Channel-cut cushion supports

• US 8,250,689 B2
• Filed: 09/16/2008
• Issued: 08/28/2012
• 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): Santos, Robert G
• Assistant Examiner(s): Polito, Nicholas
• Application Number:
  US12/283,909
• Publication Number:
  US 20090139033A1
• Time in Patent Office: 1,442 Days
• Field of Search: 565/58, 565/59, 571/8, 572/0, 5727-730, 574/0, 593/5, 593/6, 563/0, 563/2, 563/6, 564/5, 573/9
• US Class Current: 5/729
• 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 foam body made of a plurality of types of foam, each having a different mechanical characteristic, the foam body having a top surface, a bottom surface, 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 plurality of channels extending into the body perpendicularly therefrom and extending to one or more of the other surfaces of the foam body, wherein a layer of material is added to the first and second end surfaces; and

a plurality of inserts, each insert affixed within each of the plurality of channels, each insert reinforcing the body, wherein an insert of the plurality of inserts includes a row of pocket springs.

2. The mattress of claim 1, wherein the body comprises a plurality of layers of foam.

3. The mattress of claim 2, wherein the top and bottom surfaces are substantially parallel and each of the plurality of layers of foam progresses layer upon layer between the top and bottom surfaces.

4. The mattress of claim 2, wherein the first and second side surfaces are substantially parallel and each of the plurality of layers of foam progresses layer upon layer between the first and second side surfaces.

5. The mattress of claim 2, wherein the first and second end surfaces are substantially parallel and each of the plurality of layers of foam progresses layer upon layer between the first and second end surfaces.

6. The mattress of claim 1, wherein the plurality of types of foam comprises at least one of a flexible and resilient open-celled elastomeric material, a synthetic foam, a natural foam, a rubber foam, a plastic foam, a blown foam, and a molded foam.

7. The mattress of claim 1, wherein a mechanical characteristic comprises at least one of a firmness, a density and a support characteristic.

8. The mattress of claim 1, wherein an insert of the plurality of inserts includes one or more springs.

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

10. The mattress of claim 1, further comprising a mattress cover surrounding the mattress.

11. The mattress of claim 1, wherein an insert of the plurality of inserts is substantially flush with the channel surface.

12. The mattress of claim 1, wherein a channel of the plurality of channels extends to an opening in at least one of the surfaces adjacent to the channel surface.

13. The mattress of claim 1, wherein each insert includes one or more types of material, each material having a different mechanical characteristic.