Foam mattress with symmetrical wavy foam layers

• US 10,357,115 B2
• Filed: 02/28/2013
• Issued: 07/23/2019
• Est. Priority Date: 02/28/2013
• Status: Active Grant

• Current Assignee: Zinus Incorporated
• Original Assignee: Zinus Incorporated
• Inventors: Oh, Suk Kan
• Primary Examiner(s): Kurilla, Eric J
• Application Number:
  US13/780,100
• Publication Number:
  US 20140237728A1
• Time in Patent Office: 2,336 Days
• CPC Class Codes: A47C 27/144 inside the mattress or cushion
• CPC Class Codes: A47C 27/146 on the outside surface of the mattress or cushion
• CPC Class Codes: A47C 27/148 of different resilience
• CPC Class Codes: A47C 27/15 consisting of two or more layers A47C27/16 takes precedence

Abstract

A symmetrical zoned foam mattress includes an upper foam layer with a wavy lower side and a lower foam layer with a wavy upper side. The lower layer has top, middle and bottom lateral valleys. The wavy lower side of the upper layer is glued to the wavy upper side of the lower layer. The top lateral valley has a minimum located within eighteen inches of the top head end of the lower layer. The bottom lateral valley has a minimum located within eighteen inches of the bottom foot end of the lower layer. A center plane intersects the lower foam layer at a minimum of the middle lateral valley. The minimum of each of the top and bottom lateral valleys is about fifteen inches from the end of the mattress regardless of whether the consumer chooses to use the top or bottom end as the head of the mattress.

Claims

1. A mattress comprising:

an upper foam layer with a wavy lower side having a top upside-down hill; and

a lower foam layer with a wavy upper side, a center plane, a top and a bottom, wherein the wavy lower side of the upper foam layer is adjacent to the wavy upper side of the lower foam layer, wherein the lower foam layer has a top lateral valley, a middle lateral valley and a bottom lateral valley, wherein the top upside-down hill of the upper foam layer fits into and is adjacent to the top lateral valley of the lower foam layer, wherein the top lateral valley has a minimum located between twelve and eighteen inches from the top of the lower foam layer, wherein the bottom lateral valley has a minimum located within eighteen inches of the bottom of the lower foam layer, and wherein the center plane intersects the lower foam layer at a minimum of the middle lateral valley.

2. The mattress of claim 1, wherein a cross section of the wavy upper side forms a curve, and wherein the curve from the center plane towards the top is a mirror image of the curve from the center plane towards the bottom.

3. The mattress of claim 1, wherein the upper foam layer together with the lower foam layer have a combined thickness that remains constant from the top to the bottom of the mattress.

4. The mattress of claim 1, wherein the top lateral valley and the bottom lateral valley are disposed symmetrically to the center plane.

5. The mattress of claim 1, wherein the lower foam layer has a top lateral hill between the top lateral valley and the middle lateral valley, and wherein the top lateral hill has a maximum located within eighteen inches of the center plane.

6. The mattress of claim 1, wherein the upper foam layer is made of memory foam, and the lower foam layer is made of high-density polyurethane foam.

7. The mattress of claim 6, wherein the memory foam above the top lateral valley of the lower foam layer imparts an indentation load deflection (ILD) to the mattress above the top lateral valley that allows a person'"'"'s shoulders to sink into the mattress so as to keep the person'"'"'s spine straight.

8. The mattress of claim 1, wherein the mattress has a lower indentation load deflection (ILD) above the top lateral valley than above other regions immediately adjacent to the top lateral valley.