AIR FLOW MATTRESS CONSTRUCTIONS AND VARIABLE DENSITY MATTRESS CORES

• US 20140033440A1
• Filed: 03/12/2013
• Published: 02/06/2014
• Est. Priority Date: 08/01/2012
• Status: Active Grant

• Current Assignee: Sealy Technology LLC (Tempur Sealy International, Inc.)
• Original Assignee: Sealy Technology LLC (Tempur Sealy International, Inc.)
• Inventors: TYREE, Steven W.
• Granted Patent: US 9,211,017 B2
• Time in Patent Office: Days
• US Class Current: 5/706
• CPC Class Codes: A47C 21/042 for ventilating or cooling A47C21/028 and A47C27/007 take precedence
• CPC Class Codes: A47C 21/046 without active means, e.g. with openings or heat conductors
• CPC Class Codes: A47C 23/04 using springs in compression, e.g. coiled
• CPC Class Codes: A47C 27/064 Pocketed springs
• CPC Class Codes: A47C 27/081 of pneumatic type
• 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

Abstract

The present disclosure and related inventions includes various mattress constructions with improved air flow characteristics, and in particular mattress constructions which induce or control air flow when force is applied to the mattress support surface.

Claims

1. An air flow mattress comprising:

a mattress core;

a mattress topper located at the uppermost planar surface of the mattress, the mattress topper comprising one or more layers of foam;

a plurality of air flow passages in the form of elongate tubes located between the mattress core and the mattress topper, each air flow passage having at least one intake and an exhaust, the exhaust having a valve which operates as a one-way valve to allow air to escape the air flow passage.

2. The air flow mattress of claim 1, wherein the mattress core comprises one or more foam layers.

3. The air flow mattress of claim 1, wherein the mattress core comprises an innerspring.

4. The air flow mattress of claim 1, wherein the mattress core comprises one or more air bladders.

5. The air flow mattress of claim 1, wherein the mattress core and mattress topper may be made of polyurethane foam or visco-elastic foam.

6. The air flow mattress of claim 1, wherein the plurality of air flow passages are embedded in a layer of foam.

7. The air flow mattress of claim 1, wherein the plurality of air flow passages transverse the width of the mattress.

8. The air flow mattress of claim 1, wherein the plurality of air flow passages transverse the length of the mattress.

9. An air flow mattress comprising:

a mattress core;

a mattress topper located at the uppermost planar surface of the mattress, the mattress topper comprising one or more layers of foam;

a spacer fabric located between the mattress core and mattress topper, the spacer fabric having a plurality of valves disposed in an array on an upper surface of the spacer fabric, each of the plurality of valves having a generally circular opening which is hinged for opening and closing and an actuator which when opened allows air to escape the mattress.

10. The air flow mattress of claim 9, wherein each actuator is opened downward into the spacer fabric.

11. The air flow mattress of claim 10, wherein each actuator is opened by pressure applied from above by the mattress topper.

12. The air flow mattress of claim 9, wherein the plurality of valves is located at a head and foot region of the mattress.

13. The air flow mattress of claim 12, wherein the plurality of valves are oriented by the location of the hinge to induce air flow through the mattress by intake at the foot region of the mattress and exhaust at the head region of the mattress in response to changing forces applied from above.

14. An air flow mattress comprising:

a mattress core comprising two or more layers of foam material, air, springs or a combination thereof;

an intermediate layer having a plurality of openings adapted to receive an insert;

a plurality of inserts in extruded form inserted into each of the plurality of transverse openings.

15. The air flow mattress of claim 14, wherein the plurality of openings transverse a width of the mattress core.

16. The air flow mattress of claim 14, wherein the plurality of openings extend longitudinally along the length of the mattress core.

17. The air flow mattress of claim 14, wherein the plurality of inserts have a circular cross-section.

18. The air flow mattress of claim 14, wherein the plurality of inserts have a triangular cross-section.

19. The air flow mattress of claim 14, wherein the plurality of inserts extend an entire cross-sectional width of the mattress core.

20. The air flow mattress of claim 14, wherein the plurality of inserts include both right and left half inserts.