Channel-cut cushion supports

• US 9,549,620 B2
• Filed: 12/24/2014
• Issued: 01/24/2017
• Est. Priority Date: 10/17/2002
• Status: Expired due to Term

• Current Assignee: Dreamwell Limited (Serta Simmons Bedding LLC)
• Original Assignee: Dreamwell Limited (Serta Simmons Bedding LLC)
• Inventors: Gladney, Richard F.
• Primary Examiner(s): LAGMAN, FREDERICK LYNDON
• Application Number:
  US14/582,331
• Publication Number:
  US 20150107027A1
• Time in Patent Office: 762 Days
• US Class Current: 1/1
• CPC Class Codes: A47C 23/04 using springs in compression, e.g. coiled
• CPC Class Codes: A47C 27/05 with padding material, e.g. foamed material, in top, bottom, or side layers
• CPC Class Codes: A47C 27/064 Pocketed springs
• CPC Class Codes: A47C 27/142 with projections, depressions or cavities
• 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

Abstract

The support characteristics within a foam mattress body may be varied by inserting reinforcements into channels cut or otherwise formed within the foam.

Claims

1. A mattress comprising:

a foam body comprising a parallelepiped shape having a planar top surface, a planar bottom surface, two planar side surfaces parallel to each other and perpendicular to the planar top and bottom surfaces, and two planar end surfaces parallel to each other and perpendicular to the planar top and bottom surfaces, wherein the two planar side surfaces have a length greater than the two planar end surfaces;

at least one channel disposed within the foam body along an axis connecting the two planar side surfaces; and

an insert of a size equal to the at least one channel, the insert comprising two or more adjacent rows of springs and a foam strip disposed thereon located within the at least one channel, wherein the insert, the two or more adjacent rows of springs, and the foam strip have a height equal to the channel height, and wherein the insert provides a different firmness or support characteristic than the foam body.

2. The mattress of claim 1, wherein the foam strip is selected to have a lower indention load deflection value than the foam body.

3. The mattress of claim 1, wherein the at least one channel has a rectangular cross section.

4. The mattress of claim 1, wherein the insert is of a size smaller than the at least one channel.

5. The mattress of claim 1, wherein the springs comprise two or more adjacent strings of connected pocketed coil springs.

6. The mattress of claim 1, wherein the insert is permanently affixed to a surface defining the at least one channel.

7. The mattress of claim 1, further comprising a layer of foam overlaying the planar top surface of the foam body and overlaying the insert.

8. The mattress of claim 1, wherein the at least one channel and the insert extend between the two planar side surfaces.

9. The mattress of claim 1, wherein the at least one channel and the insert extend between the two planar end surfaces.