Foam spring mattress configured with variable firmness

• US 9,504,333 B2
• Filed: 05/22/2014
• Issued: 11/29/2016
• Est. Priority Date: 08/29/2006
• Status: Active Grant

• Current Assignee: Ascion LLC
• Original Assignee: Ascion LLC
• Inventors: Rawls-Meehan, Martin B., Chang, Teng-An
• Primary Examiner(s): CONLEY, FREDRICK C
• Application Number:
  US14/285,083
• Publication Number:
  US 20140251219A1
• Time in Patent Office: 922 Days
• Field of Search: 574/0, 573/8, 572/7, 573/0
• 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 providing a bed using a plurality of interchangeable adjustable firmness springs to provide localized comfort and support to the user of the bed. The plurality of interchangeable springs may have a plurality of different firmnesses to provide customizable local comfort to a user. The foam springs are color coded based on the firmness associated with the foam spring. The foam springs have markings and/or health devices attached to an end of the foam spring.

Claims

1. In combination:

a map that defines;

(i) a first pattern of a first plurality of different firmness foam springs for a first zone of foam springs, the first pattern based on a predetermined position for the first plurality of foam springs, the first pattern providing foam spring positions and firmness values for the first plurality of foam springs, and (ii) a second pattern of a second plurality of different firmness foam springs for a second zone of foam springs, the second pattern based on a predetermined position for the second plurality of foam springs, the second pattern providing foam spring positions and firmness values for the second plurality of foam springs; and

a mattress that includes (i) a containment facility that correlates in geometry to the map and that defines predefined locations for foam spring placement; and

(ii) the first and second plurality of foam springs disposed in the predefined zones and locations defined in the containment facility based on the map, the first and second plurality of foam springs disposed in the containment facility in a single horizontal plane;

wherein each of the first and second plurality of foam springs has a characteristic firmness;

wherein the first plurality of foam springs includes foam springs with a first firmness and the second plurality of foam springs includes foam springs with a second firmness different than the first firmness;

wherein each of the first and second plurality of foam springs has a visually distinguishable color associated therewith, the foam springs with the first firmness having a first color and the foam springs with the second firmness having a second color different from the first color, with each color visible when viewing the foam springs disposed in the containment facility;

wherein individual positioning and individual placement of the foam springs in the containment facility is based on correlation of the visually distinguishable color of the foam springs with the map;

wherein the individual positioning and individual placement of the foam springs in the containment facility is operable to provide a firmness configuration corresponding to user input relating to a firmness of the mattress;

wherein the first zone of foam springs includes at least two foam springs of the first plurality of foam springs having the first firmness and having the first color, the first color correlating to the first firmness; and

wherein the second zone of foam springs includes at least two foam springs of the second plurality of foam springs having the second firmness and having the second color, the second color correlating to the second firmness.

2. A combination in accordance with claim 1, wherein each of the plurality of foam springs is barrel shaped with a flat top surface, a flat bottom surface and a curved side surface extending between the top and bottom surfaces.

3. A combination in accordance with claim 2, wherein the plurality of barrel shaped foam springs are disposed side by side in the containment facility with the side surfaces of the foam springs in contact with each other.

4. A combination in accordance with claim 1, wherein the containment facility is a webbing with a plurality of openings for receiving the foam springs.

5. A combination in accordance with claim 1, wherein an equal number of foam springs are disposed in the containment facility for a degree of firmness associated with a soft, a medium, or a hard degree of firmness.

6. A combination in accordance with claim 1, wherein the plurality of foam springs further includes foam springs with a third firmness different than the first and second firmness, the foam springs with the third firmness having a third color.

7. A combination in accordance with claim 6, wherein the plurality of foam springs further includes foam springs with a fourth firmness different than the first, second and third firmness, the foam springs with the fourth firmness having a fourth color.

8. A combination in accordance with claim 1, wherein the colors associated with foam springs are selected such that increasing firmness is indicated by a natural progression of color in a light spectrum.

9. A combination in accordance with claim 1, wherein the plurality of foam springs are disposed side by side in the containment facility with the side surfaces of the foam springs in contact with each other.

10. A combination in accordance with claim 1, wherein each of the foam springs has the same size and shape such that any of the foam springs may be disposed in any location in the containment facility.

11. A combination in accordance with claim 1, wherein each of the plurality of foam springs is individually removable and replaceable.

12. In combination:

a map that defines;

(i) a first pattern of a first plurality of different firmness foam springs for a first zone of foam springs, the first pattern based on a predetermined position for the first plurality of foam springs, the first pattern providing foam spring positions and firmness values for the first plurality of foam springs, and (ii) a second pattern of a second plurality of different firmness foam springs for a second zone of foam springs, the second pattern based on a predetermined position for the second plurality of foam springs, the second pattern providing foam spring positions and firmness values for the second plurality of foam springs; and

a mattress that includes;

(i) a containment facility that correlates in geometry to the map and that defines predefined locations for foam spring placement; and

(ii) the first and second plurality of foam springs disposed in the predefined zones and locations defined in the containment facility based on the map, the first and second plurality of foam springs disposed in the containment facility in a single horizontal plane;

wherein the first plurality of foam springs includes foam springs with a first firmness and the second plurality of foam springs includes foam springs with a second firmness different than the first firmness;

wherein each of the first and second plurality of foam springs has a visually distinguishable color associated therewith, the foam springs with the first firmness having a first color and the foam springs with the second firmness having a second color different from the first color, with each color visible when viewing the foam springs disposed in the containment facility;

wherein individual positioning and individual placement of the foam springs in the containment facility is based on correlation of the visually distinguishable color of the foam springs with the map;

wherein the individual positioning and individual placement of the foam springs in the containment facility;

(i) includes foam springs with the first firmness and foam springs with the second firmness, (ii) is operable to provide a firmness configuration corresponding to user input relating to a firmness of the mattress, the user input determining the individual positioning and individual placement of the foam springs with the first firmness and the foam springs with the second firmness 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 and the second color;

wherein the first zone of foam springs includes at least two foam springs of the first plurality of foam springs having the first firmness and having the first color, the first color correlating to the first firmness; and

wherein the second zone of foam springs includes at least two foam springs of the second plurality of foam springs having the second firmness and having the second color, the second color correlating to the second firmness.

13. A combination in accordance with claim 12, wherein each of the plurality of foam springs is barrel shaped with a flat top surface, a flat bottom surface and a curved side surface extending between the top and bottom surfaces;

and

wherein the plurality of barrel shaped foam springs are disposed side by side in the containment facility with the side surfaces of the foam springs in contact with each other.

14. A combination in accordance with claim 12, wherein the plurality of foam springs further includes foam springs with a third firmness different than the first and second firmness, the foam springs with the third firmness having a third color.

15. A combination in accordance with claim 14, wherein the plurality of foam springs further includes foam springs with a fourth firmness different than the first, second and third firmness, the foam springs with the fourth firmness having a fourth color.

16. A combination in accordance with claim 12, wherein the colors associated with foam springs are selected such that increasing firmness is indicated by a natural progression of color in a light spectrum.

17. A combination in accordance with claim 12, wherein each of the foam springs has the same size and shape such that any of the foam springs may be disposed in any location in the containment facility.

18. A combination in accordance with claim 12, wherein each of the plurality of foam springs is individually removable and replaceable.

19. A mattress comprising:

a containment facility;

a plurality of foam springs disposed in the containment facility and arranged into a plurality of zones, the plurality of foam springs including foam springs with a first firmness and foam springs with a second firmness different than the first firmness, each of the plurality of foam springs having a visually distinguishable color associated therewith, the foam springs with the first firmness having a first color and the foam springs with the second firmness having a second color different from the first color, with each color visible when viewing the foam springs disposed in the containment facility;

wherein the plurality of foam springs are disposed in the containment facility in a selected pattern and arranged into the plurality of zones, the plurality of foams springs disposed in the containment facility in a single horizontal plane;

wherein the pattern;

(i) includes foam springs with the first firmness and foam springs with the second firmness, (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 the foam springs with the first firmness and the foam springs with the second firmness 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 and the second color;

wherein the colors associated with the foam springs are selected such that increasing firmness is indicated by a natural progression of color in a light spectrum;

wherein a first zone of foam springs includes at least two foam springs having the first firmness and having the first color, the first color correlating to the first firmness; and

wherein a second zone of foam springs includes at least two foam springs having the second firmness and having the second color, the second color correlating to the second firmness.