Channel-cut cushion supports

• US 20040074007A1
• Filed: 10/17/2002
• Published: 04/22/2004
• Est. Priority Date: 10/17/2002
• Status: Active Grant

• Current Assignee: Dreamwell Limited (Serta Simmons Bedding LLC)
• Original Assignee: Dreamwell Limited (Serta Simmons Bedding LLC)
• Inventors: Gladney, Richard F.
• Granted Patent: US 7,036,173 B2
• Time in Patent Office: Days
• US Class Current: 5/727
• CPC Class Codes: A47C 23/04 using springs in compression, e.g. coiled
• CPC Class Codes: A47C 27/05 with padding material, e.g. foamed material, in top, bottom, or side layers
• CPC Class Codes: A47C 27/064 Pocketed springs
• CPC Class Codes: A47C 27/142 with projections, depressions or cavities
• CPC Class Codes: A47C 27/148 of different resilience
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material

Abstract

The support characteristics within a foam mattress body may be varied by inserting reinforcements into channels cut or otherwise formed within the foam.

Claims

1. A mattress comprising:

A body made of foam, the body having a top surface, a bottom surface, a first and second side surfaces and a first and second end surfaces, at least one of the surfaces being a channel surface that includes a channel extending into the body perpendicularly therefrom; and

an insert affixed within the channel, the insert reinforcing the body.

2. The mattress of claim 1 wherein the insert includes one or more springs.

3. The mattress of claim 1 wherein the insert includes a row of pocket springs.

4. The mattress of claim 1 wherein the channel extends to an opening in at least one of the surfaces adjacent to the channel surface.

5. The mattress of claim 1 wherein the channel extends to an opening in a surface parallel to the channel surface.

6. The mattress of claim 1 further comprising a material that covers the channel, the material securing the insert within the channel.

7. The mattress of claim 6 further comprising a mattress cover surrounding the mattress.

8. The mattress of claim 1 further comprising a plurality of channels, each channel having affixed therein an insert that reinforces the body of the mattress.

9. A method of manufacturing a mattress comprising:

providing a body of foam shaped and sized for use as a mattress;

locating a region of the body where increased support is desired;

forming a channel into the body within the region; and

affixing an insert into the channel, the insert having a greater firmness than the body of foam.

10. The method of claim 9 wherein forming the channel comprises cutting foam out of the body.

11. The method of claim 9 wherein forming the channel comprises molding the channel into the foam.

12. The method of claim 9 wherein forming the channel comprises assembling a plurality of rectangular foam pieces into a mattress that includes the channel.

13. The method of claim 9 further comprising covering the mattress with one or more conventional mattress covering materials.

14. A mattress comprising:

A foam support means for supporting a person lying thereon, the foam support means including a channel within the foam support means; and

an reinforcing means within the channel for reinforcing a surface of the foam support means.

15. A mattress comprising:

A body made of foam, the body having at least one surface within a channel formed therein; and

a string of pocket springs affixed within the channel, the pocket springs having a greater firmness than the foam body.