Foam spring mattress configured with variable firmness

• US 9,510,690 B2
• Filed: 09/14/2015
• Issued: 12/06/2016
• 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:
  US14/853,453
• Publication Number:
  US 20160029811A1
• Time in Patent Office: 449 Days
• Field of Search: 574/0, 573/8, 572/7, 573/0
• US Class Current: 1/1
• 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 27/144 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: 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

This disclosure concerns a method of configuring a foam spring mattress including assigning a relevance rating to a foam spring location in the mattress, wherein the relevance rating relates to the relevance of the location to the impact it has on the firmness feel of the mattress and configuring a plurality of foam springs of varied firmnesses in a mattress according to a placement pattern to obtain a firmness, wherein the placement pattern is generated based on a match between a foam spring of a particular firmness and the relevance rating.

Claims

1. A mattress comprising:

a containment facility;

a plurality of generally barrel shaped foam springs each having a side surface and a pair of opposed end surfaces, the plurality of foam springs being disposed side by side in the containment facility such that the side surfaces of the foam springs are in contact with each other, the foam springs being individually removable and replaceable in the containment facility;

each of the foam springs having a color that is visible when viewing the foam springs disposed in the containment facility, the color of each spring selected from a plurality of different colors;

each of the foam springs having a firmness selected from a plurality of different firmnesses, the color of each foam spring providing an indication of the firmness such that springs with different firmnesses have visually distinguishably different colors; and

the plurality of foam springs disposed in the containment facility including a plurality of different firmnesses and associated colors such that the plurality of foam springs form a color pattern indicative of a firmness profile of the mattress;

wherein the pattern;

(i) is operable to provide a firmness configuration corresponding to user input relating to the firmness profile of the mattress, the user input determining the individual positioning and individual placement of the foam springs disposed in the containment facility, and (ii) includes an arrangement of foam springs based on foam spring color.

2. A method of re-configuring a foam spring mattress, comprising:

receiving a first input relating to a first firmness of a mattress;

assigning a first relevance rating to a first foam spring location in the mattress, wherein the first relevance rating relates to the relevance of the first foam spring location to the impact it has on the first firmness feel of the mattress;

assigning a second relevance rating to a second foam spring location in the mattress, wherein the second relevance rating relates to the relevance of the second foam spring location to the impact it has on the first firmness feel of the mattress;

generating a first foam spring placement pattern based on;

(i) the first input relating to the first firmness of the mattress, (ii) a match between foam springs of a first particular firmness and the first relevance rating, and (iii) a match between foam springs of a second particular firmness and the second relevance rating;

configuring a plurality of foam springs of varied firmnesses in the mattress according to a first placement pattern to obtain the first firmness of the mattress, the foam springs of the first particular firmness are a first color and the foam springs of the second particular firmness are a second color different from the first color;

receiving a second input relating to a second firmness of the mattress;

assigning a third relevance rating to the first foam spring location in the mattress, wherein the third relevance rating relates to the relevance of the first foam spring location to the impact it has on the second firmness feel of the mattress;

assigning a fourth relevance rating to the second foam spring location in the mattress, wherein the fourth relevance rating relates to the relevance of the second foam spring location to the impact it has on the second firmness feel of the mattress;

generating a second foam spring placement pattern based on;

(i) the second input relating to the second firmness of the mattress, (ii) a match between foam springs of a third particular firmness and the third relevance rating, and (iii) a match between foam springs of a fourth particular firmness and the fourth relevance rating;

re-configuring the plurality of foam springs of varied firmnesses in the mattress according to the second placement pattern to obtain the second firmness of the mattress, the foam springs of the third particular firmness are a third color and the foam springs of the fourth particular firmness are a fourth color different from the third color.

3. The method of claim 2, wherein the first foam spring location includes areas designated for shoulders and hips;

and

wherein the second foam spring location includes outer edge areas and areas designated for feet.

4. The method of claim 3, wherein the first and second relevance ratings are numerical relevance ratings;

wherein the first relevance rating is a first number and the second relevance rating is a second number different from the first number; and

wherein the first number is greater than the second number.

5. The method of claim 2, wherein the mattress includes a top cover that is resealable.

6. The method of claim 2, wherein the same set of foam springs are used in the re-configuring without addition or subtraction.

7. The method of claim 2, wherein the first and second relevance ratings are numerical relevance ratings;

and

wherein the first relevance rating is a first number and the second relevance rating is a second number different from the first number.

8. A method of configuring a foam spring mattress, comprising:

receiving at least one input relating to a firmness of a mattress;

assigning a first relevance rating to a first foam spring location in the mattress, wherein the first relevance rating relates to the relevance of the first foam spring location to the impact it has on the firmness feel of the mattress;

assigning a second relevance rating to a second foam spring location in the mattress, wherein the second relevance rating relates to the relevance of the second foam spring location to the impact it has on the firmness feel of the mattress;

generating a foam spring placement pattern based on;

(i) the at least one input relating to the firmness of the mattress, (ii) a match between foam springs of a first particular firmness and the first relevance rating, and (iii) a match between foam springs of a second particular firmness and the second relevance rating;

configuring a plurality of foam springs of varied firmnesses in the mattress according to the foam spring placement pattern to obtain the firmness of the mattress;

wherein the foam springs of the first particular firmness are a first color and the foam springs of the second particular firmness are a second color different from the first color.

9. The method of claim 8, wherein the first foam spring location includes areas designated for shoulders and hips;

and

wherein the second foam spring location includes outer edge areas and areas designated for feet.

10. The method of claim 8, wherein the mattress includes a top cover that is resealable.

11. The method of claim 9, wherein the first and second relevance ratings are numerical relevance ratings;

wherein the first relevance rating is a first number and the second relevance rating is a second number different from the first number; and

wherein the first number is greater than the second number.

12. The method of claim 8, wherein the first and second relevance ratings are numerical relevance ratings;

and

wherein the first relevance rating is a first number and the second relevance rating is a second number different from the first number.