Mattress with foam springs

• US 9,370,253 B2
• Filed: 10/22/2007
• Issued: 06/21/2016
• Est. Priority Date: 08/29/2006
• Status: Active Grant

• Current Assignee: Hsiu Chen Liao
• Original Assignee: Hsiu Chen Liao
• Inventors: Rawls-Meehan, Martin B
• Primary Examiner(s): Sosnowski, David E
• Application Number:
  US11/876,741
• Publication Number:
  US 20080281613A1
• Time in Patent Office: 3,165 Days
• Field of Search: 572/7, 574/0, 571/7, 571/8, 571/9, 572/0, 573/9, 570/6, 568/5, 705/1, 267/142, 267/245
• 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

An aspect of the present invention relates to a method and system of receiving information of a user'"'"'s support facility comfort requirements; using a software application to determine a proper support facility firmness configuration to match the user'"'"'s requirement; selecting foam springs with the proper user required firmness as determined by the software application; and configuring the selected foam springs within the support facility to match the user'"'"'s firmness requirements.

Claims

1. A mattress assembly, comprising:

a mattress having a plurality of foam springs arranged into a plurality of zones, each foam spring of the plurality of foam springs mounted in an individually removable and replaceable manner on an interior portion of the mattress such that a longitudinal axis of each foam spring of the plurality of foam springs is perpendicular to a top surface of the mattress, wherein each zone of the plurality of zones is of a different integrated firmness; and

a layer of foam configured for contacting the plurality of foam springs;

wherein the plurality of foam springs are mounted in a horizontal plane relative to the top surface of the mattress;

wherein the layer of foam is positioned above or below the horizontal plane of foam springs;

wherein the plurality of foam springs includes at least one a first foam spring characterized by a first firmness and at least a second foam spring characterized by a second firmness, wherein the first firmness is different from the second firmness;

wherein each zone of the plurality of zones includes two or more foam springs of the plurality of foam springs, each zone defining a firmness pattern embodied in at least a face of each of two or more foam springs of each respective zone, at least two of the zones having different firmness patterns; and

wherein a first firmness pattern correlates to the first firmness and a second firmness pattern correlates to the second firmness.

2. The mattress assembly of claim 1 wherein the layer of foam further includes transverse rails arranged in a grid pattern to create a pattern of holes, the pattern of holes defining a plurality of rectangular sockets, each of the rectangular sockets shaped to receive, hold, and release a corresponding individual one foam spring of the plurality of foam springs.

3. The mattress assembly of claim 1 wherein at least one zone of the plurality of zones is configured according to a user firmness requirement.

4. The mattress assembly of claim 1 wherein one zone of the plurality of zones includes a head zone with two or more foam springs of the plurality of foam springs encased in a rectangular fabric.

5. The mattress assembly of claim 1 wherein one zone of the plurality of zones includes a foot zone with two or more foam springs of the plurality of foam springs encased in a rectangular fabric.

6. The mattress assembly of claim 1 wherein each zone of the plurality of zones includes two or more foam springs of the plurality of foam springs encased in a fabric.

7. The mattress assembly of claim 1 wherein at least one zone of the plurality of zones includes a patterned holding device that securely positions two or more foam springs of the plurality of foam springs within an outer case of the mattress.

8. The mattress assembly of claim 1 wherein each zone of the plurality of zones is each encased in a respective attachment facility, each respective attachment facility encasing and containing two or more foam springs of the plurality of foam springs therein.

9. The mattress assembly of claim 1, wherein the plurality of foam springs are positioned within a pattern of holes formed in the layer of foam.

10. The mattress assembly of claim 1, wherein the first foam spring characterized by the first firmness includes a first color designation and wherein the second foam spring characterized by the second firmness includes a second color designation.

11. The mattress assembly of claim 10, wherein the first color designation and the second color designation are different.

12. The mattress assembly of claim 1, wherein at least one zone of the plurality of zones is configured to support an anatomical region selected from the group consisting of a neck region, a head region, a back region, a leg region, a shoulder region and a hip region.

13. A mattress assembly, comprising:

a mattress having a plurality of foam springs arranged into a plurality of zones, each foam spring of the plurality of foam springs mounted in an individually removable and replaceable manner on an interior portion of the mattress such that a longitudinal axis of each foam spring of the plurality of foam springs is perpendicular to a top surface of the mattress, each foam spring of the plurality of foam springs having a top face; and

a layer of foam configured for contacting the plurality of foam springs;

wherein the plurality of foam springs are mounted in a horizontal plane relative to the top surface of the mattress;

wherein the layer of foam is positioned above or below the horizontal plane of foam springs;

wherein a first zone of the plurality of zones includes at least two foam springs of the plurality of foam springs having a first firmness and a first firmness pattern embodied in at least the top faces of the at least two foam springs of the first zone, the first firmness pattern correlating to the first firmness;

wherein a second zone of the plurality of zones includes at least two foam springs of the plurality of foam springs having a second firmness and a second firmness pattern embodied in at least the top faces of the at least two foam springs of the second zone, the second firmness pattern correlating to the second firmness;

wherein the first firmness and the second firmness are different from each other; and

wherein the first firmness pattern and the second firmness pattern are different from each other.

14. The mattress assembly of claim 13, wherein a third zone of the plurality of zones includes at least two foam springs of the plurality of foam springs having a third firmness and a third firmness pattern embodied in at least the top faces of the at least two foam springs of the third zone, the third firmness pattern correlating to the third firmness;

wherein the first firmness, the second firmness and the third firmness are different from each other; and

wherein the first firmness pattern, the second firmness pattern and the third firmness pattern are different from each other.

15. A mattress assembly comprising:

a mattress having a plurality of foam springs arranged into a plurality of zones, each foam spring of the plurality of foam springs mounted in an individually removable and replaceable manner on an interior portion of the mattress such that a longitudinal axis of each foam spring of the plurality of foam springs is perpendicular to a top surface of the mattress, each foam spring of the plurality of foam springs having a top face;

a layer of foam configured for contacting the plurality of foam springs;

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

wherein the plurality of foam springs are mounted in a horizontal plane relative to the top surface of the mattress;

wherein the layer of foam is positioned above or below the horizontal plane of foam springs;

wherein a first zone of the plurality of zones includes at least two foam springs of the plurality of foam springs having a first firmness and a first firmness pattern embodied in at least the top faces of the at least two foam springs of the first zone, the first firmness pattern correlating to the first firmness;

wherein a second zone of the plurality of zones includes at least two foam springs of the plurality of foam springs having a second firmness and a second firmness pattern embodied in at least the top faces of the at least two foam springs of the second zone, the second firmness pattern correlating to the second firmness;

wherein the first firmness and the second firmness are different from each other;

wherein the first firmness pattern and the second firmness pattern are different from each other; and

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