Abstract
Embodiments of a mattress and methods of manufacturing the same, wherein the mattress includes a body having one or more openings for removable inserts that a user can position within the openings to adjust the mechanical characteristics of the mattress, including the amount and location of support provided by the mattress to the user. Some embodiments of the mattress include one or more covers, such as a fire-retardant cover, that can encompass the mattress body while still allowing a user to access the openings of mattress body.
Claims
1. A mattress comprising: a body having one or more openings formed within portions of a side or and end of the body, the one or more openings configured to receive one or more removable inserts; a fire-retardant cover that substantially encloses the body, the fire-retardant cover configured to permit access by a mattress user to the one or more openings, and the fire-retardant cover comprising a first closeable slit configured to permit access by a mattress user to the one or more openings; a second cover that substantially encloses the fire-retardant cover, the second cover configured to permit access by a mattress user to the one or more openings through a second closeable slit aligned with the first closeable slit; a fire shield configured to be positioned over the first closeable slit, and between the body and the fire-retardant cover or between the fire-retardant cover and the second cover, the fire shield configured to permit access by a mattress user to the one or more openings; a first fastening device, the first fastening device configured to open and close the first closeable slit; and a second fastening device, the second fastening device configured to open and close the second closeable slit.
2. The mattress of claim 1, further comprising one or more removable inserts positioned within the one or more openings, the one or more removable inserts having different mechanical characteristics than the portions of the body forming the one or more openings.
3. The mattress of claim 2, further comprising at least two removable inserts positioned within a single opening.
4. The mattress of claim 1, wherein the body comprises a top, a bottom, sides, and ends, and the one or more openings can be accessed from at least one of the sides or ends but not from the top or the bottom.
5. The mattress of claim 1, wherein the body further comprises one or more layers, the one or more openings positioned within the one or more layers such that a removable insert can be received within the one or more openings without moving the one or more layers.
6. The mattress of claim 5, wherein the one or more layers comprise a first layer positioned immediately adjacent a second layer and the one or more openings are positioned between the first layer and the second layer.
7. The mattress of claim 1, wherein a mattress user may access the one or more openings to position a removable insert within or remove a removable insert from the one or more openings.
8. The mattress of claim 1, wherein the fire shield extends entirely over the first closeable slit of the fire-retardant cover such that no portion of the mattress body is in direct contact with the first closeable slit of the fire-retardant cover.
9. The mattress of claim 1, wherein the fire shield extends entirely over the first closeable slit of the fire-retardant cover such that no portion of the second cover is in direct contact with the first closeable slit of the fire-retardant cover.
10. The mattress of claim 1, wherein the fire shield is coupled on at least one side to the fire-retardant cover to cover the first closeable slit of the fire-retardant cover and the fire shield is open on at least one side to allow a user to move a portion of the fire shield to gain full access to the openings in the mattress body through the first closeable slit of the fire-retardant cover.
11. A method of forming a mattress comprising: forming two or more mattress layers for a body of the mattress; forming openings in a side or an end of the body of the mattress in or between the two or more mattress layers, the openings for receiving one or more removable inserts; affixing the two or more mattress layers together such that the openings are disposed in the mattress layers and can receive one or more removable inserts without having to move or separate the mattress layers; substantially enclosing the two or more mattress layers in a fire-retardant cover, the fire-retardant cover configured to permit access by a mattress user to the openings, the fire-retardant cover comprising a first closeable slit in the fire-retardant cover, the first closeable slit configured to permit access by a mattress user to the openings; substantially enclosing the fire-retardant cover in a second cover comprising a second closeable slit aligned with the first closeable slit, the second closeable slit configured to permit access by a mattress user to the openings, the fire-retardant cover comprising a first fastening device coupled to the first closeable slit, the first fastening device configured to open and close the first closeable slit, and a second fastening device coupled to the second closeable slit, the second fastening device configured to open and close the second closeable slit; and coupling a fire shield over the first closeable slit, and between the body and the fire-retardant cover or between the fire-retardant cover and the second cover, the fire shield configured to permit access by a mattress user to the openings.
12. The method of claim 11, wherein the step of forming openings comprises removing material from at least one of the mattress layers to form the openings.
13. The method of claim 12, wherein the removed material is removed after affixing the two or more mattress layers together.
14. The method of claim 12, further comprising: removing material from at least two mattress layers, wherein the removed material in each of the two mattress layers creates only portions of one or more openings; and affixing the two mattress layers together such that the portions of openings in each of the two mattress layers align to form openings that can receive one or more removable inserts without having to move or separate the two mattress layers.
15. The method of claim 11, further comprising positioning one or more removable inserts into the openings, the one or more removable inserts having different mechanical characteristics than the material of the mattress layers forming the openings.
16. The method of claim 11, wherein coupling the fire shield comprises coupling the fire shield to extend entirely over the first closeable slit of the fire-retardant cover such that no portion of the mattress body is in direct contact with the first closeable slit of the fire-retardant cover.
17. The method of claim 11, wherein coupling the fire shield comprises coupling the fire shield to extend entirely over the first closeable slit of the fire-retardant cover such that no portion of the second cover is in direct contact with the first closeable slit of the fire-retardant cover.
18. The method of claim 11, wherein coupling the fire shield comprises coupling on at least one side to the fire-retardant cover to cover the first closeable slit of the fire-retardant cover and the fire shield is open on at least one side to allow a user to move a portion of the fire shield to gain full access to the openings in the mattress body through the first closeable slit of the fire-retardant cover.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale for at the least the embodiments shown.
(2) FIGS. 1, 2, and 3 depict isometric, partial cross-sectional views of mattresses according to embodiments of the disclosed apparatuses and methods.
(3) FIGS. 1A, 2A, and 3A depict partially exploded isometric views of the mattresses of FIGS. 1-3, respectively (without a mattress cover, for clarity), according to embodiments of the disclosed apparatuses and methods.
(4) FIGS. 4A and 4B depict removable inserts according some embodiments of the disclosed apparatuses and methods.
(5) FIG. 5 depicts a user-accessible mattress according to an embodiment of the disclosed apparatuses and methods.
(6) FIG. 6 depicts a partial side view of the mattress of FIG. 5.
(7) FIG. 7 depicts a partial side view of the mattress of FIG. 5 in a partially open configuration according to an embodiment of the disclosed apparatuses and methods.
(8) FIGS. 8A-8C depict partial side views of the mattress of FIG. 5 in an open configuration according to some embodiments of the disclosed apparatuses and methods.
(9) FIGS. 9 and 10 depict a partial side view of a mattress in a partially open configuration according to some embodiments of the disclosed apparatuses and methods.
(10) FIG. 11 depicts a partial side view of the mattress of FIGS. 9 and 10 in an open configuration according to an embodiment of the disclosed apparatuses and methods.
(11) FIGS. 12A and 12B depict flow charts of methods of forming mattresses according to embodiments of the disclosed apparatuses and methods.
(12) FIG. 13 depicts a partial side view of a mattress formed according to embodiments of the disclosed methods.
DETAILED DESCRIPTION
(13) Referring now to the drawings, and more particularly to FIG. 1, mattress 100 includes a top 104, bottom 108, two ends 112 (only one shown), and two sides 116 (only one shown). Ends 112 extend from top 104 to bottom 108 and to sides 116. Similarly, sides 116 extend from top 104 to bottom 108 and to ends 112. A cover 120 entirely encloses a body 160. Cover 120 can be made from upholstery or other materials, including materials designed to be seen by and be in contact with a user. For example, cover 120 can include an aesthetically pleasing image or pattern and/or a brand identifier and/or be made with stain-resistant and/or moisture-removing material. Portions of cover 120 (e.g., corresponding to top 104, bottom 108, ends 112, sides 116) can be made from different materials and/or have different characteristics. For example, the portions of cover 120 positioned at top 104 may be made from stain-resistant material while the portions of cover 120 positioned at bottom 108 may not. Body 160 is formed from a series of stacked foam layers (e.g., made from phase change memory foam, though the layers may be made from other or additional types of materials, such as gel and/or plastic), including top layer 124, support layer 128 beneath top layer 124, and foundation layers 132, 136 beneath support layer 128 in that order. Body 160 also includes a wicking interface 144 positioned between support layer 128 and foundation layer 132, as well as air flow channels 148 formed between foundation layers 132, 136. Wicking interface 144 can be made from cloth and/or other materials and can be substantially similar to the intermediate layer described in U.S. Pat. No. 7,520,012, which is incorporated by reference herein. Layers 124, 128, 132, 136 and interface 144 are shaped e.g., via cutting with a laser and/or using computer numerical control (CNC)) to maintain contact with one another by friction (i.e., with mating surfaces that resist relative movement), but may also be affixed to one another with a laminate or by other means. Various features, such as the grooves at the bottom of foundation layer 136 or others described herein, may be formed into any of layers 124, 138, 132, 136 and interface 144 (e.g., via cutting with a laser, CNC, or other manufacturing methods), as desired.
(14) Top layer 124 can be made from a relatively soft and non-rigid material, and can include ergonomic grooves/blocks 140 formed (e.g., via cutting with a laser and/or using CNC) into the top of top layer 124 that have channels for ventilating heat, for example from a user's body, and that can aid in providing pressure relief to, for example, a user's head, shoulders, hips, back, and/or knees. Support layer 128 can be more or less soft, rigid and/or dense than top layer 124 and can support a user's body past the top layer. Foundation layer 132 can be more rigid and/or dense than support layer 128 to provide more support to a user as well as provide structural integrity to the mattress. Foundation layer 136 can be as rigid and dense or more rigid and dense than foundation layer 132 to similarly provide support and structural integrity to body 160. The structural integrity of foundation layers 132, 136 also helps maintain the structure (e.g., the shape and position) of openings 156 (fourteen total, seven of which are in the side 116 that is not shown) positioned in foundation layers 132, 136, so a user may insert and remove inserts 152 within and from openings 156 multiple times without undue difficulty.
(15) Openings 156 can extend though some or all of foundation layers 132, 136 between sides 116, as shown, and/or between ends 112. Openings 156 can include exposed ends for receiving removable inserts 152 on either side 116 (or end 112, depending on the configuration). An opening 156 can include an exposed interior surface (not shown) that mates with removable inserts 152 and runs the length of the opening 156. The exposed exterior surface can be configured to provide less resistance (e.g., friction) when inserting or removing a removable insert 152 by, for example, lining such exposed interior surface with low friction materials such as plastic or by melting plastic fibers, if any, in the foam, gel, and/or plastic of foundation layers 132, 136 immediately surrounding the opening 156. Openings in layers of a mattress can also be formed between mattress layers as shown and described with reference to FIGS. 2 and 2A or entirely within a support layer of a mattress as shown and described with reference to FIGS. 3 and 3A.
(16) FIG. 2 shows an embodiment of a mattress 200 according to the disclosed apparatuses and methods that is similar to mattress 100, including a similar top 204, bottom 208, ends 212 (only one shown), sides 216 (only one shown), and cover 220. Mattress 200 also includes a mattress body 260 comprising a series of stacked foam layers (e.g., made from phase change memory foam, though the layers may be made from other or additional types of materials, such as gel and/or plastic) that are shaped to maintain contact with one another by friction (i.e., with mating surfaces that resist relative movement), but may also be affixed with laminate or by other means. Unlike mattress body 160, mattress body 260 includes only a single foundation layer 232 disposed below support layer 228, wicking interface 244, and top layer 224, in that order. These layers have substantially the same mechanical characteristics (e.g., strength, stiffness, rigidity, density) as foundation layer 132, support layer 128, and top layer 124, respectively, of mattress 100. Top layer 224 includes ergonomic grooves 240 formed (e.g., via cutting with a laser and/or using CNC) into the top of top layer 224 that can aid in providing pressure relief to a user's body.
(17) Also unlike body 160, body 260 includes only ten openings 256 (five of which are in the side 216 that is not shown) and the openings 256 are formed partially by recesses in the bottom surface of support layer 228 and partially by recesses in the top surface of foundation layer 232, as shown. Although different embodiments of the mattress may have more or less openings. Openings 256 are otherwise identical to openings 156 of FIGS. 1 and 1A. Removable inserts 252 may provide different amounts of support to a user when in direct contact with a support layer (e.g., support layer 228) rather than when disposed entirely within a foundation layer (e.g., foundation layers 132, 136).
(18) FIG. 3 shows an embodiment of a mattress 300 that is similar to mattress 100, including a similar top 304, bottom 308, ends 312 (only one shown), sides 316 (only one shown), and cover 320. Mattress 300 also includes a mattress body 360 comprising a series of stacked foam layers (e.g., made from phase change memory foam, though the layers may be made from other or additional types of materials, such as gel and/or plastic) that are shaped to maintain contact with one another by friction (i.e., with mating surfaces that resist relative movement), but may also be affixed with laminate or by other means. Unlike mattress body 160, mattress body 360 includes only a single foundation layer 332 disposed below support layer 328, wicking interface 344, and top layer 324, in that order. These layers have substantially the same mechanical characteristics (e.g., strength, stiffness, rigidity, density) as the foundation layer 132, support layer 128, and top layer 124, respectively, of mattress 100. Top layer 324 includes ergonomic grooves 340 formed (e.g., via cutting with a laser and/or using CNC) into the top of top layer 324 that can aid in providing pressure relief to a user's body.
(19) Also unlike body 160, body 360 includes only four openings 356 (two of which are in the side 316 that is not shown) and the openings 356 are formed entirely within support layer 328, as shown, although any number of openings is possible. Openings 356 are otherwise identical to openings 156 of FIGS. 1 and 1A. Removable inserts 352 may provide different amounts of support to a user when in a support layer (e.g., support layer 328) rather than in a foundation layer (e.g., foundation layers 132, 136). Support layer 328 also includes air flow channels 348.
(20) Referring now to FIGS. 4A and 4B, removable inserts 152a, 152b (also referred to as wands or rods) may be similar to removable inserts 252 and 352 of FIGS. 2, 2A, 3 and 3A. Removable inserts 152a, 152b can be made from a variety of materials, such as plastic, plastic-encased foam, polyethylene, or other materials, and can have mechanical characteristics (e.g., strength, stiffness, density, rigidity) similar to or different from the material of the mattress layer or layers forming the openings in which removable inserts 152a, 152b are received (e.g., foundation layers 132, 136). For example, if no additional support is desired by a user at a particular opening location, then removable inserts 152a, 152b can have the same mechanical characteristics as the material of the layers or layers forming such opening. If additional support is desired, then removable inserts 152a, 152b can have, for example, greater rigidity than the material of the layers or layers forming such opening. Removable inserts 152a, 152b include a sloping tip 168 having a blunted end 172 to help guide removable inserts 152a, 152b into the openings of a mattress body (e.g., openings 156) without damaging the material forming the openings. Removable inserts 152a, 152b may have different lengths 164a, 164b, respectively. In one embodiment, a twin-size mattress may only be able to receive a single removable insert 152b in each of its openings, for example, where the openings are short and/or lie in a common transverse and vertical plane of the mattress (i.e., at same location on opposite sides or ends of the mattress body). In such a mattress, a removable insert 152a may be too long and could protrude substantially past the end of such openings. However, a king size mattress of the present disclosure may fit a removable insert 152a to substantially fill its openings. Alternatively or additionally, a single removable insert may be used to fill an opening that runs the entire length or width of a mattress. For example, removable insert 152b may substantially fill and not extend beyond or substantially beyond the ends of an opening that runs the entire length or width of a twin-size mattress of the present disclosure; or removable insert 152a may substantially fill and not extend beyond or substantially beyond the ends of an opening that runs the entire length or width of a king size mattress of the present disclosure. In some embodiments, two or more removable inserts of same or different sizes may be inserted into an opening to provide a mattress feel that varies across the mattress. For example, rods of one characteristic may be inserted in openings on a first side of the mattress and rods of a different characteristic may be inserted in openings on a second side of the mattress. Using multiple rods in the openings may provide a sleeper on a left-side of the mattress a different feel than a sleeper on a right-side of the mattress. It will be appreciated that removable inserts 152a, 152b are merely representative and that similar inserts of any size or shape (including length and diameter) may be configured for use with various mattress types, sizes, and/or shapes.
(21) For a user to position or remove inserts 152a, 152b (or similar removable inserts) in openings of a mattress body of the present disclosure, the outer cover of such mattress, if present, must permit access to the openings. FIG. 5 illustrates mattress 400 having a top 404, bottom 408, ends 412 (only one shown), and sides 416 (only one shown). Mattress 400 may also include an outer cover 496 having slits 432 (only one shown) on side 416. Mattress 400 can be one of the mattresses 100, 200, and 300 previously discussed and outer cover 496 can entirely or partially enclose the body of mattress 400. Although positioned on the sides 416 of mattress 400, it will be appreciated that slits 432 (or additional or alternative slits) may be alternatively or additionally be positioned on ends 412 of mattress 400.
(22) FIG. 6 depicts a partial side view of mattress 400 showing a slit 432 of outer cover 496 in a side 416 of mattress 400. Slit 432 includes a zipper 420 to allow a user to open and close slit 432 as desired, though other means (e.g., buttons, hook-and-loop fasteners) may be employed in addition to or in place of zipper 420. FIG. 7 depicts another partial side view of mattress 400 with zipper top 424 and zipper bottom 428 of zipper 420 separated such that a user can access another slit 456 of an inner fire-retardant cover 436. Fire-retardant cover 436 can entirely encompass mattress 400 to reduce deaths and injuries associated with mattress fires by limiting the size of the fire generated by a mattress or mattress set. Fire-retardant cover 436 may not be required in every embodiment of the present apparatuses and methods (though it may be legally required in some jurisdictions, for example to comply with 16 C.F.R. 1633.1), such that slit 432 in cover 496 could permit direct access to the body of mattress 400, including to the openings formed therein. Fire-retardant cover 436 includes a zipper 440 to allow a user to open and close slit 456 as desired, though other means (e.g., buttons, hook-and-loop fasteners) may be employed in addition to or in place of zipper 440.
(23) Conventionally, users are not allowed access through a fire-retardant barrier cover. This conventional practice is intended to increase the likelihood of the fire-resistance cover operating as intended, and thus passing certain jurisdictional safety laws. Allowing the user an ability to remove the fire-retardant cover could lead to unintended harm to the user based on their inability to re-apply the covering in an effective manner. Even when a user intended to reinstall the cover correctly, errors could be made that affect the fire-resistance capability. Furthermore, removing the fire-retardant cover on a large-size mattress may be difficult without more than one person or for small-sized users. The slits in the fire-retardant cover and a second cover over the fire-retardant cover allow a user to quickly access the openings to adjust the mattress while limiting the likelihood of compromising the fire-retardant aspect of the cover. With the slits and zippers in the cover, the user does not need to remove the entire cover. Instead, a user is provided access only to the portion of the body of the mattress that can be user adjusted. Furthermore, that access is provided in a manner that is easy to close and return the mattress to its factory-original safety rating.
(24) FIGS. 8A-8C depict partial side views of embodiments 400a-400c, respectively, of mattress 400 with zipper top 444 and zipper bottom 448 of zipper 440 (as well as zipper top 424 and zipper bottom 428 of zipper 420 of outer cover 496) separated such that a user can access mattress bodies 460a-460c, respectively. Mattress body 460a (shown in FIG. 8A) includes openings 452 formed by aligning recesses 476, 480 of two adjacent mattress body layers 464, 468, respectively. Some of the openings 452 are not substantially aligned. An embodiment of such a mattress body is shown and described generally with reference to mattress body 660 of FIG. 13. As shown in FIG. 13, such a mattress body may also include additional openings in or between adjacent mattress layers.
(25) Mattress body 460b (shown in FIG. 8B) includes openings 452 formed directly within body layer 464 between body layers 468 and 472. Embodiments of such a mattress body are shown and described with reference to mattress body 160 of FIGS. 1 and 1A and mattress body 360 of FIGS. 3 and 3A. As shown in FIGS. 1 and 1A, such a mattress body may also include additional openings in adjacent mattress layers. Such a mattress body may also include openings between adjacent layers.
(26) Mattress body 460c (shown in FIG. 8C) depicts openings 452 formed by aligning recesses 476, 480 of adjacent mattress body layers 464, 468, respectively. Openings 452 are substantially aligned. An embodiment of such a mattress body is shown as mattress body 260 of FIGS. 2 and 2A. While not shown in FIGS. 2 and 2A, such a mattress body may also include additional openings in or between adjacent mattress layers.
(27) FIGS. 9-11 depict partial side views of embodiments of a mattress 500 that is similar to mattress 400 but includes one or more fire shields 584 positioned behind and coupled to a fire-retardant cover 536. Horizontal dotted lines 592 are shown for location reference. Like mattress 400, mattress 500 includes a zipper top 524 and zipper bottom 528 that can be used in conjunction to open or close a slit formed in an outer cover 596 positioned on a side 516 of mattress 500 (though other means such as buttons or hook-and-loop fasteners may additionally or alternatively be used). A similar system (e.g., slit with zipper) may be employed on another side or end (e.g., opposite side 516 that is not shown) of mattress 500. Although positioned on the sides 516 of mattress 500, it will be appreciated that the slits of mattress 500 (or additional or alternative slits) may be alternatively or additionally be positioned on the ends (not shown) of mattress 500. Outer cover 596 can partially or entirely enclose a body of mattress 500 when zipper top 524 and zipper bottom 528 are in a closed configuration. FIGS. 9-11 show zipper top 524 and zipper bottom 528 in an open configuration.
(28) Also like mattress 400, mattress 500 includes an inner fire-retardant cover 536 that can entirely encompass mattress 500 to reduce deaths and injuries associated with mattress fires by limiting the size of the fire generated by a mattress or mattress set. Fire-retardant cover 536 may not be required in every embodiment of the present apparatuses and methods (though it may be legally required in some jurisdictions, for example to comply with 16 C.F.R. 1633.1). Fire-retardant cover 536 includes a zipper top 544 and zipper bottom 548 that can be used in conjunction to open and close a slit formed in fire-retardant cover 536 (though other means such as buttons or hook-and-loop fasteners may additionally or alternatively be used). The slit in fire-retardant cover 536 is conveniently located directly behind the slit of outer cover 596, so that a user can quickly and easily access both in sequence, although other alignments of the cover and slit may allow access. A similar system (e.g., slit with zipper) may be employed in fire-retardant cover on another side or end (e.g., opposite side 516 that is not shown) of mattress 500. Positioned behind and entirely covering the shown slit of fire-retardant cover 536 is a fire shield 584. Fire shield 584 can be made of similar or different materials than fire-retardant cover 536, and can accomplish a similar purpose of reducing deaths and injuries associated with mattress fires by limiting the size of the fire generated by a mattress or mattress set. Mattress shield 584 may be legally required in some jurisdictions, for example, to comply with 16 C.F.R. 1633.1. Mattress shield 584 is positioned directly behind the shown slit of fire-retardant cover 536 to help ensure that no portion of the body of mattress 500 is exposed to the shown slit of fire-retardant cover 536 because such slit may inadvertently be left open by a user or may not provide on its own sufficient fire-resistance. Although depicted behind the shown slit of fire-retardant cover 536, a fire shield 584 may also or additionally be positioned in front of the shown slit of fire-resistance cover 536.
(29) As shown in FIG. 10, fire shield 584 is not coupled at its lower end 588 to fire-resistance cover 536 such that a user may further open the shown slit of fire-retardant cover 536 (and the shown slit of outer cover 596) to expose a portion of mattress body 560, including openings 552 positioned therein. As shown in FIG. 11, fire shield 584 may be flexible such that a user can move a portion of fire shield 584 (e.g., from lower end 588) to gain full access to openings 552 of mattress body 560. Mattress body 560 depicts openings 552 formed by aligning recesses 576, 580 of adjacent mattress body layers 564, 568, respectively. An embodiment of such a mattress body is shown as mattress body 260 of FIGS. 2 and 2A. While not shown in FIGS. 2 and 2A, such a mattress body may also include additional openings in or between adjacent mattress layers.
(30) The mattresses of the present disclosure, including mattresses 100, 200, 300, 400, and 500 can be created by one or more of the methods disclosed and described with reference to FIGS. 12A and 12B. A method 1000 of forming a mattress may include, at step 1004, forming one or more mattress layers. Such layers can be formed using any known or later-developed method of manufacturing, such as forming or molding, including injection molding and foam molding. At step 1008, material, such as foam, gel, and/or plastic, is removed from at least some of the mattress layers to create openings through the sides and/or ends of the mattress layers. Such openings are used to receive one or more removable inserts as described herein. Step 1008 may not include forming such openings by removing material from the top surface of the top layer or the bottom surface of the bottom layer. Accordingly, access to the openings may be only through the ends or sides of the mattress layers. Step 1008 may form openings that are entirely contained in one layer of the mattress. Steps 1012 and 1016 may form openings that span multiple layers of the mattress. Alternatively or additionally, at step 1012, material, such as foam, gel, and/or plastic, is removed from at least some of the mattress layers to form one or more recesses in the layers. At step 1016, layers having such recesses are aligned on top of or next to one another (depending on the configuration) to together form openings between the adjacent layers. Such openings are used to receive one or more removable inserts as described herein. Steps 1012 and 1016 may not include forming such recesses to create such openings by removing material from the top surface of the top layer or from the bottom surfaces of the bottom layer. Accordingly, access to the openings may be only through the ends or sides of the mattress layers.
(31) At step 1020, the mattress layers are affixed together to form a mattress body. Such mattress layers can be affixed on top of each other and/or next to each other by friction (i.e., with mating surfaces of the layers that resist relative movement), by laminating, and/or by other means. A mattress body may be created by performing step 1020 before step 1008 or step 1012, such that the mattress layers are affixed together and then material removed. In such a method, step 1016 can occur as part of step 1020. In method 1000, the exposed (i.e. inner) surface of the openings, regardless of how the openings are formed, can be made to provide less resistance (e.g., friction) when inserting or removing a removable insert by, for example, lining such exposed interior surface with low friction materials, such as plastic, or by melting plastic fibers, if any, in the foam, gel, and/or plastic immediately surrounding the opening. Such smoothing can be performed before or after performing step 1020.
(32) Once a mattress body has been formed having the desired openings via some or all of steps 1004, 1008, 1012, 1016, and 1020, the mattress body may be enclosed in a fire-retardant cover in step 1024. The fire-retardant cover will include at least one slit configured to be positioned over at least some of the openings of the mattress body, for example, as shown and described with reference to FIGS. 5-8C. Additionally, at step 1028, the fire-retardant cover may be coupled to one or more fire shields, such that each fire shield is positioned entirely over at least one slit of the fire-retardant cover. Such a configuration is shown and described, for example, with reference to FIGS. 9-11. At step 1032, the mattress body (within a fire-retardant cover and with a fire-retardant shield, depending on performance of steps 1024 and 1028) is enclosed by an outer cover having one or more slits positioned over the location of at least some of the openings. Such an outer cover can be, for example, an outer cover 120, 220, 320, 496, or 596, as described herein with reference to FIGS. 1-11. It will also be appreciated that step 1032 can be performed without performing one or both of steps 1024 and 1028, though performing one or both of steps 1024 may be legally required in some jurisdictions, for example, to comply with 16 C.F.R. 1633.1.
(33) Method 2000 shown and described with reference to FIG. 12B is similar to method 1000 of FIG. 12A, but does not include the steps of removing material from one or more mattress layers to create recesses and/or openings in the sides and/or ends thereof. Instead, method 2000 begins by directly forming either openings (step 2004) or recesses (step 2008) in the sides and/or ends of at least some of the mattress layers when the mattress layers are themselves formed. This can be performed, for example, by using a mattress layer mold designed to create such openings and/or recesses. If recesses are formed in step 2008, then at step 2012, such recesses are aligned when the mattress layers are put together such that the recesses of adjacent layer together form one or more openings for receiving one or more removable inserts, similar to step 1012 of method 1000. Steps 2016, 2020, 2024, and 2028 are similar to steps 1016, 1020, 1024, and 1028, including the having the options described in method 1000, such as performing only some of the steps and/or performing the steps in different orders.
(34) The mattress body 660 shown in FIG. 13 can be formed using either of methods 1000 or 2000 or another method. Mattress body 660 includes multiple layers, including top layer 624, support layer 626, foundation layer 632 (formed of foundation layers 632a and 632b), and foundation layer 636 (formed of foundation layers 636a, 636b, and 636c). Such layers have substantially similar mechanical characteristics (e.g., strength, stiffness, rigidity, density, thermal resistance) as the respective top, support, and foundation layer(s) of mattress bodies 160, 260, and 360 of FIGS. 1-3A, and can also have other similar features. For example, top layer 624 can include grooves/blocks 640 formed (e.g., via cutting with a laser and/or using CNC) into the top of top layer 624 that have channels for ventilating heat, for example from a user's body, and that can aid in providing pressure relief to, for example, a user's head, shoulders, hips, back, and/or knees. As another example, air flow channels 648 can be positioned between the bottoms of sections of foundation layers 632a and the tops of foundation layers 636a, 636b, and 636c.
(35) Four different openings 652a-652d within mattress body 660 are shown in FIG. 13. Opening 652a is formed by aligning mattress layers 632a and 632b vertically such that recesses 676a and 680a of such layers, respectively, are substantially aligned. Opening 652a can receive one more removable inserts (not shown). Opening 652b is similarly formed by aligning mattress layers 632a and 632b vertically, but in such a manner that recesses 676b, 680b of such layers, respectively, are not substantially aligned. Opening 652b may not be able to receive one or more removable inserts (not shown) depending on how substantially recesses 676b, 680b are misaligned.
(36) While misaligned recesses are not generally desirable, a manufacturer may nonetheless create layered mattress bodies in a more cost-efficient manner by have a standard manufactured layer, such as foundation layer 632a, with recesses, such as recesses 676a and 676b, cut/formed therein at standard intervals. When assembling the mattress layers, a layer, such as layer 632a, may be aligned with another layer, such as layer 632b, such that at least some (e.g., the maximum number possible) recesses of the mattress layers are substantially aligned to form openings for receiving one or more removable inserts. In such a configuration, a certain number of openings may nonetheless be created that cannot receive one or more removable inserts, but that loss may be compensated by cost efficiencies gained from having one or more standardized mattress layers, such as layer 632a. For example, the standard layer 632a can be designed to create the most number of openings with a lower layer 632b for the most common or otherwise cost-beneficial size and/or type of mattress body produced. In this way, fewer molds and/or processes need to be made/used to create a mattress, while still capturing the benefits of having a number of user-accessible openings for receiving removable inserts, as described herein.
(37) Opening 652c is similar to opening 652a in that it is formed from recesses 676c and 676d of adjacent mattress segments such that it can receive one or more removable inserts. However, opening 652c is formed by two horizontally-adjacent mattress segments 636a, 636b of foundation layer 636. Such horizontally-adjacent mattress layers will generally, but need not necessarily, be affixed by more than just friction (e.g., by laminating). Finally, opening 652d is formed directly within segment 636c and can receive one or more removable inserts. Some or all of openings 652a-652d may be formed in any number or variety of mattress layers and on any end or side of such mattress layers, including the embodiments of the mattress layers shown and described with reference to FIGS. 1-13. Similarly, any number of mattress layers may be used and joined in any number of segments (e.g., three) or orientations (e.g., angled) to create embodiments of the mattress bodies disclosed herein, including the embodiments shown and/or described in any of FIGS. 1-13.
(38) The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) means for or step for, respectively.
