Symmetrical pressure relief foam mattress

• US 20100223734A1
• Filed: 06/06/2009
• Published: 09/09/2010
• Est. Priority Date: 03/04/2009
• Status: Active Grant

• Current Assignee: Zinus Incorporated
• Original Assignee: Zinus Incorporated
• Inventors: Oh, Suk Kan
• Granted Patent: US 8,245,341 B2
• Time in Patent Office: Days
• US Class Current: 5/727
• CPC Class Codes: A47C 27/144 inside the mattress or cushion
• CPC Class Codes: A47C 27/148 of different resilience
• CPC Class Codes: Y10T 29/481 Method

Abstract

A symmetrical pressure relief foam mattress includes an upper foam layer placed on a zoned foam layer. A plurality of cylindrical holes are distributed throughout each of a first, a second and a third lateral region of the zoned foam layer. The first lateral region is less than twelve inches wide and has a middle that is within eighteen inches of the top of the zoned foam layer. The third lateral region is also less than twelve inches wide and has a middle that is within eighteen inches of the bottom of the zoned foam layer. The second lateral region has a middle disposed at the center axis of the zoned foam layer. The middle of both the first and third lateral regions is about fifteen inches from the edge of the mattress regardless of which end the consumer chooses to use as the head of the mattress.

Claims

1. A mattress comprising:

an upper foam layer with a lower side; and

a zoned foam layer with an upper side, a center axis, a top and a bottom, wherein the lower side of the upper foam layer is adjacent to the upper side of the zoned foam layer, wherein the zoned foam layer has a first lateral region, a second lateral region and a third lateral region, wherein a plurality of cylindrical holes are distributed throughout each of the first, second and third lateral regions, wherein the first lateral region is less than twelve inches wide and has a middle that is within eighteen inches of the top of the zoned foam layer, wherein the third lateral region is less than twelve inches wide and has a middle that is within eighteen inches of the bottom of the zoned foam layer, and wherein the second lateral region has a middle disposed at the center axis of the zoned foam layer.

2. The mattress of claim 1, wherein the first lateral region and the third lateral region are disposed symmetrically to the center axis of the zoned foam layer.

3. The mattress of claim 1, wherein the first lateral region has a width that equals that of the third lateral region, wherein the zoned foam layer has a length, and wherein the second lateral region is as wide as the length of the zoned foam layer minus six times the width of the first lateral region.

4. The mattress of claim 1, wherein the cylindrical holes pass entirely through the zoned foam layer.

5. The mattress of claim 1, wherein the upper foam layer is made of memory foam, and the zoned foam layer is made of polyurethane foam.

6. The mattress of claim 1, wherein the holes are adapted to have a spacing and a diameter that impart an indentation load deflection (ILD) to the first lateral region that allow a person'"'"'s shoulders to sink into the mattress so as to keep the person'"'"'s spine straight.

7. The mattress of claim 1, wherein the first lateral region has a lower indentation load deflection (ILD) than do other regions of the zoned foam layer immediately adjacent to the first lateral region.

8. The mattress of claim 1, wherein the cylindrical holes penetrate only part way into the zoned foam layer.

9. A method comprising:

forming a first plurality of cylindrical holes in a first lateral region of a zoned foam layer, wherein the zoned foam layer has an upper side, a top, a bottom and a center axis;

forming a second plurality of cylindrical holes in a second lateral region of the zoned foam layer;

forming a third plurality of cylindrical holes in a third lateral region of the zoned foam layer; and

placing a lower side of an upper foam layer on top of the upper side of the zoned foam layer, wherein the first lateral region is less than twelve inches wide and has a middle that is within eighteen inches from the top of the zoned foam layer, wherein the third lateral region is less than twelve inches wide and has a middle that is within eighteen inches from the bottom of the zoned foam layer, and wherein the second lateral region has a middle disposed at the center axis of the zoned foam layer.

10. The method of claim 9, wherein the first lateral region and the third lateral region are disposed symmetrically to the center axis of the zoned foam layer.

11. The method of claim 9, wherein the cylindrical holes pass entirely through the zoned foam layer.

12. The method of claim 9, wherein the cylindrical holes penetrate only part way into the zoned foam layer.

13. The method of claim 9, wherein the first lateral region has a lower indentation load deflection (ILD) than do other regions of the zoned foam layer immediately adjacent to the first lateral region.

14. The method of claim 9, wherein the holes are adapted to have a spacing and a diameter that impart an indentation load deflection (ILD) to the first lateral region that allow a person'"'"'s shoulders to sink into the mattress so as to keep the person'"'"'s spine straight.

15. A mattress comprising:

an upper foam layer with a lower side;

a zoned foam layer with an upper side, a top and a bottom, wherein the lower side of the upper foam layer is adjacent to the upper side of the zoned foam layer, and wherein the zoned foam layer has a first shoulder zone and a second shoulder zone; and

means for imparting to the first shoulder zone and the second shoulder zone a lower indentation load deflection (ILD) than that exhibited by other regions of the zoned foam layer immediately adjacent to the first shoulder zone and the second shoulder zone, wherein the first shoulder zone is less than twelve inches wide and has a middle that is within eighteen inches of the top of the zoned foam layer, and wherein the second shoulder zone is less than twelve inches wide and has a middle that is within eighteen inches of the bottom of the zoned foam layer.

16. The mattress of claim 15, wherein the zoned foam layer has a hip zone and a center axis, and wherein the hip zone has a middle disposed at the center axis of the zoned foam layer.

17. The mattress of claim 15, wherein the zoned foam layer has a center axis, and wherein the first shoulder zone and the second shoulder zone are disposed symmetrically to the center axis of the zoned foam layer.

18. The mattress of claim 15, wherein the means imparts an ILD to the first shoulder zone that allows a person'"'"'s shoulders to sink into the mattress so as to keep the person'"'"'s spine straight.

19. The mattress of claim 15, wherein the means is formed using a mold.

20. The mattress of claim 15, wherein the upper foam layer is made of memory foam, and wherein the zoned foam layer is made of polyurethane foam.