Multi-zone mattress

• US 10,542,825 B1
• Filed: 07/12/2017
• Issued: 01/28/2020
• Est. Priority Date: 07/12/2017
• Status: Active Grant

• Current Assignee: ProTech, LLC
• Original Assignee: ProTech, LLC
• Inventors: Antinori, Steven J., Frame, Bill, Studner, Jon
• Primary Examiner(s): Polito, Nicholas F
• Assistant Examiner(s): Zaman, Rahib T
• Application Number:
  US15/731,633
• Time in Patent Office: 930 Days
• CPC Class Codes: A47C 27/062 of different resiliencies
• CPC Class Codes: A47C 27/064 Pocketed springs
• CPC Class Codes: A47C 27/065 of special shape
• CPC Class Codes: A47C 27/142 with projections, depressions or cavities
• CPC Class Codes: A47C 27/144 inside 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
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: A47C 31/02 Upholstery attaching means quilting, quilting means, fastening, fixing or finishing upholstery B68G7/00
• CPC Class Codes: A47C 31/123 for beds or mattresses

Abstract

A multi-zone mattress comprising a top layer, an intermediate layer and a bottom layer disposed in substantially parallel relationship relative to each other including a first plurality of zones each having a first firmness profile to support a person thereon separated by a second plurality of zones each having a second firmness profile less than the firmness of the first firmness profile of the first plurality of zones, the first plurality of zones and the second plurality of zones each cooperatively formed by corresponding sections of the top layer, intermediate layer and bottom layer disposed in substantially parallel alignment relative to each other.

Claims

1. A mattress comprising a top layer, an intermediate layer and a bottom layer disposed in substantially parallel relationship relative to each other including a first plurality of zones each having a first firmness profile to support a person thereon separated by a second plurality of zones each having a second firmness profile less than said firmness of said first firmness profile of said first plurality of zones, said first plurality of zones and said second plurality of zones each cooperatively formed by corresponding sections of said top layer, said intermediate layer and said bottom layer disposed in substantially parallel alignment relative to each other wherein said top layer comprises an outer upholstery or fabric panel and an inner fabric backing having a panel of resilient material disposed therebetween, said outer upholstery or fabric panel comprises a first plurality of sections including a proximal section, a middle section and a distal section separated by a second plurality of sections including a pair of interior sections, said first plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections having a second firmness profile less than said first firmness profile of said first plurality of sections.

2. The mattress of claim 1 wherein said intermediate support layer comprises an intermediate panel or block of resilient material.

3. The mattress of claim 2 wherein said bottom foundation layer comprises a foundation resilient base of coil springs arranged or disposed in rows and columns.

4. The mattress of claim 1 wherein said second plurality of sections further comprises a pair of exterior sections formed on each end portion of said top layer of said mattress.

5. The mattress of claim 1 wherein said intermediate support layer comprises a panel or block of resilient material comprising said first plurality of sections including a proximal section, a middle section and a distal section separated by said second plurality of sections including a pair of interior sections, said first plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections of said intermediate support layer having a second firmness profile less than the first firmness profile of said first plurality of sections of said intermediate support layer.

6. The mattress of claim 5 wherein said second plurality of sections of said intermediate support layer further comprises a pair of exterior sections formed on each end portion of said intermediate support layer of said mattress.

7. The mattress of claim 5 wherein said bottom foundation layer comprises a foundation resilient base comprising said first plurality of sections including a proximal section, a middle section and a distal section separated by said second plurality of sections including a pair of interior sections, said plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections of said bottom foundation layer having a second firmness profile less than the first firmness profile of the said first plurality of sections of said bottom foundation layer.

8. The mattress of claim 7 wherein said second plurality of sections of said bottom foundation layer may further comprises a pair of exterior sections formed on each end portion of said bottom foundation layer of said mattress.

9. The mattress of claim 7 wherein said proximal section of said top layer, said proximal section of said intermediate support layer and said proximal section of said bottom foundation layer cooperatively form a proximal support zone;

said middle section of said top layer, said middle section of said intermediate support layer and said middle section of said bottom foundation layer cooperatively form a middle support zone and said distal section of said top layer, said distal section of said intermediate support layer and said distal section of said bottom foundation layer cooperatively form a distal support zone to form the said first plurality of zones having a first firmness profile to support a person on the mattress.

10. The mattress of claim 7 wherein corresponding interior sections of said top layer, said intermediate support layer and said bottom foundation layer cooperatively form corresponding second plurality of zones having a firmness profile less than the first firmness profile of said first plurality of zones.

11. The mattress of claim 1 wherein said proximal section, said intermediate section and said distal section of said top layer each comprises a separate panel of fabric having a weight or density greater than the weight or density of said separate panels forming said interior sections.

12. The mattress of claim 1 wherein said top layer comprises a single sheet of fabric having a second sheet of fabric sewn or otherwise held in place on said single sheet of fabric.

13. The mattress of claim 5 wherein said intermediate layer comprises a panel or block having a plurality of resilient projections extending upwardly from the upper surfaces of said interior sections.

14. The mattress of claim 7 wherein said bottom foundation layer comprises a plurality of coil springs arranged in columns, said coil springs of said first plurality of zones in adjacent rows are off-set to form a nested configuration and said plurality of coil springs of said interior sections are symmetrically arranged in rows and columns such that nested configurations are firmer than the symmetrically non-nested configurations to provide more support than the symmetrical non-nested configurations.

15. The mattress of claim 7 wherein said bottom foundation layer of said mattress comprises a plurality of symmetrically arranged coil springs, said coil springs of said proximal section, said middle section and said distal section are less resilient than said coil springs of said interior sections.

16. The mattress of claim 5 wherein said intermediate layer comprises a block of resilient material including a plurality of substantially convex resilient projections extending upwardly from said first plurality of sections and a plurality of substantially convex resilient projections extending upwardly from said second plurality of sections;

an upper surface of said substantially convex resilient projections of said first plurality of sections being greater than said upper surfaces of said substantially convex resilient projections of said second plurality of sections.

17. The mattress of claim 16 wherein said a plurality of substantially convex resilient projections extending upwardly from said second plurality of sections are disposed in spaced relationship relative to each other.

18. The mattress of claim 5 wherein upper surfaces of said first plurality of sections of said intermediate layer are substantially flat and a plurality of resilient projections extend upwardly from said upper portions of said interior sections.

19. The mattress of claim 18 wherein adjacent resilient projections within each said interior section is separated by a trough and upper surfaces of said resilient projections are substantially flat.

21. The mattress of claim 16 wherein said intermediate layer comprises a block of resilient material including a plurality of substantially convex resilient projections extending upwardly from said first plurality of sections and a plurality of substantially convex resilient projections extending upwardly from said second plurality of sections;

an upper surface of said substantially convex resilient projections of said first plurality of sections being greater than said upper surfaces of said substantially convex resilient projections of said second plurality of sections.

22. The mattress of claim 17 wherein said a plurality of substantially convex resilient projections extending upwardly from said second plurality of sections are disposed in spaced relationship relative to each other.

20. A mattress comprising a top layer, an intermediate layer and a bottom layer disposed in substantially parallel relationship relative to each other including a second plurality of zones each having a first firmness profile to support a person thereon separated by a first plurality of zones each having a second firmness profile less than the firmness of said first firmness profile of said first plurality of zones, said first plurality of zones and said second plurality of zones each cooperatively formed by corresponding sections of said top layer, said intermediate layer and said bottom layer disposed in substantially parallel alignment relative to each other, said top layer comprises an outer upholstery or fabric panel and an inner fabric backing having a panel of resilient material disposed therebetween, said intermediate support layer comprises an intermediate panel or block of resilient material, said outer upholstery or fabric panel comprises a second plurality of sections including a proximal section, a middle section and a distal section separated by a first plurality of sections including a pair of interior sections, said first plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections having a second firmness profile less than said first firmness profile of said first firmness profile of said first plurality of sections, said intermediate support layer comprises a panel or block of resilient material comprising said second plurality of sections including a proximal section, a middle section and a distal section separated by said first plurality of sections including a pair of interior sections, said first plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections of said intermediate support layer having a second firmness profile less than first firmness profile of said first plurality of sections of said intermediate support layer, and said bottom foundation layer comprises a resilient base comprising said second plurality of sections including a proximal section, a middle section and a distal section separated by said first plurality of sections including a pair of interior sections, said plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections of said bottom foundation layer having a second firmness profile less than said first firmness profile of the said first plurality of sections of said bottom foundation layer.

23. The mattress of claim 20 wherein said second plurality of sections of said intermediate support layer further comprises a pair of exterior sections formed on each end portion of said intermediate support layer of said mattress and said bottom foundation layer comprises a foundation resilient base comprising said first plurality of sections including a proximal section, a middle section and a distal section separated by said second plurality of sections including a pair of interior sections, said plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections of said bottom foundation layer having a second firmness profile less than the first firmness profile of the said first plurality of sections of said bottom foundation layer.

24. A mattress comprising a top layer, an intermediate layer and a bottom layer disposed in substantially parallel relationship relative to each other including a first plurality of zones each having a first firmness profile to support a person thereon separated by a second plurality of zones each having a second firmness profile less than the firmness of said first firmness profile of said first plurality of zones, said first plurality of zones and said second plurality of zones each cooperatively formed by corresponding sections of said top layer, said intermediate layer and said bottom layer disposed in substantially parallel alignment relative to each other wherein said top layer comprises an outer upholstery or fabric panel having a first plurality of sections including a proximal section, a middle section and a distal section separated by a second plurality of sections including a pair of interior sections, said first plurality of sections having a first firmness profile to support a person thereon and said second plurality of sections having a second firmness profile less than said first firmness profile of said first plurality of sections.