WO2003047394A1 - Single piece foam toppers with perimeter areas having variable support and firmness properties - Google Patents
Single piece foam toppers with perimeter areas having variable support and firmness properties Download PDFInfo
- Publication number
- WO2003047394A1 WO2003047394A1 PCT/US2002/033874 US0233874W WO03047394A1 WO 2003047394 A1 WO2003047394 A1 WO 2003047394A1 US 0233874 W US0233874 W US 0233874W WO 03047394 A1 WO03047394 A1 WO 03047394A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- foam
- mattress
- single piece
- area
- Prior art date
Links
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
- A47C27/053—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers with only one layer of foamed material
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S5/00—Beds
- Y10S5/901—Mattress or pad with a convoluted, e.g. egg crate surface
Definitions
- the present invention pertains generally to resilient support devices, foam structures, and support devices which include foam structures as an integral component.
- foam is used as either the principle shock or load absorbing material, or in combination with a resilient structure such as an array of springs as a topper layer over the ends of the springs.
- a resilient structure such as an array of springs as a topper layer over the ends of the springs.
- the foam in this type of application is typically in slab-like form, with planar surfaces which rest upon supporting springs and over which covering or upholstery is laid.
- the foam may be molded or otherwise contoured to a particular shape.
- a single unibody slab of foam is used to cover the entire surface.
- U.S. Patent No. 5,579,549 describes a pad of fibrous material which is coated with adhesive material in designated areas to alter the firmness of the mattress in those areas.
- U.S. Patent 5,604,021 describes a multi-layer support pad with regions of differing firmness formed by various layers of convoluted or sculpted foam in combination with underlying slab layers of foam.
- U.S. Patent No. 5,701,623 describes a mattress topper having a latex foam core surrounded by border
- U.S. Patent No. 5,704,085 describes a foam layer in a mattress which has an edge of foam attached by adhesive about a perimeter of a foam layer, wherein the edge foam is of a different type, such as polyurethane which is firmer than the center foam to which it is attached, such as latex.
- edge foam is of a different type, such as polyurethane which is firmer than the center foam to which it is attached, such as latex.
- Contouring or cutting away portions of the surface of foam changes the support characteristics of the foam in a layered application, even when upholstery or other padding layers are placed over the foam, h the planar or slab-like layers of foam used in mattresses, the layers are dimensioned to cover the entire area of the mattress, or to cover the entire underlying spring array, and any contour or shaping is done across an entire surface area of the layer, giving the layer a modified but uniform support characteristic.
- the present invention provides shaped, contoured or sculpted foam for use as a load bearing layer which has variable support characteristics selectively formed about different areas of the layer. Variations in the topical form of the foam are created by patterned voids formed by removal of foam material from an otherwise uniform or planar surface.
- This type of unibody, multi-dimensional foam layer when combined with underlying support and topical layers, provides a support system with differing support or feel characteristics corresponding to the areas of differing foam contour.
- a thick comforting upholstery layer for use in a mattress construction where the center section of the layer has foam contoured or extracted in a pattern that results in the foam's physical properties (important to its cushioning behavior such as ILD and SAG
- a nominal thickness of a foam layer of the invention is in the range of one inch or greater, and the average density in an approximate range of 1.2 to 5.0 lbs./ cu. ft.
- a preferred IFD approximate range is from about 25 to about 70 lbs./sq. in.
- FIG. 1 is a perspective view of a single piece foam layer of the invention
- FIG. 2 is a top view of a single piece foam layer of the invention
- FIG. 3 is a cross-sectional view of a mattress construction incorporating a single piece foam layer of the invention
- FIG. 4 is a top view of single piece foam layer of the invention.
- FIG. 5 is a side elevation of a single piece foam layer of the invention.
- FIG. 6 is a top view of an alternate embodiment of a single piece foam layer of the invention.
- a single unibody foam piece generally indicated at 10, which in this case is in the general form of a planar slab dimensioned to extend over a support surface area, such as the expanse of a mattress spring array or "innerspring", generally indicated at 15 in FIG. 3.
- an innerspring is an array of individual coils or springs connected together so that axes of the coils are parallel and the ends of the coils provide a resilient support surface (as described for example in U.S. Patent No. 4,726,572) and across which various layers of material, such as matting, foam and padding are laid to create a mattress.
- An external upholstery layer 18 is sewn over the innerspring and internal layers to complete the mattress.
- An underside 14 of the foam piece 10 may be generally smooth, for flush contact with an adjacent layer, which may be another internal layer or component of a mattress, such as a mat layer 16 between the foam and the springs.
- An upper side 12, which serves as the supporting or load- bearing side of the foam piece 10, is initially smooth or planar, as produced by a mold or extrusion process. Side 12 is then selectively contoured by various applicable processes, such as by automated cutting technology, etching, or other types of surface modification techniques, to selectively form different surface topographies.
- topography refers to the relief features or surface configuration of an area or adjacent areas, in this case an area or areas of the foam layer of the invention.
- the single unibody foam piece 10 has the physical characteristics of a single type of foam with homogeneous foam cell structure throughout the piece, with the differing surface topographies altering the aggregate density and ultimate support characteristics of the zones. This is very different from foam assemblies or structures which are made of combined pieces of foam of different materials and densities.
- the sculpting or shaping of side 12 of the foam involves the removal of foam material in a pattern within one or more zones 121, 122, etc.
- An example of one type of foam removal pattern is a matrix of valleys or voids 20, and corresponding adjacent projections 22.
- the "projections" 22 extend generally from the bottom of the valleys or voids 20, so that it is the top or tip of the projections which collectively form a cushioned support surface, over which an upholstery layer is placed.
- zone 121 in the case of foam piece 10 used as a layer in a mattress, zone 121 maybe generally rectangular, covering a major expanse of the sleeping area, while adjoining zone 122 (having a different topography) is formed as lateral rail areas, or as a complete perimeter of the piece 10.
- zone 122 has a higher density than zone 121 as a result of less material being removed, and thus provides a firmer support as desired for edge seating function of the mattress, h this particular embodiment, zone 122 has a topography which is generally smooth and planar, i.e., no foam material has been removed from the surface of the rail sections.
- the rail sections/zone 122 having a different or higher degree of firmness than the central zone 121, even though the layer 10 is formed as a single unibody piece.
- a higher degree of firmness at the longitudinal edges or entire perimeter of the mattress is desirable to provide a more functional sleeping and seating surface. Whereas a topper of uniform density tends to be excessively compressed at the edges and thus effectively reduces the effective sleeping area of the mattress, the higher density edge of zone 122 maximizes the support area of the mattress all the way to the edge of the underlying innerspring.
- zones with varying topography can be laterally arranged to create a combination support mattress, or different zones head-to-toe.
- the foam topography modification may be configured to have gradual transitions between areas of differing topographies and resultant densities.
- the projections of the first zone can be made to decrease in height or depth as they approach the flat second zone, so that the transition in firmness is less perceptible when felt through the upholstery layers.
- transition zone 123 in FIG. 3.
- multiple zones of differing density can be made in a single layer, with graduated transitions between the zones, so that the transitions from one foam density to another foam density are less perceptible through the overlying upholstery.
- a single unibody component in a responsive flexible support structure has distinct zones with distinct support characteristics, the zones corresponding in location with the anticipated loads and loading patterns of a flexible support device in use.
- Foam materials suitable for the practice of this invention include any of the latex or polyurethane varieties, adaptable to the described foam cutting processes which form the varying topographies.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MXPA04005166A MXPA04005166A (en) | 2001-11-29 | 2002-10-23 | Single piece foam toppers with perimeter areas having variable support and firmness properties. |
BRPI0214480-8A BR0214480A (en) | 2001-11-29 | 2002-10-23 | One-piece foam covers with perimeter areas having varying support and firmness properties |
CA002465578A CA2465578A1 (en) | 2001-11-29 | 2002-10-23 | Single piece foam toppers with perimeter areas having variable support and firmness properties |
AU2002337961A AU2002337961B2 (en) | 2001-11-29 | 2002-10-23 | Single piece foam toppers with perimeter areas having variable support and firmness properties |
EP02773866A EP1448081A4 (en) | 2001-11-29 | 2002-10-23 | Single piece foam toppers with perimeter areas having variable support and firmness properties |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/996,457 | 2001-11-29 | ||
US09/996,457 US6701557B2 (en) | 2001-11-29 | 2001-11-29 | Single piece foam toppers with perimeter areas having variable support and firmness properties |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2003047394A1 true WO2003047394A1 (en) | 2003-06-12 |
Family
ID=25542951
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2002/033874 WO2003047394A1 (en) | 2001-11-29 | 2002-10-23 | Single piece foam toppers with perimeter areas having variable support and firmness properties |
Country Status (7)
Country | Link |
---|---|
US (1) | US6701557B2 (en) |
EP (1) | EP1448081A4 (en) |
AU (1) | AU2002337961B2 (en) |
BR (1) | BR0214480A (en) |
CA (1) | CA2465578A1 (en) |
MX (1) | MXPA04005166A (en) |
WO (1) | WO2003047394A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11026517B2 (en) | 2016-12-29 | 2021-06-08 | Sealy Technology, Llc | Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same |
Families Citing this family (23)
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US6701557B2 (en) * | 2001-11-29 | 2004-03-09 | Sealy Technology Llc | Single piece foam toppers with perimeter areas having variable support and firmness properties |
US6721982B2 (en) * | 2002-03-25 | 2004-04-20 | Sealy Technology Llc | Quilt-stitched internal mattress pillows |
US20110173757A1 (en) * | 2009-09-02 | 2011-07-21 | Denver Mattress Co. Llc | Cushioning devices and methods |
US7284494B2 (en) * | 2003-11-10 | 2007-10-23 | Denver Mattress Co., Llc | High comfort mattresses having fiberballs |
US20110047708A1 (en) * | 2009-09-02 | 2011-03-03 | Denver Mattress Co. Llc | Mattresses with heat dissipation |
US6895620B1 (en) * | 2003-11-10 | 2005-05-24 | Denver Mattress Co., Llc | High comfort mattresses and methods for constructing them |
US7013515B1 (en) * | 2004-02-27 | 2006-03-21 | Price J Wesner | Body impression-resistant mattress assembly |
US7617556B2 (en) * | 2004-09-17 | 2009-11-17 | Denver Mattress Co., Llc | Mattress systems and methods of making |
ES2268956B1 (en) * | 2005-02-14 | 2008-03-01 | Pedro Montorio Sanjuan | IMPROVED FIRM AND COMFORT MATTRESS. |
BE1016665A3 (en) * | 2005-06-30 | 2007-04-03 | Imhold Nv | IMPROVED COMFORT LAYER FOR MATTRESSES, PILLOWS AND THE LIKE. |
US8359689B2 (en) * | 2009-04-24 | 2013-01-29 | Fxi, Inc. | Mattress adapted for supporting heavy weight persons |
US7886388B2 (en) * | 2009-04-24 | 2011-02-15 | Foamex Innovations Operating Company | Mattress adapted for supporting heavy weight persons |
WO2011011076A1 (en) * | 2009-07-22 | 2011-01-27 | Nook Sleep Systems, Llc | Systems, components and related methods |
US8621694B2 (en) * | 2009-09-12 | 2014-01-07 | Fxi, Inc. | Sleep support surface that includes a layer with large diameter cleaving |
WO2011034800A2 (en) * | 2009-09-18 | 2011-03-24 | Carpenter Co. | Cushioning device and method of manufacturing |
US20110145996A1 (en) * | 2009-12-22 | 2011-06-23 | Kara Johan | Reversible Foam Mattress and Method of Construction |
US8793821B2 (en) | 2010-07-12 | 2014-08-05 | Doug Fowkes | Cushion with double stacked off-set honeycomb |
JP2014512936A (en) * | 2011-05-12 | 2014-05-29 | シーリー テクノロジー エルエルシー | Tension reducing foam and mattress structure |
US8832888B2 (en) | 2011-07-29 | 2014-09-16 | Dreamwell, Ltd. | Mattress and side rail assemblies having high airflow |
CA2783753A1 (en) * | 2011-07-29 | 2013-01-29 | Dreamwell, Ltd. | Foam mattress assembly with increased airflow and independent suspension |
US11122910B2 (en) | 2012-10-22 | 2021-09-21 | Dreamwell, Ltd. | Multi-layered convoluted foam layer |
US9771186B1 (en) | 2016-06-17 | 2017-09-26 | Bag Strategies and Solutions, LLC | Shipping bag with non-registering handle |
US11317733B2 (en) * | 2017-11-17 | 2022-05-03 | Purple Innovation, Llc | Mattresses including an elastomeric cushioning element and a pocketed coil layer and related methods |
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-
2001
- 2001-11-29 US US09/996,457 patent/US6701557B2/en not_active Expired - Lifetime
-
2002
- 2002-10-23 EP EP02773866A patent/EP1448081A4/en not_active Withdrawn
- 2002-10-23 AU AU2002337961A patent/AU2002337961B2/en not_active Ceased
- 2002-10-23 WO PCT/US2002/033874 patent/WO2003047394A1/en active IP Right Grant
- 2002-10-23 MX MXPA04005166A patent/MXPA04005166A/en unknown
- 2002-10-23 BR BRPI0214480-8A patent/BR0214480A/en not_active IP Right Cessation
- 2002-10-23 CA CA002465578A patent/CA2465578A1/en not_active Abandoned
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11026517B2 (en) | 2016-12-29 | 2021-06-08 | Sealy Technology, Llc | Mattress assembly with a mattress topper that includes pocketed coil springs and methods of producing the same |
Also Published As
Publication number | Publication date |
---|---|
MXPA04005166A (en) | 2004-08-11 |
US6701557B2 (en) | 2004-03-09 |
AU2002337961B2 (en) | 2007-04-05 |
BR0214480A (en) | 2006-05-30 |
EP1448081A4 (en) | 2006-12-20 |
US20030097715A1 (en) | 2003-05-29 |
CA2465578A1 (en) | 2003-06-12 |
AU2002337961A1 (en) | 2003-06-17 |
EP1448081A1 (en) | 2004-08-25 |
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