Foam Mattress With Symmetrical Wavy Foam Layers

• US 20140237728A1
• Filed: 02/28/2013
• Published: 08/28/2014
• Est. Priority Date: 02/28/2013
• Status: Active Grant

• Current Assignee: Zinus Incorporated
• Original Assignee: Zinus Incorporated
• Inventors: Oh, Suk Kan
• Granted Patent: US 10,357,115 B2
• Time in Patent Office: Days
• US Class Current: 5/730
• 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; 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 lateral valley has a minimum located within eighteen inches of 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.

9. A method comprising:

cutting a first slab of foam to form a first top lateral valley, a first top lateral hill and a middle lateral valley in an upper side of a first foam layer;

cutting a second slab of foam to form a second top lateral hill, a second top lateral valley and a middle lateral hill in a lower side of a second foam layer; and

placing the lower side of the second foam layer over the upper side of the first foam layer such that the second top lateral hill fits into the first top lateral valley, and the middle lateral hill fits into the middle lateral valley, wherein the first top lateral valley has a minimum located within eighteen inches from a maximum of the first top lateral hill, and wherein the first foam layer together with the second foam layer have a combined thickness that is constant.

10. The method of claim 9, further comprising:

cutting the first foam layer to form a first planar top side that is approximately forty inches from the middle lateral valley.

11. The method of claim 10, further comprising:

cutting the second foam layer to form a second planar top side that is approximately forty inches from the middle lateral hill, wherein the first planar top side and the second planar top side are coplanar after the placing the lower side of the second foam layer over the upper side of the first foam layer.

12. The method of claim 10, further comprising:

cutting the first foam layer to form a first planar bottom side that is approximately forty inches from the middle lateral valley, wherein the upper side from a minimum of the middle lateral valley towards the first planar top side is a mirror image of the upper side from the minimum of the middle lateral valley towards the first planar bottom side.

13. The method of claim 9, wherein the first foam layer has a top, wherein the minimum of the first top lateral valley is located within eighteen inches from the top of the first foam layer.

14. The method of claim 9, wherein the first foam layer has a center plane, and wherein the center plane intersects the upper side of the first foam layer at a minimum of the middle lateral valley.

15. The method of claim 9, wherein the cutting the first slab forms a top piece and a bottom piece, wherein the first top lateral valley and the first top lateral hill are on the bottom piece, further comprising:

forming the first foam layer by attaching the bottom piece to the top piece at a minimum of the middle lateral valley.

16. The method of claim 15, wherein the top piece has a first bottom lateral valley, and wherein the first top lateral valley and the first bottom lateral valley are disposed symmetrically to a center plane of the first foam layer that intersects the upper side of the first foam layer at the minimum of the middle lateral valley.

17. The method of claim 9, wherein an indentation load deflection (ILD) above the top lateral valley is lower than above other lateral regions immediately adjacent to the top lateral valley after the lower side of the second foam layer is placed over the upper side of the first foam layer.

18. A mattress comprising:

an upper foam layer with a planar upper side, a top, a bottom, a top shoulder zone and a bottom shoulder zone;

a lower foam layer with a planar lower side, wherein the planar lower side is parallel to the planar upper side; and

means for imparting a lower indentation load deflection (ILD) to the planar upper side above the top shoulder zone and above to the bottom shoulder zone than that exhibited above other lateral regions of the upper foam layer immediately adjacent to the top shoulder zone and to the bottom shoulder zone, wherein the top shoulder zone has a middle that is within eighteen inches of the top of the upper foam layer, wherein the bottom shoulder zone has a middle that is within eighteen inches of the bottom of the upper foam layer, and wherein the means imparts a variable thickness to the upper foam layer.

19. The mattress of claim 18, wherein the upper foam layer has a hip zone and a center plane, wherein the center plane is perpendicular to the planar upper side and midway between the top and the bottom, and wherein the hip zone has a middle disposed at the center plane of the upper foam layer.

20. The mattress of claim 18, wherein the upper foam layer has center plane that is perpendicular to the planar upper side and midway between the top and the bottom, and wherein the top shoulder zone and the bottom shoulder zone are disposed symmetrically to the center plane of the upper foam layer.

21. The mattress of claim 18, wherein the means imparts an ILD to the top shoulder zone that allows a person'"'"'s shoulders to sink into the upper side of the upper foam layer so as to keep the person'"'"'s spine straight.

22. The mattress of claim 18, wherein the upper foam layer is made of memory foam, and wherein the lower foam layer is made of high density polyurethane foam.