Channel-cut cushion supports
DC CAFCFirst Claim
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1. A mattress comprising:
- a multilayered foam body having a planar top surface, the foam body including a plurality of channels extending from the planar top surface into at least one of the foam layers defining the multilayered foam body; and
at least one insert having planar top and bottom surfaces affixed to each one of the plurality of channels, each insert reinforcing the foam body, wherein each of the plurality of channel has a physical shape configured to receive one or more of the inserts, wherein the inserts comprise foam and have a different mechanical property than the foam body, and wherein the insert does not entirely fill the channel.
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Abstract
The support characteristics within a foam mattress body may be varied by inserting reinforcements into channels cut or otherwise formed within the foam.
48 Citations
16 Claims
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1. A mattress comprising:
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a multilayered foam body having a planar top surface, the foam body including a plurality of channels extending from the planar top surface into at least one of the foam layers defining the multilayered foam body; and at least one insert having planar top and bottom surfaces affixed to each one of the plurality of channels, each insert reinforcing the foam body, wherein each of the plurality of channel has a physical shape configured to receive one or more of the inserts, wherein the inserts comprise foam and have a different mechanical property than the foam body, and wherein the insert does not entirely fill the channel. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of manufacturing a mattress comprising:
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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 rectangular foam pieces to form the body having a channel in the region; and affixing at least one insert having planar top and bottom surfaces into the channel, wherein the channel has a physical shape configured to receive the at least one insert, the insert having a different mechanical property than the body of the foam, and wherein the insert does not entirely fill the channel. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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Specification