Channel-cut cushion supports

• US 7,424,763 B2
• Filed: 05/01/2006
• Issued: 09/16/2008
• 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:
  US11/415,816
• Publication Number:
  US 20060195988A1
• Time in Patent Office: 869 Days
• Field of Search: 574/0, 572/7, 572/9, 573/0, 572/8, 575/3, 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 having a mechanical characteristic, 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 and bottom surfaces including a plurality of channels extending into the body perpendicularly therefrom; and

a plurality of inserts, each insert having a mechanical characteristic different from the mechanical characteristic of the foam and affixed within one of the plurality of channels, each insert reinforcing the body.

2. The mattress of claim 1 wherein at least one of the inserts includes one or more springs.

3. The mattress of claim 1 wherein at least one of the inserts includes a row of pocket springs.

4. The mattress of claim 1 further comprising a material that covers at least one of the channels, the material securing at least one of the inserts within one of the channels.

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

6. The mattress of claim 1, wherein at least one of the insert is substantially flush with the at least one of the top and bottom surfaces.

7. The mattress of claim 1, wherein each channel extends to an opening in at least one of the surfaces adjacent to the channel surface.

8. A method of manufacturing a mattress comprising:

providing a plurality of rectangular foam pieces to form a body of foam shaped and sized for use as a mattress;

locating a region of the body where increased support is desired;

assembling the plurality of rectangular foam pieces to form the body having a channel in the region; and

affixing an insert into the channel, the insert having a different firmness than the body of foam.

9. The method of claim 8 wherein forming the channel comprises cutting foam out of the body.

10. The method of claim 8 wherein forming the channel comprises molding the channel into the foam.

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

12. The method of claim 8, wherein the size of the insert is substantially equal to the size of the channel.