to the other. As there is vertical movement between the block 151 and the mattress elements 157, 157' and 157", edqe separation sheet 159 can be provided on one or prefc ably both longitudinal sides of block 151. The straps 153 attach the mattress elements 156 and 157 to block 150. Velcro patches 154 are sewn to straps 153 and glued to the mattress elements, such that the elements can easily be interchanged. As shown, mattress elements 157, 157' and 157" can be provided with wedge shaped modulation panels 158 having a firmness selected to give the mattress elements 157 a combined firmness adjacent block 150 substantially equal to a firmness of block 151 including panel 152. The block 150 includinr panel 152 may be connected to the base 65 with the .dvantage of being able to absorb better sideways movement and prevent mats 156" and 157" from sliding or moving on base 65. The panel 152 need not then extend the full length of the bed, and in particular it may be absent at the head and foot regions.

A further aspect of the invention is illustrated in Figure 9. A stack of mattress elements

160, 161 and 162 having different firmnesses is provided on a base 65. The elements can be rearranged to adjust the firmness of the stack. Separation sheets 165 are provided on central portions of the upper side of mattress element 162 and both sides of mattress element

161. The separation sheets 165 enhance independent compression and flexion of the elements. However, the exposed portions of the elements at 166, 167 and 168 serve an important purpose of allow the high friction or adherence property of the foam to keep the elements 160, 161 and 162 aligned in the vertical stack. While foam to foam contact will provide a high degree of adherence, the force required to contain the elements in a stack need not be so great, and contact between foam and cloth as at 166 where the foam of element 161 contacts fitted sheet 164 is sufficient. Similarly, element 162 has contact surface 168 against base 65 which provides an anti-slip or anti-skid contact. The side edges of the mattress elements are shown bare, however, they may also be covered with a decorative fabric making the stack a complete mattress system when covered by a single fitted sheet 164.

Figure 10 shows a detailed sectional view of an embodiment of the containment means comprising a surrounding narrow foam piece 170. The piece 170 has a separation sheet 178 for allowing the mattress 172 to compress and flex independently. A first horizontal slit 176 is provided around the containment piece 170 to allow for a mattress cover 177 or "ticking" to be tucked in. The slits 176 and 174 are shown for the purposes of illustration to be through slits on the left side and three quarter slits on the right side although both sides are to be provided with the same kind of slits. The through slits allow the cover 177 and sheet 175 to be removed with their respective portions of the foam piece 170 in order to quickly and easily gain access to the mattress 172 which may comprise a stack of rearrangeable mattress elements. A fitted sheet or an ordinary flat sheet 175 is tucked in to lower slit 174. If the sheet 175 is not a fitted sheet, then a border of the sheet can be tucked through the foam piece 170 for more solid bedding. In the case of slits 174 and 176 as shown on the right side of Fig. 27, the foam piece 170 is lifted as a whole. The containment piece 170 may be loosely placed on base 56 in which case blankets can be tucked under piece 170 and mattress 172, or the containment piece may be attached to base 56. If mattress 172 is a stack of mattress elements, the elements can be removed vertically from the containment for rearranging the order of the stack. If mattress 172 is an air mattress, a firm foam containment frame 170 can be advantageous to provide a more solid edge to the mattress when sitting thereon, _n addition to the ability to hold a mattress cover and sheet. Figure 11 shows a plan view of an embodiment including four L-shaped containment members 182 attached together by straps 184 and containing two mattresses 180 and 180'. The straps may be elastic -^'-αemselves or may be simply attached under tension and r^Iy on the elasticity of the foam members 182 for containment tension. The elasticity allows the members to snugly fit around mattresses 180 and 180'. The members 182 along with mattresses 180 and 180' can be sized to receive conventional single, double, queen or king size bedding. Alternatively, the elasticity can make it easier to hold bedding tucked in. The straps 184 can be undone to make it easier to insert bedding or to loosen contact between frame members 182 and the mattress elements 180 for rearranging. The mattresses can be single slab mattresses with different firmnesses between sides or multilayer mattresses having a plurality of rearrangeable stacked mattress elements. The L-shaped members 182 can be provided with corner lifter members 186 which are strips or triangular sheets connected to the underside of the members 182 as shown for the purposes of strengthening the members and allowing a lifting of a corner of the members 182 to lift the mattress 180 or 180'. This can be useful when the he ¹ is designed so that the bedding fits over the frame members 182. It is also possible to provide only two larger C-shaped members connected together by straps 184 at the head and foot of the bed. Also, a single continuous rectangular frame member can be used and preferably such a member is made from molded foam.

Figure 12 is an end view of a spring support base similar to the one shown in Figure 5, except that the support panels 195, 196 and 197 extend lengthwise to the mattresses. Thus while each mattress 190 and 191 can flex independently to be at different heights from head to foot, at the center line, a substantially even base support is provided which can resiliently flex under the weight of each user on different sides of the center line. On the center line itself, a lengthwise even base support is provided which under the action of springs 192, 193 and 194 provides a transition from one mattress or mattress set to the other.

Figure 13 shows a perspective view of an embodiment of the invention in which the containment means include a base 200, and edge members 206 connected to the base. The edge members may be made of foam, or they may comprise collapsible members made of foam or other materials. For example, the edge members 206 could be bow-shaped, i.e. having an arched upper surface and a lower central hole, in order to be more flexible when subjected to a downward pressure. The members 206 can be removable from base 200 (as shown) to facilitate moving the mattresses, exchanging mattress elements with a stack and applying bedding. Rods 208 are part of edge members 206 and are inserted into complementary boreholes in base 200. As shown, when a stack of mattress elements 202, 204 is provided, the uppermost mat 204 is retained by the edge members 206. It is possible for the base 200 to provide a frame which holds lower members of the mattress element set. It is also possible with any of the side by side mattress arrangements according to the present invention to exchange on one side a foam mattress for a different kind of mattress, such as coil spring, air, water or futon. The containment means, edge separation means, movement block or modulator panel of the foam side will a. serve their usual function.

Claims

CLAIMS :

1. A mattress system comprising: a first mattress; a second mattress adjacent said first mattress to provide two contiguous sleeping zones having a border therebetween extending from head to toe; and a sectional spring base having a first and a second vertically mobile, resilient, substantially horizontal panels supporting each of said sleeping zones of said mattress system, and a third narrow vertically mobile, resilient, substantially horizontal panel extending from head to toe for supporting independently an area of said first and said second mattress near said border.

2. The mattress system according to claim 1, further comprising a fourth and a fifth narrow vertically mobile, resilient, substantially horizontal panel provided one on each side of said third panel.

3. The mattress system according to claim 1 or 2, wherein said first and said second mattresses each comprises at least two foam mattress elements, at least one of which having a different hardness to the others, and further comprising separation means for permitting each of said mattress elements to compress and flex separately when stacked one above the other.

4. The mattress system according to claim 3, further comprising a containment means adapted and constructed to ensure that said mattress elements remain situated in their chosen order in a substantially vertical stack, and to subject said mattress elements to slight lateral compression.

5. A mattress comprising: a first foam mattress; edge sep tion means provided on a longitudinal side edge said first element; and a second mattress longitudinally adjacent said first mattress, said edge separation means allowing said first mattress to compress and move vertically with reduced friction while in contact with said second mattress.

6. The mattress according to claim 5, wherein said first and second mattresses comprise two sets of said mattress elements, eεch of which are of the same length, width and thickness, sai elements forming two side by side vertical stacks substantially equal in height, whereby a two-person bed is formed in which mattress elements can be exchanged between said two sets.

7. The mattress according to claim 6, further comprising a first and a second fitted sheet each containing one of said sets of mattress elements, together with a third fitted sheet constructed and arranged to contain both said sets of mattress elements contained in the first and second sheets.

8. The mattress according to claim 7, wherein said first and second fitted sheets are single sheets and said third fitted sheet is a king size fitted sheet.

9. The mattress according to claim 5, further comprising a block of foam provided between said first and second mattresses, said block having a height substantially equal to said height of said mattresses and a narrow width for absorbing sideways movement between said mattresses, said block including said edge separation means allowing independent movement between said block and said first mattress.

10. The mattress according to claim 9, further comprising means for attaching said block to said first mattress.

11. The mattress according to claim 10, wherein said attaching means comprise means for attaching to both said first and said second mattresses.

12. The mattress according to claim 9, 10 or 11, wherein said block incorporates a vertical core panel member providing additional movement insulation between said first and second mattresses.

13. The mattress according to claim 9, 10 or 11, wherein said block is attached to a base, said block incorporating a vertical core panel member providing additional movement insulation between said first and second mattresses.

14. A multilayer mattress comprising: at least two mattress elements, at least one of which being made of foam and having a different hardness from the others; open top containment means adapted and constructed to ensure that said mattress elements remain situated in their chosen order in a substantially vertical stack, and to subject said mattress elements to slight lateral compression, said containment means allowing said elements to be removed from said stack vertically; and edge separation means for allowing said elements to flex and move vertically with reduced friction between said elements and said containment means.

15. The mattress according to claim 14, wherein said containment means comprise a surrounding foam frame provided with two surrounding horizontal slits for receiving a mattress cover and a sheet, whereby a border of said mattress cover is tucked into an upper one of said slits and a border of said sheet is tucked into a lower one of said slits.

16. The mattress according to claim 14 or 15, wherein said containment means comprise four horizontal surrounding foam frame members and means connecting adjacent ones of said frame members together, said frame members being L-shaped and connected together at their ends.

17. The mattress according to claim 14, wherein said containment means comprises an outer surrounding wall member providing with inwardly facing lip projections for maintaining said elements at a small fixed distance with respect to said wall member, whereby bedding can more easily be inserted between said elements and said surrounding wall member.