Foam mattress with resilient reinforcing members and air channels

• US 9,259,099 B1
• Filed: 04/28/2014
• Issued: 02/16/2016
• Est. Priority Date: 04/30/2013
• Status: Active Grant

• Current Assignee: Sound Sleep Products, Inc.
• Original Assignee: Sound Sleep Products, Inc.
• Inventors: Larsen, John Robert, Horton, Peter Henry, Puterbaugh, David E., Anderson, Thomas R.
• Primary Examiner(s): Cuomo, Peter M
• Assistant Examiner(s): Wilson, Brittany
• Application Number:
  US14/263,398
• Time in Patent Office: 659 Days
• Field of Search: 572/1, 573/0, 572/7, 572/2, 574/0, 590/1
• US Class Current: 1/1
• CPC Class Codes: A47C 21/042 for ventilating or cooling A47C21/028 and A47C27/007 take precedence
• CPC Class Codes: A47C 21/046 without active means, e.g. with openings or heat conductors
• CPC Class Codes: A47C 27/14 with foamed material inlays
• CPC Class Codes: A47C 27/142 with projections, depressions or cavities
• CPC Class Codes: A47C 27/144 inside the mattress or cushion
• CPC Class Codes: A47C 27/148 of different resilience
• CPC Class Codes: A47C 27/15 consisting of two or more layers A47C27/16 takes precedence
• CPC Class Codes: A47C 27/16 reinforced with sheet-like or rigid elements, e.g. profiled
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material

Abstract

A mattress comprising a foam base, a foam core, and a foam comfort layer. The foam core may be reinforced with firmer transverse members selectively placed along the length of the core. The core may also include air passages. The comfort layer may comprise interlocking upper and lower layers configured to form ventilation channels that operate in a bellows-like fashion moving moist, warm out and drawing fresh air in as the sleeping body moves and shifts through the sleep cycle. The ventilation channels in the core and the comfort layer provide for effective dissipation of heat and moisture even from the innermost regions of the mattress. A cooling gel top layer may be included, and the entire assembly may be covered with a fabric top panel and surround. The surround may be vented to facilitate air movement in and out of the mattress.

Claims

1. A foam mattress comprising:

a foam base;

a foam core above the foam base; and

a comfort layer above the foam core, wherein the comfort layer comprises a top layer with a profiled lower surface and a bottom layer with a profiled upper surface, the profiled upper and lower surfaces configured for interlocking engagement and to provide ventilation channels within the interlocking top and bottom layers, which ventilation channels extend continuously through the comfort layer to allow air movement therethrough and to dissipate heat and moisture from the center of the comfort layer to the periphery.

2. The foam mattress of claim 1 wherein the one of the profiled upper surface of the bottom layer and the profiled lower surface of the top layer comprises a plurality of ridges and wherein the other one of the profiled upper surface of the bottom layer and the profiled lower surface of the top layer comprises a plurality of the grooves, wherein the ridges are sized so that when received in the grooves, upper the interlocking ridges and grooves define the ventilation channels between the inner sidewalls of the grooves and the outer side walls of the ridges.

3. The foam mattress of claim 2 wherein one of the top and bottom layers of the comfort layer is formed of memory foam.

4. The foam mattress of claim 3 wherein the top layer of the comfort layer is formed of memory foam.

5. The foam mattress of claim 1 further comprising a gel layer on top of the comfort layer.

6. The foam mattress of claim 5 wherein the gel layer comprises a layer of medical grade gel between upper and lower layers of memory foam.

7. The foam mattress of claim 6 further comprising a fabric cover panel covering the top of the gel layer.

8. The foam mattress of claim 7 further comprising a fabric surround extending from the periphery of the fabric cover panel to the bottom of the base layer.

9. The foam mattress of claim 8 wherein the fabric surround comprises a circumferential section of open weave material to facilitate the passage of air therethrough.

10. The foam mattress of claim 1 further comprising a fabric surround extending around the periphery of assembled comfort, core, and base layers.

11. The foam mattress of claim 10 wherein the fabric surround comprises a circumferential section of open weave material to facilitate the passage of air therethrough.

12. The foam mattress of claim 1 wherein the foam core comprises:

a core body formed of resilient material and having upper and lower surfaces, first and second ends, and first and second sides, wherein the distance between the first and second sides defines the width of the body and the distance between the first and second ends defines the length of the body, wherein the length of the body defines a first end zone, a second end zone, and a central zone extending between the first and second end zones; and

a plurality of elongate resilient reinforcing members, each having a length corresponding to the width of the body of the foam core and extending transversely completely through the body between the first and second sides and being permanently fixed therein, wherein the plurality of reinforcing members includes at least two members in the central zone, and at least one member in each of the head and foot zones, and wherein the firmness of the reinforcing members is at least about 1.5 times the firmness of the core body.

13. The foam mattress of claim 12 wherein each of the plurality of reinforcing members is cylindrical in shape.

14. The foam mattress of claim 12 wherein the at least two reinforcing members in the central zone comprises four spaced apart members in the central zone.

15. The foam mattress of claim 12 wherein the plurality of reinforcing members are formed of polyurethane foam having a firmness of between about 1.5 to about four times the firmness of the core body.

16. The foam mattress of claim 12 wherein the plurality of reinforcing members are formed of polyurethane foam having a firmness of about three times the firmness of the core body.