Mattress arrangement, such as a bed, having adjustable firmness

Abstract

A mattress arrangement, such as a bed arrangement (1), having adjustable firmness is disclosed. The mattress arrangement comprises an upper mattress (3) and a lower mattress (4) being arranged beneath said upper mattress (3). At least one side (41) of the lower mattress (4) is moveable in relation to an opposite side (42) of the lower mattress (4), the lower mattress (4) thereby being expandable into an expanded state, having a lower firmness, and compressible into a contracted state, having a higher firmness. A support layer (6) is arranged between the upper mattress (3) and the lower mattress (4), to partly support the upper mattress (3), and arranged overlying the at least one moveable side (41) of the lower mattress (4). Hereby, at least one compartment is formed beneath the upper mattress (3), wherein the compartment(s) is at least partly empty when the lower mattress (4) is in the contracted state and at least partly filled when the lower mattress (4) is in the expanded state.

Claims

1. A mattress arrangement, such as a bed arrangement, comprising: an upper mattress; a lower mattress being arranged beneath said upper mattress; a support layer arranged between the upper mattress and the lower mattress, to partly support the upper mattress, said support layer being arranged only partly to support the upper mattress, such that a greater part of a lower surface of the upper mattress remains unsupported by the support layer, said greater part of the lower surface of the upper mattress instead being supported directly by the lower mattress; wherein the lower mattress has a variable extension in a length direction of the lower mattress and/or a width direction of the lower mattress, such that at least one side of the lower mattress is an at least one moveable side that is moveable in the length direction of the lower mattress and/or the width direction of the lower mattress in relation to an opposite side of the lower mattress, such that the lower mattress is expandable into an expanded state, having a lower firmness, and compressible into a contracted state, having a higher firmness; and wherein said support layer is arranged overlying said at least one moveable side of the lower mattress to form at least one compartment beneath the upper mattress, said at least one compartment being at least partly empty when the lower mattress is in the contracted state and at least partly filled when the lower mattress is in the expanded state.

2. The mattress arrangement of claim 1, wherein the lower mattress has the variable extension in at least the length direction of the lower mattress.

3. The mattress arrangement of claim 1, wherein at least a side arranged at a foot-end of the lower mattress is moveable in relation to a side arranged at a head end of the lower mattress.

4. The mattress arrangement of claim 3, wherein the side arranged at the head end of the lower mattress is fixed.

5. The mattress arrangement of claim 1, wherein the lower mattress in its expanded state has outer dimensions corresponding to the outer dimensions of the upper mattress.

6. The mattress arrangement of claim 1, wherein the lower mattress may further assume at least one, and preferably a plurality, of intermediate states, between said expanded state and said contracted state.

7. The mattress arrangement of claim 1, wherein the lower mattress is a pocket spring mattress, comprising a plurality of coil springs arranged in pockets.

8. The mattress arrangement of claim 7, wherein the pocket spring mattress comprises a plurality of parallel strings interconnected side by side, each string comprising a plurality of continuous casings and each casing comprising a coil spring, wherein expansion of the mattress into the expanded state occurs in a least one of a direction being parallel to the plurality of parallel strings and a direction being perpendicular to the plurality of parallel strings.

9. The mattress arrangement of claim 8, further comprising a pulling or pushing arrangement connected to said at least one side of the lower mattress, to provide a pulling or pushing force to bring the lower mattress to the expanded state.

10. The mattress arrangement of claim 1, wherein the lower mattress comprises at least one elastic element extending between said at least one moveable side of the lower mattress and said opposite side of the lower mattress, said at least one elastic element being arranged to provide a contraction force to bring the lower mattress to the contracted state.

11. The mattress arrangement of claim 1, further comprising a frame arranged to at least partly accommodate the lower mattress, wherein said support layer is connected to said frame.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing currently preferred embodiments of the invention.

(2) FIG. 1 a-c show a schematic perspective view of an embodiment of a bed arrangement according to the present invention, where FIG. 1 a shows the bed arrangement with a part of the bed arrangement being shown in cross-section, FIG. 1b show the bed arrangement in a schematic cross-section, where the lower mattress is in an expanded state, and FIG. 1c show the bed arrangement in a schematic cross-section, where the lower mattress is in a contracted state;

(3) FIG. 2 shows a schematic exploded perspective view of a bed arrangement according to another embodiment of the present invention;

(4) FIG. 3 shows a schematic exploded perspective view of a bed arrangement according to another embodiment of the present invention;

(5) FIG. 4 shows a schematic exploded perspective view of a bed arrangement according to yet another embodiment of the present invention;

(6) FIGS. 5a and 5b show an embodiment of the lower mattress, illustrated in a perspective side view and a top view, respectively;

(7) FIG. 6 shows another embodiment of the lower mattress, illustrated in a perspective side view;

(8) FIGS. 7a-c show still another embodiment of the lower mattress, illustrated in a perspective side view and a side views, respectively, where FIGS. 7a and c illustrates the mattress in an expanded state and FIG. 7b illustrates a contracted state;

(9) FIGS. 8 a-f illustrate various embodiments of the lower mattress having elastic elements or the like to retract the mattress to a contracted state or to expand the mattress to an expanded state;

(10) FIGS. 9 a-e illustrate various embodiments where the supporting layer(s) are arranged at various parts of the mattress arrangement;

(11) FIGS. 10 a-d illustrate various embodiments of pulling arrangement for bringing the lower mattress to an expanded state;

(12) FIG. 11 shows a schematic exploded perspective view of a bed arrangement according to one embodiment of the present invention having additional layers; and

(13) FIG. 12 shows a schematic exploded perspective view of a bed arrangement according to a further embodiment of the present invention.

DETAILED DESCRIPTION

(14) In the following, the invention will be exemplified by means of bed arrangements. However it is to be acknowledged by the skilled reader that the same principles and functions may also be used in other types of mattress arrangements using mattresses, e.g. in the form of a bed mattress, a cushion or the like, such as seats for all sorts of vehicles, upholstered furniture, and the like. Accordingly, when reference in the following is made to a bed or bed arrangement, it is to be understood that this may also be used in other types of mattress arrangements, and in particular other types of furniture arrangements.

(15) A bed arrangement 1 having adjustable firmness according to a first embodiment of the invention is shown schematically in FIG. 1a. The bed arrangement is enclosed in a cover 2, but in a cut-out section in the middle the interior of the bed arrangement is visible. The bed arrangement comprises an upper mattress 3, a lower mattress 4, and a frame 5. A further padding layer 7 or the like may be provided between the upper and lower mattress.

(16) In the cross-sectional views of FIGS. 1b and 1c, a support layer 6 is further illustrated, providing partly a support for the upper mattress at an end of the bed arrangement, such as the foot end. The support layer may be connected to a bed frame or the like, on which the lower mattress rests. However, as will be further explained in the following, the support layer may also be connected to side supports being connected to a base of the lower mattress, a base of the bed, or the like. The support layer may also be connected to a frame arranged between the upper and lower mattresses, such as a frame encircling the perimeter of the lower side of the upper mattress. In this case, the support layer may form an integral part with the upper or lower mattress.

(17) The support layer 6 is preferably inelastic, and may be form as a rigid structure, such as a plate, a lattice, bars etc. It may also be formed by pliable/flexible and preferably non-elastic elements, such as a fabric, flexible bands, cords, or the like. In the embodiment of FIG. 1, a plate like structure is used. However, elastic elements may also be used to form the support layer.

(18) The support layer is arranged to overlie the displaceable end(s) of the lower mattress, and have an extension so that it provides support for the upper layer over the empty space(s) formed when the lower mattress is compressed into the contracted state. The support layer has a width dimension being equal, or nearly equal, to the width dimension of the upper mattress, and a length dimension being much smaller than the length dimension of the upper mattress.

(19) The lower mattress 4 has a moveable end 41 arranged underneath the support layer 6, and the opposite end 42 is fixed, and aligned with the corresponding end of the upper mattress 3.

(20) The support layer forms a compartment beneath the upper mattress for receiving the moveable side 41 of the lower mattress, in which the lower mattress is free to move. Hence, in an expanded state, providing lower firmness, the compartment is filled by the lower mattress, as illustrated in FIG. 1b, whereas in a contracted state, providing greater firmness, the compartment is at least partly empty, as illustrated in FIG. 1c.

(21) The support layer may be held in place in various ways, as will be exemplified in the following.

(22) In one embodiment, shown in an exploded view in FIG. 2, the bed frame 5 is arranged to extend up over the sides of the lower mattress 4, at least in one end of the mattress. This end is preferably the foot end of the bed arrangement. The support layer may be connected to the bed frame by means of nails, screws, adhesive or any other suitable fastener, thereby providing a fixed support of this part of the upper mattress 3, and allowing the lower mattress to move in and out from the compartment hereby formed beneath the upper mattress.

(23) In another embodiment, illustrated in FIG. 3, the support layer is attached to or integrated with supporting sides 61, such as side walls, rods or the like. These may be connected to a frame 5 arranged beneath the lower mattress.

(24) In another embodiment, illustrated in FIG. 4, the supporting layer is attached to a bed frame, in the same way as in the embodiment discussed in relation to FIG. 2. In this embodiment, the support layer 6 is formed of pliable/flexible and preferably non-elastic elements, flexible bands, cords, or the like. Alternatively, a flexible fabric or the like may be used instead.

(25) Further, the support layer may be connected to a support structure arranged entirely between the upper mattress 3 and the lower mattress 4. Such an embodiment is illustrated in FIG. 12. Here, the support layer is connected to a rigid support frame 62, arranged around the perimeter of the upper mattress. The support layer may, as in the previous examples, be a rigid plate, but may alternatively be a flexible fabric, flexible straps or the like.

(26) The upper mattress may be of various types, such as being an inflatable element(s), a resilient foam element(s), a resilient rubber element, and the like. However, preferably the upper mattress comprises a plurality of coil springs, and preferably coil springs individually arranged in separate pockets of a cover material, to define a pocket spring mattress. The lower mattress may also be of various types. The lower mattress may be of the same type as the upper mattress, or of a different type.

(27) Preferably, the lower mattress is a pocket spring mattress, comprising a plurality of coil springs arranged in pockets. Most preferably, the pocket spring mattress comprises a plurality of parallel strings interconnected side by side, each string comprising a plurality of continuous casings and each casing comprising a coil spring, wherein expansion of the mattress into the expanded state occurs in a least one of a direction being parallel to the strings and a direction being perpendicular to the strings. Each string is preferably formed by continuous cover material, and the separation between adjacent pockets being formed by lateral separation joints. These separation joints, as well as longitudinal joints, may be formed through any form of adhesive bonding, welding, stapling, sewing, or any combination thereof. In a preferred embodiment, welding is used. Coil springs of many different sizes could be used in conjunction with the present invention, and in principle any desired spring size, large or small, may be used. Preferably, however, the coil springs have a diameter in the range 2-10 cm, and preferably in the range 4-8 cm, such as 6 cm. In addition, the coil springs are preferably manufactured from helically coiled wires. The springs preferably comprise at least three turns, and preferably fewer than 10 turns. Moreover they are advantageously made of spiral wire with a thickness in the range 0.5-3.0 mm, preferably a wire thickness in the range 1.25-2.50 mm. Preferably the springs are slightly spool-shaped, that is with smaller turns at the top and bottom. Mattresses of these types are per se known.

(28) One mattress type which is suitable for use as the lower mattress is the one disclosed in U.S. Pat. No. 8,176,589, by the same applicant, said document hereby incorporated in its entirety by reference. Such a mattress is illustrated in FIGS. 5a and 5b. This pocket spring mattress comprises pockets 51 arranged in strings 52. In each pocket there is a coil spring. Each string is made of a continuous cover material, and the pockets are formed by separation joints 53, e.g. formed by welding. The strings are connected to each other in parallel in a side-by-side arrangement, by connections 55. These connections may be formed by adhesive, but may alternatively be effected by welding, Velcro or the like. Further, the pockets are provided with a plurality of stretch openings 54, providing a net-like surface structure. This allows the strings to be separated from each other.

(29) Another mattress type which is suitable for use as the lower mattress is the one disclosed in U.S. Pat. No. 7,048,263, also by the same applicant, said document also being incorporated by reference in its entirety. Such a mattress is illustrated in FIG. 6. This mattress have the same general structure as in the previous example, with coil springs being arranged in pockets 51, forming strings 52 that are connected to each other in parallel. However, in this embodiment an increased separation distance between the pockets/springs in each string is provided. This may be effected by provision of two spaced apart separation joints 53, or alternatively by using wide separation joints or the like. Hereby, a separation distance is formed between adjacent springs/pockets within each string, allowing the mattress to be expanded and contracted in the direction of the strings.

(30) Still another mattress type which is suitable for use as the lower mattress is the one disclosed in US 2007/124865, also by the same applicant, said document also being incorporated by reference in its entirety. Such a mattress is illustrated in FIG. 7. This mattress have the same general structure as in the previous example, with coil springs being arranged in pockets 51, forming strings 52 that are connected to each other in parallel. Further, there is provided an increased separation distance between the pockets/springs in each string is provided, effected by provision of two spaced apart separation joints 53 or the like. To further increase the flexibility of the strings, slit openings 56 are provided between pockets, and between the separation joints 53. The slit openings are preferably enclosed within the material, without any open ends. FIG. 7b illustrate this mattress in a contracted state, whereas FIG. 7c illustrate the same mattress in an expanded state.

(31) The lower mattress further preferably comprises at least one elastic element extending between said moveable side and said opposite side of the lower mattress, wherein the at least one elastic element is arranged to provide a contraction force to bring the lower mattress to the contracted state. Hereby, the lower mattress will resume a contracted state when no exterior force is applied. This simplifies operation of the mattress and also ensures that the distribution of springs in the lower mattress remains uniform also in every intermediate state, between the expanded state and the contracted state. The elastic element may e.g. a band, string, cord or the like of an elastic material. Preferably, a plurality of elastic elements is provided, being distributed over or within the lower mattress. Further, it is preferred that each elastic element is connected to the lower mattress at a plurality of distributed connection points. In case of a pocket spring mattress, it is preferred that each elastic element is connected to a plurality of pockets, and preferably to each pocket it is in contact with. Specifically, such elastic elements may be combined with any of the pocket spring mattress types discussed above in relation to FIGS. 5-7.

(32) In FIG. 8, some alternative ways of providing such elastic elements 57 are illustrated.

(33) In FIG. 8a, a pocket spring mattress is illustrated in which elastic elements 57 are arranged on the top and bottom of the lower mattress. In the illustrated example, elastic elements are arranged both on the top and the bottom of the lower mattress, but alternatively elastic elements may be arranged only at the top or only at the bottom. Further, the elastic elements are here arranged aligned with the strings. However, alternatively or additionally, elastic elements may also be arranged perpendicular to the string direction. Further, in this example, elastic elements are arranged along each string, but fewer elastic elements may also be used. The elastic elements are preferably connected at to the strings at a plurality of positions, such as to every pocket it comes into contact with.

(34) Alternatively or additionally, the elastic elements 57 may be arranged on the sides of the mattress, and in between the strings. Such an embodiment is illustrated in FIG. 8b. In this embodiment, elastic elements are provided between each pair of strings. Again, fewer elastic elements may be used, and an example of such an embodiment is illustrated in FIG. 8c.

(35) In the embodiments illustrated in FIGS. 8a-c, the elastic elements 57 are arranged in parallel with the strings of the mattress. However, the contraction and expansion of the mattress may, as has already been discussed in the foregoing, occur in a direction perpendicular to the string direction. In such a mattress, the elastic elements may instead be arranged with an orientation perpendicular to the string direction. Such an embodiments is illustrated in FIG. 8d.

(36) In the embodiments discussed with reference to FIGS. 8a-d, the elastic elements are arranged to exert a force to bring the mattress to a contracted state. However, the elastic elements may instead be arranged to exert a force to bring the mattress to an expanded state. Such an embodiment is illustrated in FIG. 8e. Here, the elastic elements 57 may be formed of an elastic compressible material, such as latex or polyether, and arranged to be compressed between the springs when the mattress is contracted, and thereby providing a force to expand the mattress again when the contraction force is removed. In the illustrative example of FIG. 8e, the elastic compressible material is arranged between adjacent springs within the same string/row of the mattress. However, additionally or alternatively, the elastic compressible material may be arranged between adjacent springs within neighboring strings/rows, i.e. arranged between adjacent strings/rows, rather than being in-line with the strings/rows.

(37) Further, other types of elements may also be used to bring the mattress to an expanded and/or contracted state. For example, inflatable tubes 57, cushions or the like may be arranged between the springs, as is illustrated in FIG. 8f. By inflating the tubes 57, the mattress will be brought to an expanded state, and by deflating the tubes, and evacuating the air from them, the mattress will be brought to a contracted state. Thus, this pneumatic principle and such inflatable elements may be used to provide that the mattress resumes a contracted and/or expanded state when an external force is lowered. However, it may also be used to replace other arrangements to move the mattress from a contracted state to an expanded state, and vice versa, and thus be used as a sole means for effecting such state transition.

(38) In the illustrative example of FIG. 8f, the inflatable elements extend in a direction perpendicular to the strings/rows of the mattress, and are arranged between adjacent springs within the same string/row. However, additionally or alternatively, the inflatable elements may extend in a direction parallel to the strings/rows, so that the inflatable elements are arranged between adjacent springs within neighboring strings, i.e. arranged between adjacent strings/rows.

(39) In the above-discussed embodiments, the support layer has been arranged at the foot end of the bed arrangement. In this area, there is normally anyway no need for firmness adjustments. Further, in a bed, this part of the mattress arrangement is often used also for sitting, and the increased stability provided by the support layer improves the sitting comfort.

(40) However, additionally or alternatively, the support layer may be arranged along the long sides of the bed arrangement. Again, this would not impair the sleeping comfort, since the outer edges are normally not used when sleeping. On the contrary, the increased stability towards the edges may often be beneficial, since it again improves the comfort when sitting on the side of the mattress arrangement, and also lowers the risk of accidentally falling out of the bed. Arrangement of the support layer along one or both long sides of the mattress arrangement would also be advantageous when using the mattress arrangement in sofas, davenports and the like.

(41) In FIGS. 9 a-e, various arrangements of the support layer are schematically illustrated. In FIG. 9a, a support layer 6 is arranged at the foot end of the bed arrangement, as in the previously discussed examples. In FIG. 9b, a support layer 6 is arranged both at the foot end and at the head end, thereby enabling movement of the lower mattress at both ends. In FIG. 9c, support layers 6 are arranged at both long sides of the bed arrangement, allowing the lower mattress to expand and contract in the width direction. In FIG. 9d, a combination of the embodiments of FIGS. 9b and 9c is shown, allowing the lower mattress to expand and contract in both the width and length direction. Finally, FIG. 9e illustrate an embodiment in which a support layer 6 is arranged solely at one long side of the bed arrangement, allowing the opposite end of the lower mattress to be fixed.

(42) Further, the mattress arrangement preferably comprises a pulling or pushing arrangement connected to the at least one moveable side of the lower mattress, to provide a pulling or pushing force to bring the lower mattress to the expanded state. The pulling arrangement may be one or several ropes, strings or the like connected to a side of the lower mattress or within the lower mattress. Such an arrangement is very cost efficient, and is in particular suitable for manual operation. The ropes/strings may e.g. be locked in a suitable pulled out position by a locking arrangement, be tied together, or in any other way secured. However, the ropes/strings may also be operated by an electric motor or the like. Further, the moveable side of the lower mattress may be connected to a rigid pulling or pushing element, which may be displaced automatically, by an electric motor or the like, or manually, by a screw arrangement or the like. For example, a lead screw or translation screw may be used. A knob, wheel or any other type of handle may then be manually rotated, thereby rotating the screw, resulting in a corresponding displacement of the rigid pulling or pushing element.

(43) Some embodiments of such pulling arrangements will be illustrated in the following.

(44) In FIG. 10a, maneuvering elements 8, e.g. flexible elements, such as ropes or strings, or more rigid elements, such as rods or the like, are shown, which are attached to the moveable side 41 of the lower mattress 4, being arranged beneath the support layer 6. The maneuvering elements 8 extend within or beneath the lower mattress, and are accessible from the opposite side. By pulling the maneuvering elements 8, the mattress will be contracted, and the maneuvering elements may be fastened in any suitable way to lock the mattress in the desired intermediate or contracted state. The movable side of the mattress may be connected to resilient elements (not shown), such as springs, acting to bring the mattress back to an expanded state. Alternatively or additionally, the maneuvering elements 8 may be relatively rigid, and usable instead or additionally for pushing the movable side away, towards an expanded state. In this case, the mattress may comprise elastic elements, as discussed in the foregoing, acting to bring the lower mattress into a contracted state.

(45) In FIG. 10b, a similar arrangement is shown. Here, the maneuvering elements 8 are also connected to the movable side 41 of the lower mattress, but are instead displaced from the same side, and by pulling the maneuvering elements inwardly, the mattress is compressed, and by pulling the maneuvering elements, the mattress is expanded.

(46) In FIG. 10c, an arrangement is illustrated with maneuvering elements 8, such as ropes or strings or the like extending in both directions from the moveable end 41 of the lower mattress 4, and being accessible from both ends. This arrangement may be used both to pull the moveable end to a contracted state, as in the embodiment of FIG. 10a, and to pull the moveable end back to an expanded state from the other side. In such there may not be any need for any the elastic or resilient elements acting to bring the lower mattress into a contracted or expanded resting position.

(47) In FIG. 10d, an automated arrangement is illustrated. Here, the moveable end 41 is connected to a rigid side element 8a, which in turn is connected, via a displacement arm 8c, to an electric displacement arrangement, such as an electric motor, an electric pump 8b or the like.

(48) In addition to the upper and lower mattresses 3 and 4, and the frame 5, additional mattress or padding layers may be provided. One such example is schematically illustrated in FIG. 11, where an upper surface padding 7b is provided, an intermediate mattress or padding layer 7a is provided between the upper and lower mattresses, and where padding or mattress sides 7c are provided around the lower mattress. Fewer or additional padding or mattress layers are naturally also feasible.

(49) The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. For instance, both the upper and lower mattress may be of other mattress types than pocket spring mattress, such as resilient elements formed by foam, rubber, coil springs, inflatable elements, and the like. Further, the lower mattress may be contracted and expanded in various directions, and the support layer may be held in place in different ways. Further, the firmness of the mattress arrangement may be controlled either manually or electrically aided. Such obvious variants must be considered to be comprised by the invention as defined by the appended claims.