Mattress

• US 7,520,012 B2
• Filed: 03/08/2006
• Issued: 04/21/2009
• Est. Priority Date: 03/08/2005
• Status: Active Grant

• Current Assignee: Continental Silverline Products, L.P.
• Original Assignee: Continental Silverline Products LP General Partner, Continental Silverline Products Management LLC
• Inventors: Robins, John A.
• Primary Examiner(s): Trettel; Michael
• Application Number:
  US11/370,694
• Publication Number:
  US 20060288492A1
• Time in Patent Office: 1,140 Days
• Field of Search: 572/4, 573/6, 574/0, 572/7
• US Class Current: 5/740
• 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 27/15 consisting of two or more layers A47C27/16 takes precedence
• CPC Class Codes: A47C 27/22 with both fibrous and foamed material inlays

Abstract

A mattress.

Claims

1. A mattress comprising:

a top layer of visco elastic foam comprising a substantially planar top surface, a thickness of approximately 3.5 inches, and a density of approximately 5 lbs/ft³;

a bottom layer of urethane foam comprising a thickness of approximately 4.5 inches and a density of approximately 1.65 lbs/ft³; and

a polyester fiber intermediate layer positioned between the top layer of visco elastic foam and the bottom layer of urethane foam.

2. The mattress of claim 1 wherein the polyester fiber intermediate layer comprises an approximately 1.1 ounce low melt polyester fiber.

3. The mattress of claim 1 where the polyester fiber intermediate layer comprises an approximately 100% spun polyester fiber on a top surface and a bottom surface of the intermediate layer and an approximately 100% monofilament polyester fiber spacer located between the top surface and the bottom surface of the intermediate layer.

4. The mattress of claim 1 further comprising:

a non-waterproof covering layer encasing the top layer of visco elastic foam, the bottom layer of urethane foam, and the polyester fiber intermediate layer.

5. A mattress comprising:

a top layer of visco elastic foam comprising a ventilated non-planar top surface, a thickness of approximately 4 inches, and a density of approximately 5 lbs/ft³;

a bottom layer of urethane foam comprising a thickness of approximately 6 inches and a density of approximately 1.65 lbs/ft³; and

a polyester fiber intermediate layer positioned between the intermediate layer of visco elastic foam and the bottom layer of urethane foam.

6. The mattress of claim 5 wherein the polyester fiber intermediate layer comprises an approximately 1.1 ounce low melt polyester fiber.

7. The mattress of claim 5 where the polyester fiber intermediate layer comprises an approximately 100% spun polyester fiber on a top surface and a bottom surface of the intermediate layer, and an approximately 100% monofilament polyester fiber spacer located between the top surface and the bottom surface of the intermediate layer.

8. The mattress of claim 5 further comprising:

a non-waterproof covering layer encasing the top layer of visco elastic foam, the bottom layer of urethane foam, and the polyester fiber intermediate layer.

9. A mattress comprising:

a top layer of talalay latex natural foam comprising a thickness of approximately 1 inch and a density of approximately 2.5 lbs/ft³;

an intermediate layer of visco elastic foam comprising a ventilated nonplanar top surface, a thickness of approximately 4 inches, and a density of approximately 5 lbs/ft³;

a bottom layer of urethane foam comprising a thickness of approximately 6 inches and a density of approximately 1.65 lbs/ft³; and

a polyester fiber intermediate layer positioned between the top layer of visco elastic foam and the bottom layer of urethane foam.

10. The mattress of claim 9 wherein the polyester fiber intermediate layer comprises an approximately 1.1 ounce low melt polyester fiber.

11. The mattress of claim 9 where the polyester fiber intermediate layer comprises an approximately 100% spun polyester fiber on a top surface and a bottom surface of the intermediate layer, and an approximately 100% monofilament polyester fiber spacer located between the top surface and the bottom surface of the intermediate layer.

12. The mattress of claim 9 further comprising:

a non-waterproof covering layer encasing the top layer of talalay latex natural foam, the intermediate layer of visco elastic foam, the bottom layer of urethane foam, and the intermediate polyester fiber layer.

13. A mattress comprising:

a layer of urethane foam;

a layer of visco elastic foam; and

an intermediate layer for enhancing humidity transport positioned between the layer of urethane foam and the layer of visco elastic foam;

the intermediate layer comprising polyester fiber.

14. The mattress of claim 13 wherein said polyester fiber comprises a low melt polyester fiber.

15. The mattress of claim 13 wherein the polyester fiber comprises 1.1 ounce low melt polyester fiber.

16. The mattress of claim 13 wherein the polyester fiber comprises spun polyester fiber.

17. The mattress of claim 13 wherein the intermediate layer comprises a monofilament polyester fiber spacer.

18. The mattress of claim 13 wherein the intermediate layer comprises a spun polyester fiber top surface and bottom surface and a monofilament polyester fiber spacer located between the top and bottom surface.

19. The mattress of claim 18 wherein the intermediate layer comprises a top and bottom surface, both comprising about 100% spun polyester fiber, and a spacer located between said top and bottom layer, said spacer comprising about 100% monofilament polyester fiber.

20. A mattress comprising:

a layer of urethane foam;

a layer of visco elastic foam;

an intermediate layer for enhancing humidity transport positioned between the layer of urethane foam and the layer of visco elastic foam; and

a layer of natural foam positioned on top of the layer of visco elastic foam, the layer of urethane foam, and the intermediate layer.

21. The mattress of claim 20 wherein the layer of natural foam comprises a thickness of about 1 inch.

22. The mattress of claim 20 wherein the layer of natural foam comprises density of about 2.5 lbs/ft³.

23. The mattress of claim 20 wherein the layer of natural foam comprises talalay latex natural foam.

24. The mattress of claim 20 further comprising:

a covering layer encasing the layer of urethane foam, the layer of visco elastic foam, the intermediate layer and the layer of natural foam.

25. The mattress of claim 24 wherein the covering layer provides a breathable area around the perimeter of the mattress.

26. The mattress of claim 24 wherein the covering layer comprises a non-waterproof material.

27. A method for manufacturing a mattress comprising:

providing a layer of urethane foam having a urethane foam top surface;

coupling an intermediate layer for enhancing humidity transport to said urethane foam top surface, the intermediate layer having an intermediate layer top surface;

coupling a layer of visco elastic foam to said intermediate layer top surface, said visco elastic foam having a visco elastic foam top surface; and

coupling a layer of natural foam to the visco elastic foam top surface.

28. The method of claim 27 further comprising:

increasing the layer of natural foam, the layer of visco elastic foam, the intermediate layer and the layer of urethane foam with a covering layer.