Mattress with removable insert

• US 5,107,558 A
• Filed: 06/28/1991
• Issued: 04/28/1992
• Est. Priority Date: 07/11/1990
• Status: Expired due to Fees

• Current Assignee: Werner Luck
• Original Assignee: Werner Luck
• Inventors: Luck, Werner
• Primary Examiner(s): TRETTEL, MICHAEL
• Application Number:
  US07/722,682
• Time in Patent Office: 305 Days
• Field of Search: 5/498, 5/450, 5/464, 5/465, 5/470, 5/481
• US Class Current: 5/727
• 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
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: A61G 7/05715 with modular blocks, or inserts, with layers of different material

Abstract

A mattress has a one-piece base of hollow fibers or polyurethane foam with a rectangular recess in the upper side of its torso supporting intermediate portion. The recess is filled by a removable insert wherein a fabric envelope contains a supply of fragmentized polyurethane foam and/or polypropylene beads or superimposed layers of foamed plastic material having different specific gravities and/or hardnesses. The base and the insert are confined in a mattress cover. The intermediate portion is harder than the leg supporting end portion of the base, and the intermediate portion has two rigid lateral sections which flank the recess between the leg supporting and head supporting end portions of the base.

Claims

1. A mattress comprising a base including a head supporting first end portion, a relatively soft leg supporting second end portion and a relatively hard torso supporting intermediate portion, said base having an upper side and a recess provided in said upper side within said intermediate portion and said intermediate portion including two substantially rigid lateral sections flanking said recess between said end portions;

an insert removably received in and at least substantially filling said recess; and

a cover surrounding said base and said insert.

2. The mattress of claim 1, wherein said base is of one piece and said lateral sections have a width in the range of 5-15 cm, particularly about 10 cm.

3. The mattress of claim 1, wherein said base contains polyurethane foam.

4. The mattress of claim 1, wherein said base contains hollow fibers.

5. The mattress of claim 1, wherein said base has an array of annular holes in said upper side.

6. The mattress of claim 1, wherein said base comprises a plurality of thermally interconnected super-imposed layers of hollow fibers.

7. The mattress of claim 1, wherein said intermediate portion of said base has a slightly convex bottom surface in said recess.

8. The mattress of claim 1, wherein said base has a height of 11-17 cm, particularly about 14 cm, and said recess has a substantially rectangular outline.

9. The mattress of claim 8, wherein said recess has a length of about 90 cm between said end portions of said base, a width of about 70 cm, and a depth of about 7 cm.

10. The mattress of claim 1, wherein said upper side of said base is rough.

11. The mattress of claim 1, wherein said intermediate portion of said base has a rough bottom surface in said recess.

12. The mattress of claim 1, wherein said upper side of said base has a napped finish.

13. The mattress of claim 1, wherein said intermediate portion of said base has a bottom surface in said recess and said bottom surface has a napped finish.

14. The mattress of claim 1, wherein said insert includes a textile envelope and a supply of fragments consisting of polyurethane foam in said envelope.

15. The mattress of claim 14, wherein at least some of said fragments have a substantially rhomboidal shape and have a plurality of gas-filled pores.

16. The mattress of claim 1, wherein said insert includes a plurality of layers consisting of foamed material and having different bulk densities.

17. The mattress of claim 16, wherein said layers have different hardnesses and include neighboring first and second layers which progressively conform to each other.

18. The mattress of claim 1, wherein said insert includes a lower layer having a first specific gravity and an upper layer having a lower second specific gravity and overlying said lower layer.

19. The mattress of claim 18, wherein said layers consist of foamed material and have spaced-apart portions which are connected to each other, said insert further comprising an envelope for said layers.

20. The mattress of claim 19, further comprising at least one row of stitches connecting said envelope to at least one of said layers.

21. The mattress of claim 1, wherein said insert includes a filler and an elastic envelope for said filler.

22. A mattress comprising a base including a head supporting first end portion, a relatively soft leg supporting second end portion and a relatively hard torso supporting intermediate portion, said base having an upper side and a recess provided in said upper side within said intermediate portion;

an insert removably received in and at least substantially filling said recess, said insert comprising a textile envelope and a supply of fragments of polyurethane foam and polypropylene beads; and

a cover surrounding said base and said insert.

23. The mattress of claim 22, wherein said beads are intermixed with said fragments, said fragments having a plurality of gas-filled pores and at least some of said fragments having a substantially rhomboidal shape.