Channel-cut cushion supports

• US 7,036,173 B2
• Filed: 10/17/2002
• Issued: 05/02/2006
• Est. Priority Date: 10/17/2002
• Status: Expired due to Term

• Current Assignee: Dreamwell Limited (Serta Simmons Bedding LLC)
• Original Assignee: Dreamwell Limited (Serta Simmons Bedding LLC)
• Inventors: Gladney, Richard F.
• Primary Examiner(s): LAGMAN, FREDERICK LYNDON
• Application Number:
  US10/274,441
• Publication Number:
  US 20040074007A1
• Time in Patent Office: 1,293 Days
• Field of Search: 574/0, 572/7, 572/9, 573/0, 572/8, 595/3, 572/0, 571/6
• US Class Current: 5/730
• 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 including one or more springs affixed within the channel, the insert reinforcing the body; and

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

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

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

4. The mattress of claim 3 further comprising a mattress cover surrounding the mattress.

5. 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;

wherein forming the channel comprises assembling a plurality of rectangular foam pieces into a mattress that includes the channel.

6. The method of claim 5 wherein forming the channel further comprises cutting foam out of the body.

7. The method of claim 5 wherein forming the channel further comprises molding the channel into the foam.

8. The method of claim 5 further comprising covering the mattress with one or more conventional mattress covering materials.

9. 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 top, bottom, first end, or second end surfaces being a channel surface that includes a channel extending into the body perpendicularly therefrom; and

an insert includinn one or more springs affixed within the channel, the insert reinforcing the body; and

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

10. The mattress of claim 9 wherein the insert includes a row of pocket springs.

11. The mattress of claim 9 further comprising a material that covers the channel, the material securing the insert within the channel.

12. The mattress of claim 11 further comprising a mattress cover surrounding the mattress.