Foam spring mattress configured with variable firmness

• US 9,307,843 B2
• Filed: 06/22/2015
• Issued: 04/12/2016
• Est. Priority Date: 08/29/2006
• Status: Active Grant

• Current Assignee: Ascion LLC
• Original Assignee: Ascion LLC
• Inventors: Rawls-Meehan, Martin B.
• Primary Examiner(s): CONLEY, FREDRICK C
• Application Number:
  US14/746,111
• Publication Number:
  US 20150282635A1
• Time in Patent Office: 295 Days
• Field of Search: 574/0, 573/8, 572/7, 573/0, 700/117, 700/108
• US Class Current: 1/1
• CPC Class Codes: A01K 1/0353 Dog beds
• CPC Class Codes: A47C 23/002 with separate resilient support elements, e.g. elastomeric springs arranged in a two-dimensional matrix pattern
• CPC Class Codes: A47C 27/065 of special shape
• CPC Class Codes: A47C 27/14 with foamed material inlays
• CPC Class Codes: A47C 27/144 inside the mattress or cushion
• CPC Class Codes: A47C 27/148 of different resilience
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: A47C 31/003 Magnets
• CPC Class Codes: A47C 31/123 for beds or mattresses
• CPC Class Codes: A47C 31/126 for chairs
• CPC Class Codes: A47C 7/027 with elastomeric springs A47C7/282 takes precedence
• CPC Class Codes: A47C 7/35 Combinations of different types of springs; Adjustable springs; Attachment of springs to other springs or to the base frame ; Springs for seat parts not provided for in other groups of this subclass
• CPC Class Codes: F16F 3/093 the springs being of different materials, e.g. having different types of rubber F16F1/3835 takes precedence
• CPC Class Codes: G06Q 10/101 Collaborative creation, e.g. joint development of products or services
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• CPC Class Codes: G06Q 30/016 After-sales
• CPC Class Codes: Y10S 5/953 Comprising structurally defined foam material or configuration
• CPC Class Codes: Y10T 29/48 Upholstered article making
• CPC Class Codes: Y10T 29/481 Method
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/49863 : with prestressing of part
• CPC Class Codes: Y10T 29/49947 : by applying separate fastener
• CPC Class Codes: Y10T 29/49948 : Multipart cooperating fastener [e.g., bolt and nut]

Abstract

A method includes selecting an arrangement of foam springs, the arrangement that matches user-selected firmness requirements; attaching foam springs to a foam panel in a removable, replaceable manner; and inserting the foam springs and the foam panel into a containment facility. A mattress includes foam springs; a foam panel to which an arrangement of the foam springs is attached in a removable, replaceable manner; a containment facility within which the foam springs and the foam panel are disposed; and a side rail with indentations within which sides of at least some of the foam springs are disposed. The mattress may also include a fabric webbing, attached to the containment facility, within which some of the foam springs are disposed in a removable, replaceable manner; and an attachment device attaching together at least two of the foam springs.

Claims

1. A mattress comprising:

a containment facility;

a plurality of foam springs disposed in the containment facility, the plurality of foam springs including at least a first foam spring defining a first firmness and at least a second foam spring defining a second firmness different from the first firmness, the first foam spring with the first firmness is a first color and the second foam spring with the second firmness is a second color different from the first color;

wherein the plurality of foam springs are disposed in the containment facility in a single horizontal plane and in a selected pattern;

wherein the pattern;

(i) includes at least one of each of the first foam spring and second foam spring, (ii) is operable to provide a firmness configuration corresponding to user input relating to a firmness of a mattress, the user input determining the individual positioning and individual placement of at least the first and second foam springs within the containment facility, (iii) includes an arrangement of foam springs based on foam spring color, and (iv) is based, at least in part, on the first color of the first foam spring and the second color of the second foam spring.

2. The mattress of claim 1, wherein the plurality of foam springs each being individually removable and replaceable in the containment facility.

3. The mattress of claim 2, wherein the containment facility includes a device configured to allow access to the plurality of foam springs.

4. The mattress of claim 1, wherein the user input is input into a computer, and wherein the pattern is selected by the computer.

5. The mattress of claim 4, wherein the computer is adapted to output a schematic representing the pattern.

6. The mattress of claim 5, wherein the schematic further represents the containment facility and the pattern of the plurality of foam springs are represented as positioned within the containment facility.

7. The mattress of claim 5, wherein the schematic includes a different color for each spring firmness.

8. The mattress of claim 1, wherein the plurality of foam springs further includes at least a third foam spring defining a third firmness different from the first and second firmness, and wherein the third spring is a third color which is different from the first color and the second color.

9. The mattress of claim 8, wherein the plurality of foam springs further includes at least a fourth foam spring defining a fourth firmness different from the first, second and third firmness, and wherein the fourth spring is a fourth color which is different from the first color, second color, and the third color.

10. The mattress of claim 1, wherein the plurality of foam springs comprise barrel shaped foam springs.

11. The mattress of claim 1, wherein the first foam spring includes a material density different from a material density of the second foam spring.

12. The mattress of claim 1, further comprising an attachment facility for attaching together one or more of the foam springs disposed in the containment facility;

and

wherein the one or more of the foam springs disposed in the containment facility are attached together via the attachment facility.

13. The mattress of claim 12, wherein the attachment facility comprises a webbing with a plurality of openings, the openings removably and replaceably receiving the at least some of the foam springs.

14. The mattress of claim 12, wherein the containment facility further includes at least one foam panel disposed above or below the foam springs disposed in the containment facility.

15. The mattress of claim 1, wherein the firmness configuration provided by the pattern of foam springs includes a plurality of regions and at least one of the regions has a different local firmness than the other regions.

16. The mattress of claim 1, wherein the plurality of foam springs are disposed in the containment facility such that the foam springs with the first color and the foam springs with the second color form a color pattern representing a firmness profile.

17. A mattress comprising:

a containment facility;

a plurality of foam springs disposed in the containment facility, the plurality of foam springs including at least a first foam spring defining a first firmness and at least a second foam spring defining a second firmness different from the first firmness, the first foam spring with the first firmness is a first color and the second foam spring with the second firmness is a second color different from the first color;

wherein the plurality of foam springs each being individually removable and replaceable in the containment facility;

wherein the plurality of foam springs are disposed in the containment facility in a single horizontal plane and in a selected pattern;

wherein the pattern;

(i) includes at least one of each of the first foam spring and second foam spring, (ii) is operable to provide a firmness configuration corresponding to user input relating to a firmness of a mattress, the user input determining the individual positioning and individual placement of at least the first and second foam springs within the containment facility, (iii) includes an arrangement of foam springs based on foam spring color, and (iv) is based, at least in part, on the first color of the first foam spring and the second color of the second foam spring; and

wherein the firmness configuration is adapted to be modified by removing and replacing at least one of the plurality of foam springs with the first color with one or more foam springs with a firmness and a color different from the first foam spring.

18. The mattress of claim 17, wherein the plurality of foam springs are disposed in the containment facility such that the foam springs with the first color and the foam springs with the second color form a color pattern representing a firmness profile.

19. A sleep system comprising:

a mattress having a plurality of foam springs, the plurality of foam springs including at least a first foam spring defining a first firmness and at least a second foam spring defining a second firmness different from the first firmness, the first foam spring with the first firmness is a first color and the second foam spring with the second firmness is a second color different from the first color;

an adjustable bed foundation supporting the mattress, the adjustable bed foundation including at least one movable section;

wherein the plurality of foam springs are disposed in the mattress in a single horizontal plane and in a selected pattern;

wherein the pattern;

(i) includes at least one of each of the first foam spring and second foam spring, (ii) is operable to provide a firmness configuration corresponding to user input relating to a firmness of a mattress, the user input determining the individual positioning and individual placement of at least the first and second foam springs within the containment facility, (iii) includes an arrangement of foam springs based on foam spring color, and (iv) is based, at least in part, on the first color of the first foam spring and the second color of the second foam spring; and

wherein the at least one movable section is configured to move at least a portion of the mattress.