Hybrid Mattress

Abstract

A flippable mattress includes a first memory foam layer, a second memory foam layer, a core layer disposed therebetween and a transition layer between each foam layer and the core. The first memory foam layer has a thickness, and the second memory foam layer has a thickness that is greater than the thickness of the first memory foam layer. The first transition layer has an IFD less than that of the second transition layer. The mattress is flippable between a first orientation in which the first memory foam layer is above the core layer and the second memory foam layer, and a second orientation in which the second memory foam layer is above the core layer and the first memory foam layer.

Claims

1. A flippable mattress extending along a length between a first end and a second end, the mattress having a first side configured for supporting a person and presenting a first firmness to the person when the first side is facing in an up direction and the mattress defining a second side configured for supporting a person, the second side being opposed to and parallel to the first side, the second side presenting a second firmness to the person when the second side is in the up direction, the mattress being flippable about an axis extending between the first end and the second so as to present either the first side facing the up direction or the second side facing the up direction when the mattress is resting on a flat surface, the mattress comprising: a first layer extending between the first end of the mattress and the second end of the mattress, the first layer comprising copper-infused memory foam, the first layer having a uniform height H.sub.1 in a direction perpendicular to the length of the mattress, the first layer having a uniform indentation force deflection IFD.sub.1 in a direction perpendicular to the length of the mattress; a second layer extending between the first end of the mattress and the second end of the mattress, the second layer comprising copper-infused memory foam, the second layer having a uniform height H.sub.2 in a distance perpendicular to the length of the mattress, the second layer having a uniform indentation force deflection IFD.sub.2 in a direction perpendicular to the length of the mattress; a third layer extending between the first end of the mattress and the second end of the mattress, the third layer defining a top surface and a bottom surface, the third layer comprising a plurality of individually wrapped coils, each of the individually wrapped coils extending between the bottom surface of the third layer and the top surface of the third layer, the third layer having a uniform height H.sub.3, a side surface of each of the wrapped coils being adhered to a side surface of an adjacent coil so as to form a continuous layer having a uniform height being H.sub.3, the third layer being disposed between the first layer and the third layer; each of the first layer, the second layer, and the third layer being fixed in position relative to each other; a cover defining a volume for receiving the first layer, the second layer, and the third layer; wherein H.sub.3 is selected to enable the mattress to be compressed and rolled and packaged into a cardboard box that can be shipped by a common carrier.

2. The flippable mattress of claim 1, wherein H.sub.3 is six inches or less.

3. The flippable mattress of claim 2, further comprising: a first transitional layer extending between the first end of the mattress and the second end of the mattress, the first transitional layer comprising open cell poly urethane foam, the first transitional layer having a uniform height H.sub.T1 in a distance perpendicular to the length of the mattress; the first transitional layer being disposed between the first layer and the third layer and being fixed relative thereto; the first transitional layer having a uniform indentation force deflection IFD.sub.T1 in a direction perpendicular to the length of the mattress; wherein IFD.sub.T1 is greater than IFD.sub.1; wherein IFD.sub.T1 is greater than IFD.sub.2.

4. The flippable mattress of claim 3, further comprising: a second transitional layer extending between the first end of the mattress and the second end of the mattress, the second transitional layer comprising open cell poly urethan foam, the second transitional layer having uniform a height H.sub.T2 in a distance perpendicular to the length of the mattress; the second transitional layer being disposed between the second layer and the third layer and being fixed relative thereto; the second transitional layer having a uniform indentation force deflection IFD.sub.T1 in a direction perpendicular to the length of the mattress; wherein IFD.sub.T2 is greater than IFD.sub.1; wherein IFD.sub.T2 is greater than IFD.sub.2.

5. The flippable mattress of claim 4, wherein the first firmness presented to the person on the first side when the first side is in the up direction is different than the second firmness presented to the person on the second side when the second side is in the up direction.

6. The flippable mattress of claim 5, wherein IFD.sub.1 is the same as IFD.sub.2.

7. The flippable mattress of claim 6, wherein H.sub.1 is greater than H.sub.2.

8. The flippable mattress of claim 7, wherein H.sub.1 is between 2 and 3 inches.

9. The flippable mattress of claim 8, wherein H.sub.2 is between 0.75 and 1.5 inches.

10. The flippable mattress of claim 9, wherein HT.sub.1 is between 1 and 2 inches.

11. The flippable mattress of claim 10, wherein HT.sub.2 is between 1 and 2 inches.

12. The flippable mattress of claim 11, wherein the cover is made of a thermogel infused fabric material.

13. The flippable mattress of claim 12, wherein the cover comprises: a handle connected to the cover by a substantially not stretchable piece of fabric, thereby dispersing force transferred from the handle to the cover and inhibiting damage thereto.

14. The flippable mattress of claim 13, wherein the cover includes a first cover portion and a second cover portion, the first cover portion being visually distinct from the second cover portion; Wherein the position of the first portion and the second portion corresponds with the first firmness and the second firmness.

15. The flippable mattress of claim 14, wherein each of the first and second transitional layers have a first surface which is substantially planar and a second opposing surface which has a pattern of repeated peaks and valleys.

16. The flippable mattress of claim 15, wherein the second surface of each of the first and second transitional layers has a different pattern on the head and foot of the layer than in the center of the second surface of the transition layers.

17. The flippable mattress of claim 16, wherein the pattern on the head and foot of the second surface of each the transitional layers is a repeating diamond pattern and the pattern in the center of the second surface of the transitional layers is a repeating hexagonal pattern.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is blown-out perspective view of the mattress.

[0025] FIG. 2a is a perspective view of the top cover of the mattress.

[0026] FIG. 2b is a perspective view of the bottom cover of the mattress.

[0027] FIG. 3 is a cut away view of a blown-out view of the mattress.

[0028] FIG. 4 is a cut-out view of the mattress soft-side up.

[0029] FIG. 5 is a cut-out view of the mattress firm-side up.

[0030] FIG. 6 is an isometric view of a tri-zone transition layer.

[0031] FIG. 7 is an perspective view of a core layer.

[0032] FIG. 8 is an perspective view of a cut-out of the mattress.

[0033] FIG. 9 is a perspective view of a cut-out of the mattress.

[0034] FIG. 10 depicts a portion of the mattress having a handle.

DETAILED DESCRIPTION

[0035] Referring to FIGS. 1 and 2, the present disclosure relates to a flippable mattress 10, and a system 12 that includes the mattress 10 and a cover 14 disposed thereon. The cover 14 encloses the mattress 10, and is formed of a top shown in FIG. 2a and a bottom shown in FIG. 2b.

[0036] Referring to FIG. 3, the mattress 10 includes a core layer 16, a first memory foam layer 18, and a second memory foam layer 20. The core layer 16 is disposed between the first memory foam layer 18 and the second memory foam layer 20. The core layer 16 has a thickness 22 defined between a first surface 24 and an opposing second surface 26 thereof. The first memory foam layer 18 has a thickness 28 defined between a first surface 30 and an opposing second surface 32 thereof. The second memory foam layer 20 has a thickness 34 defined between a first surface 36 and an opposing second surface 38 thereof. The thickness 28 of the first memory foam layer 18 is greater than the thickness 34 of the second memory foam layer 20. The mattress 10 is flippable between a first orientation and second orientation. In the first orientation (see FIG. 4), the first memory foam layer 18 is above the core layer 16 and the second memory foam layer 20. In the second orientation (see FIG. 5), the second memory foam layer is above the core layer 16 and the first memory foam layer 18. In the first orientation and the second orientation a proper sleep is obtainable on the mattress. This is in contrast to a typical mattress where two orientations are obtainable, however, in one orientation a proper sleep would be prohibited by a lack of comfort.

[0037] The cover 14 is disposed on at least a portion of the mattress 10. In the illustrated embodiment, the cover 14 houses an entirety of the mattress 10 therein. In other embodiments, the cover 14 is disposed on only a portion of the mattress 10.

[0038] The cover 14a, 14b may be made from a variety of materials. In one aspect of the invention the cover is made of a thermogel infused fabric material that aids in keeping a user cool during use of the system 12. The first cover portion 14a includes a first cover panel 48 and a first cover sidewall 50. The first cover panel 48 has a size and shape corresponding to the size and shape of the first surface 30 of the first memory foam layer 18. The first cover sidewall 50 extends perpendicularly from the first cover panel 48 along an entirety of an outer edge of the first cover panel 48. The second cover portion 14b includes a second panel 52 and a second sidewall 54. The second panel 52 has a size and shape corresponding to the size and shape of the second surface 38 of the second memory foam layer 20. The second sidewall 54 extends perpendicularly from the second panel 52 along an entirety of an outer edge of the second panel 52.

[0039] Since the cover is the outermost material on the mattress it is desirable to make it soft, however, in some aspects of this invention the cover is less soft to meet the tastes of customers. Therefore, the cover 14 may be made from a super soft fabric and may be breathable. The cover 14 may have a hexagon pattern sewn into it. The hexagons could be any size, however, a reduced size such as 0.75-inch hexagons would provide cost-effective comfort. Further, the hexagons may be different sizes on the top of the cover 14a verse the bottom of the cover 14b. The cover may be made from a blend of polyester, viscose, and poly/lycra. For example, the cover may be 66% polyester, 30% viscose, and 4% poly/lycra. It is advantageous for the cover to be water-proof or water-resistant, however, in some aspects of the invention the cover is neither water-proof nor water-resistant.

[0040] The cover may also have branding, warning, or other labels on its surface. Preferably, any branding, warning, label, or tag would be on the vertical sides of the mattress 12 to avoid discomfort. The labels may be made from Nylon or other materials. Advantageously, the cover would indicate to the user which side is the soft side and which side is the firm side. This could be done through a change in color from one side of the cover to the other, or though tags. For example, the soft side of the cover 14a may be white, while the firm side of the cover 14b may be dark gray.

[0041] The color difference between the two sides may give notice to the user which side is soft and firm and may also provide a psychological phenomenon to the user. For example, a soft sleeper may aesthetically prefer the softer side color and already believe they will enjoy the mattress before seeing it. In one object of the invention the mattress could be designed such that the soft side has a color typically associated with softness, e.g. white, baby blue, etc., the firm side may have a color more associated with firmness, e.g. dark gray, red, or black. In such an object of the invention, the user may make a personal connection to a particular side of the mattress, which would lead to a greater likelihood that they will sleep soundly.

[0042] It is also possible to distinguish the colors by their color coolness of warmness. In one object of the invention, the soft side of the cover may have a cooler color than the firm side. In another embodiment of the invention the firm side may have a cooler color than the soft side.

[0043] In another object of the invention, the mattress may use colors to depict the firmness or softness of a mattress side to emphasize the thickness of the layers. For example, if the soft memory foam was larger in size than the firm memory foam, the color depicting the soft side would cover more of the mattress vertically than the color depicting the firm side. This would give the user a visualization of the plush, or lack of plush, on their desired side. Seeing the plush nature depicted by color may allow the user to trust the feeling of the mattress, thus providing a calmer sleep.

[0044] The cover may also have a handle on the vertical surface for ease in transporting or flipping the mattress 12. The handle may be made from vinyl or another material. In another aspect of the invention, there may be a plurality of handles disposed around the flippable mattress 12.

[0045] One object of the invention having a handle is shown in FIG. 10. The flap 74 folds over the cover 14b. The flap 74 is optional, but aesthetically allows a zipper or other connection between 14a and 14b to be hidden. In other objects of the invention, the flap may be laid over the cover 14a. The handle 72 may be made out of a vinyl material. In other objects of the invention the handle may be made of a different material. It is advantageous for the handle to be firm, to provide a better grip for a mover, however, the handle may also be soft.

[0046] The handle 72 may be attached to the stretchable cover 14a 14b by a secondary fabric 70. The secondary fabric 70 may be non-stretchable and durable. The secondary fabric 70 may be integrated into the cover 14a 14b. This integration may be only in the top of the cover 14a, only in the bottom of the cover 14b, or in both top and bottom of the cover. The integration of the secondary fabric 70 may be through stitching the secondary fabric into the cover 14. The secondary fabric 70 may be stitched into the cover 14 by only a slim portion of the secondary fabric 70. The secondary fabric 70 may also have a patch within the cover 14, such that the portion of the secondary fabric 70 extruding from the cover 14 only makes up a portion of the patch. In this object of the invention the secondary fabric will have multiple points of contact with the cover 14, thereby reducing the stress at any single point of contact. Since the force will be distributed over a larger portion of the cover 14 there is less of a chance that force exerted on the handle will cause the cover the rip or tear.

[0047] In another object of the invention, the handle 72 may be attached to the flap 74. This may be via a secondary fabric 70 or without the secondary fabric 70. The flap 74 also has many points of contact with the cover 14, therefore, would reduce the chance of ripping or tearing the cover.

[0048] In other objects of the invention the secondary fabric 71 may be of varied stretchability. Varied stretchability would allow for the secondary fabric 70 to be integrated into the cover 14 in larger amounts without removing more of the stretch functionality from the cover 14.

[0049] The top of the cover 14a may connect to the bottom of the cover 14b via a zipper 56, 58. Since the mattress is flippable, the terms top and bottom are relative to FIG. 1. It would be advantageous to hide the zipper 56, 58 within flaps to keep the zipper closed and for aesthetical or other technical purposes. The zipper flaps may automatically reveal the zipper 56, 58 as it pulled open. In other aspects of the invention the zipper 56, 58 may be a different type of fastener, for example: buttons, hook-and-loop, glue, or other fasteners which would be appreciated by one having ordinary skill in the art.

[0050] The first layer of the mattress 18 may be made from copper infused memory foam. They fifth layer 20 may also be made from copper infused memory foam. Copper infused memory foam has advantages over regular memory foam due to the conductive and anti-microbial nature of copper. The conductivity of the copper allows the memory foam to dissipate excess body heat, whereas other mattresses would trap the heat. Copper will also help wick and release water or other liquids quicker than typical memory foam. The anti-microbial nature of copper helps to limit bacteria growth and build up in the mattress. The memory foam infused with copper reacts under body weight with a firming response. The response is called Variable Support and unlike traditional memory foam provides increased support at deep compression areas. The memory foam layers combined with the coil layers provide advanced motion control throughout the mattress. This may help, for example, preventing movements from one side of the mattress from transitioning to the other side. Additionally, since the copper infused memory foam will react to body weight, it allows proper support for a sleeper no matter how they sleep, be it on their side, back, or stomach.

[0051] The Copper infused memory foam may have an IFD rating of about 12 lbs. The foams Density may be about 3.5 lbs. The first layer 18 is softer or equally as soft as the fifth layer 20. The soft feel of the first layer 18 relative to the fifth layer 20 comes from the thickness 28 of the first layer. A thicker copper infused memory foam layer will provide more softness, even for similar or identical densities and IFDs. The first layer 18, being the softer layer, may have a thickness 28 of 2-3 inches. In one aspect of the invention, the first layer 18 would have a thickness 28 of about 2.5 inches. The fifth layer 20, being the firmer layer, may have a thickness 34 of 0.75-1.5 inches.

[0052] The second layer 40 and the fourth layer 42 are transition layers. In one aspect of the invention the transition layer is a tri-zone transition layer as shown in FIG. 6. The transition layers may be made of polyurethane open-cell foam. The transition layer transfers the shock between the comfort layers 18, 20, and the core layer 16. The second layer 40 may have a foam density between 1.5 and 3 lbs. In one aspect of the invention the foam density may be 1.65 lbs. The IFD of the second layer is about 20-25 lbs. In one aspect of the invention the IFD is 23 lbs.

[0053] In one aspect of the invention the fourth layer will be firmer than the second layer. Therefore, the mattress 12 can be flipped about its horizontal axis to allow a user to sleep on a soft side or a firm side. The fourth layer 42 may vary from the second layer 40 in that the IFD will be much greater. For example, in one aspect of the invention the IFD of the fourth layer may be 35-45 lbs. More specifically, in another aspect of the invention, the IFD may be 40 lbs. By varying the IFD between the two layers, it creates a varying feeling of firmness as a user lies on either side. It also allows the Foam Density to be the same on both layers. However, as appreciated by one skilled in the art, in some aspects of the invention the IFD could remain the same between the transition layers, and instead the density the height of the layer could be varied to affect the firmness. For example, the height of the fourth layer may be 1.5 inches while the height of the second layer is 2 inches.

[0054] The transition layers may be manufactured using Surface Modification Technology. Surface Modulation Technology carves out indentures across the entire layer to better support a human body. In one aspect of the invention both the transition layers 40, 42 may be designed as Tri-Zone layers, for example, as shown in FIG. 6. FIG. 6 shows a transition layer 60 having a first zone 61a, a second zone 62, and a third zone 61b. The surface modification technology may carve out a different pattern in each zone. In FIG. 6, a small diamond pattern is carved out in the first zone 61a and the third zone 61b. The diamond pattern creates valleys allowing cool air to enter the mattress while pushing hot air out. The second zone 62 is shown with a hexagon pattern which is designed to better support hips and shoulders. The hexagon pattern creates valleys allowing cool air to enter the mattress 12 while pushing hot air out. In addition to cooling the mattress, the surface modification technology also provides better support and can help prevent bed sores.

[0055] The firm layer 42 and the soft layer 40 may have different surface modification technology features. For example, the softer layer 40 may have the valleys cut deeper into the transition layer than the firm layer 42. For example, if the layer was 1.5 inches the soft layer may have patterns cut 0.5 inches into the polyurethane open-cell foam, while the firm layer 42 may have patterns cut 0.25 inches deep into the polyurethane open-cell foam. The compression caused by a human lying on the bed would push the softer layer 40, having a lower IFD, into a more compressed state, thus the valleys may need to be deeper to allow hot air to escape and maintain their other functions.

[0056] The core layer 16 may be comprised of a plurality of springs or coils. As appreciated by one skilled in the art cores may come in all different forms and general provide support for the mattress. The core layer 16 has a first side 24 and a second side 26. The sides do not necessarily perform differently based on whether they face the soft side of the firm side. The core also has a thickness 22. The thickness may allow for softer or firmer mattresses or may not have an affect on the firmness of a mattress. The thickness 22 may also be desirably small to make the mattress easier to fold, compress, or roll for ease in shipping. A core that can be compressed, folded, and rolled is advantageous for shipping costs.

[0057] The core may be made from a plurality of different kinds of springs. In FIG. 7, the core 65 is shown with two zones. An outer zone 67 and an inner zone 66. The outer zone 67 may be of a higher gauge than the inner zone 66. The higher gauge of the outer zone 67 provides the mattress with superior edge support. Edge support may reduce or eliminate the feeling that you will roll-off your mattress and delivers a consistent sleep surface, even when foam layers are laid on top.

[0058] In one aspect of the invention, the outer zone 67 may be 16-gauge coils and the inner zone 66 may be 14-gauge coils. The higher gauge coils provide more resistance and thus create a flatter sleeping surface regardless of the sleeper's position. In one aspect of the invention each of the coils is individually wrapped. The individually wrapped coils prevent tangling, which allows the springs to move independently. By having independent movement in each spring, the mattress is able to resist bouncing along the entire sleeping surface of the mattress. This helps keep movement from transferring to the other side of the bed. Therefore, if two people are using the same mattress, the movement of one person will not resonate through the spring system and cause movement at the other side of the bed. Individually wrapped coils also allows for each wire to flex separately and therefore will conform to the individual contours of the body.

[0059] Coils also provide the mattress with a much cooler feel, as air is easily removed through the coils from the top and bottom foam layers. Coils also provide enough bend for adjustable bases, which causes less wear and tear on moving parts, making the mattress usable for a longer period of time. The wire that makes up the coils may also be heat-treated and stress relieved. This aids the coils in holding their shape and thus provides a more durable consistent sleep surface.

[0060] Coils may also be of varying buoyancy strategically designed to position comfort zones which support, for example, the hips, back, and shoulders. For example, having a nested center zoning would provide for more back support than a normal mattress. The high coil count in the center can also provide for an even surface across the entire mattress. Additionally, the coils may come pre-compressed. The pre-compressed coils create a firm surface that makes the unit more responsive to body movements.

[0061] A cross-section of the mattress 12 is depicted in FIG. 4 and FIG. 5. In FIG. 4 the soft side is shown on top, whereas in FIG. 5, the firm side is shown on top. The layers may be fixed together via an adhesive (not shown). The adhesive may be a spray glue, or other adhesive as understood by one having ordinary skill in the art. The layers might also be held together via their location within the cover 14. In an aspect of the invention, the cover would provide enough tension throughout the layers to prevent them from sliding relative to each other. In some aspects of the invention the adhesive may only be applied to the edges of the layers, or even only to the vertical sides of the layers and affixed to the cover 14. In other aspects of the invention the adhesive could be applied over a larger surface of each layer, or of only selected layers.

[0062] The respective materials, thicknesses, and densities of the several layers of the mattress 10 also provide the mattress 10 with more than adequate support and stability, despite the fact that a memory foam layer is positioned at the bottom of the mattress 10 in both the first orientation (see the second memory foam layer 20 in FIG. 4) and the second orientation (see the first memory foam layer 18 in FIG. 5). The mattress 10 also achieves these significant advantages despite having a relatively low total thickness of 10.5 inches (i.e., approximately 26.7 cm), which is well within the range considered acceptable for use with typical bedframes.

[0063] As shown in FIG. 4 and FIG. 5, the transitional layers having shapes cut out are beneath the flat memory foam layers. This presents a flat surface to the sleeper while still providing the benefits of the surface modification technology. The core 16 is also positioned centrally to provide a benefit to the mattress regardless of what side is facing upwards. Therefore, it is important to have a reversible core 16. Since the foam layers provide the softness or firmness as may be desired it is not pertinent that the core provides a different firmness on either side. However, a core 16 that had a different firmness on either side would still be beneficial to the system.

[0064] In FIGS. 8 and 9 the cover 14a and 14b is shown cut out to display the core layer 16. The core layer 16 is shown comprising a center core layer 66, and an outer core layer 67. The inner core layer 66 has springs with a longer diameter than the springs of the outer layer 67. The shorter diameter springs of the outer layer 67 provides a firm edge that helps prevent one from falling off the bed. The foam layers 18, 40 on top of the core layer 16 provide a softer feeling than the foam layers 20, 42 on the bottom of the core layer 16.

[0065] The cover 14a, 14b may provide a pinching effect on the layers to squish them all together and allow the foam layers to better push into the core. A looser fit of the layers may not translate the force from each layer to the next properly.

[0066] Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.