CA1327243C - Mattress - Google Patents

Mattress

Info

Publication number
CA1327243C
CA1327243C CA000614938A CA614938A CA1327243C CA 1327243 C CA1327243 C CA 1327243C CA 000614938 A CA000614938 A CA 000614938A CA 614938 A CA614938 A CA 614938A CA 1327243 C CA1327243 C CA 1327243C
Authority
CA
Canada
Prior art keywords
mattress
inner core
thickness
core region
foam material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000614938A
Other languages
French (fr)
Inventor
Alan G. Evans
Ewan J. Main
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Woodbridge Foam Corp
Original Assignee
Woodbridge Foam Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Woodbridge Foam Corp filed Critical Woodbridge Foam Corp
Priority to CA000614938A priority Critical patent/CA1327243C/en
Priority to US07/416,464 priority patent/US4975996A/en
Application granted granted Critical
Publication of CA1327243C publication Critical patent/CA1327243C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/142Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities
    • A47C27/146Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with projections, depressions or cavities on the outside surface of the mattress or cushion
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/148Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C27/00Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/20Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays with springs moulded in, or situated in cavities or openings in foamed material

Abstract

ABSTRACT

A mattress formed from foam material is provided. The mattress generally comprises a foam body having an upper surface for supporting a user and a lower surface for resting on a support. An inner core region formed from foam material having a greater Indentation Force Deflection (I.F.D.) co-efficient than the remainder of the foam body is provided therein. The inner core region extends substantially along the length of the mattress and provides greater support in the mattress along an axis substantially parallel to the longitudinal axis of the mattress.

Description

`-` 13272~3 The present invention relates to a body support and in particl~lar to a mattress.

MattresQes are well known in the art and developments thereto to increase support and comfort are continually being sought. For example, U.S. Patent 3~846,857 to Weinstock shows a polyure~hane foam mattress having various regions of different densities.
The regions are located at various positions along the length of the mattress and extend across the entire width of the mattress. This permits the mattress to exert a desired pressure to particular portions of a user when a user is supported on the mattress. However, although the mattress provides improved support to different areas of the body of a user, a problem exists in that the mattress does not provide compensation in the event that a user lies in the same region of the mattress during each use. Thus, if a user lies in the same region of the mattress during each use, as typically occurs, the mattress will weaken in that region causing the mattress to sag a~ter prolonged use.

U.S. Patent 4,713,854 to Graebe shows a foam cushion having strips of arch-shaped resillent foam ~` material formed therein. ThP strips are arranged in rows and provide a constant force on a body rPsting on the cushion regardless of the deformation of the cushion. However, the same problem still exists in that this cushion does not provide compensation in the region on whichau~rtypi~lyliesdunng ~chuse.

It is therefore an object of the present invention to obviate or mitigate the above disadvantages by providing a novel mattress.

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Broadly stated the present invention provides a mattress formed from foam material comprising:

a foam body having an upper surface for supporting a user and a lower surface for resting on a support, said foam body including an inner core region formed from one type of foam material, said one type of foam material being firmer than the remainder of said oam body, said inner core region extending substantially along the length of said mattress and providing increased support in said mattress along an axis substantially parallel to the longitudinal axis of said mattress.
Preferably, the inner core provides substantially continuous and even support along the entire axis and has an Indentation Force Deflection (I.F.D.) co-efficient at least two times greater than the remainder of the foam body. It is also preferred that the inner core includes symmetrical upper and lower surfaces, the upper and lower surfaces having a sinusoidal configuration across the width of the mattress. The portion of the inner core region having the greatest thickness is positioned on the axis to provide the increased support. The axis is positioned extend ~ong ~e ~gionofthe mat~esson whichau~r typically lies during each use.

Preferably, the upper and lower surfaces have convolutions formed thereon to facilitate air flow beneath a user supported on the mattress and to allow either side of the mattress to support a user.

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The present mattress provides advantages in that the additional support provided by the inner core region reduces sag and increases the lifetime of the mattress. Moreover, the design of the mattress provides an overall firmer feel without reducing the initial softness felt by a user lying on the mattress.
Furthermore, since the present mattress uses foams of different strengths and geometries, the increased performance of the mattress is achieved at a substantially lower cost than a foam mattress formed from a single type of higher grade foam material.

Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is a partial perspective cutaway view of a mattress;

Figure 2 is a sectional view of the mat-tress illustra~ed in Figure 1 taken along line 2-2;

Figure 3 shows graphs illustrating characteristics of a plurality of mattress configurations.

Figures 4 and 5 are enlarged sectional views of a portion of the mattress illustrated in Figure 2.

Figure 6 is a partial perspective and partial sectional view of another embodiment of a mattress; and Figure 7 is a sectional view of still yet another embodiment of a mattress.

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Referring to Figures 1 to 5, a mattress formed from polyurethane foam material is shown and is generally indicated by reference numeral 10. The mattress 10 generally comprises a foam body 12 having an upper surface 14 for supporting a user and a lower surface 16 for rest~ng on a flat surface such as a bed frame or box spring. The upper and lower surfaces 14 and 16 respectively have convolutions 18 formed therein to define a wave-shaped pattern. The mattress 10 is designed in this manner to permit ei-ther side of the mattress 14,16 ~o be used as the upper supporting surface. Rails 20 formed from foam material ex-tend along the four sides of the foam body 12 and are secured thereto via a gluing operation.
~ The foam body 12 is divided into five regions, namely an upper convoluted region 26, an upper surround region 28, an inner core region 30, a lower surround region 32 and a lower convoluted region 34. The two surround regions 28, 32 are disposed on either side of the inner core region 30 and provide flat surfaces 36 on to which the convoluted regions 2S, 34 lie. The two regions 26, 34 and the two surround regions 28, 32 are formed from polyurethane foam having an I.F.D. co-efficient of a first value. The thi¢kness of the two regions 26,34 is substantially constant and is chosen to be appro~imately 3.0 inches extending from the surfaca 36 to a peak 18a in the convolutions 18.

The inner core region 30 is symme-trical about a horizontal axis X with the upper and lower surfaces 38 of the inner core region 30 being of a generally sinusoidal configuration. As can be seen, the inner core region 30 has two peaks 40, when viewed in cross~
~ection with the two peaks 40 being equidistantly spaced , ' , , ' L

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~3~72~3 on either side of the longitudinal axis Y of the mattress 10. The peak~ extend substantially along the entir~ length of the mattress and are disposed below the upper surface 14 of the mattress 10 in the areas where users typically lie when using the mattress 10. The inner core region 30 is also formed from polyurethane foam. However, the foam selected to form the inner core 30 is typically chosen to have an I.F.D. co-efficient of a second value which is at least two times greater than the I . F. D. co-efficient of the foam forming regions 26,28,32 and 34 respectively. The inner core 30 is also shaped so that the thickness varies from approximately 2 inches at the peaks 40 to 1 inch at the longitudinal axis Y of the mattress 10 and at each side thereof adjacent the rails 20. The combined thickness of the inner core region 30 and the two surround regions 28,32 ~s maintained substantially constant and is chosen to be approximately 4 to 5 inches.

When a user ~ypically lies on a mattress 10, the user generally lies on a specific area of the mattress. For example, in a single bed, a user generally lies along the longitudinal axis of the mattress. Howeve~, in a double bed, a user or users typically lie along an axis parallel to but spaced from the longitudinal axis of the mattress. As shown in Figures 1 and 2, the present double mattress 10 is provided with an inner core 30 having a pair of peaks 40 which are equidistantly spaced from the longitudinal axis Y of the mattress. The peaks 40 extend along the entire length of the mattress. The peaks 40 are positioned ~ ex~nd ~ongthe ~ on whichau~r typically lies to provide increased support in the mattress in those regions. This increases the lifetime o the mattress and reduces sag.

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" ~3:27~3 Figure 3 illustrates characteristics of a plurality of mattress configurations having different ~icknes~sofinnercore ~gions30 ~dsu~ound ~gions 28,32. As can be seen, Figure 3 shows a 25~ I.F.D.
curve, a 65~ I~F.D. curve and modulus levels for Pleven mattress samples formed from 1830 and/or 2060 polyurethane foam material. The samples progressed from having an inner core of 5 inches in thickness with no surround regions, to a mattress sample having no inner core region 30 and 5 inches of surround region. All eleven samples included upper and lower regions 25,34 having a thickness of 1~ inches and thus, each sample was approximately 8 inches in thickness, this being the thickness of a typical mattress.

For clarity, the I.F.D. measurements are standard tests in the polyurethane foam industry. The 25% I.F.D. co-efficient relates to the force required to press an eight inch diameter plate down a distance of 25% of the thickness of the foam sample. Similarly, the 65% I.F.D. test is determined in the same manner and thus, relates to the force required to press the plate down a distance of 65% of the thickness of the foam sample. The modulus curve relates to the ratio of the 65~ I.F.D. value to the 25~ I~F~Do co-efficient for each foam sample. The thickness of the regions 28 to 32 in the present mattress lO were chosen so that the inner core has an 25% I.F.D. co-efficient appro~imately two times greater than the 25% I.F.D. co-efficient of the remainder of the mattress. This results in a mattress which provides a firmer overall feel whilst still maintaining the initial softness when used by a person.

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Referring now to Figure 6, another embodiment of the mattress is shown. In this embodiment like reference numerals will be used to indicate like components with an "A" added for clarity. In this embodiment, the inner core region 30A of the mattress lOA iS also symmetrical about the longitudinal a~is Y of the mattress but has only one peak 40A formed therein which lies on the longitudinal axis Y. This design of the inner core region 30A is suitable for single heds wherein only one person typically lies on the upper surface 14A of the mattress lOA. In use, since a person lying on a single bed typically lies along the centre line of the bed, the provision of ~he inner core 30A
positioned in this manner provides the necessary support to increase the ~ifetime of the mattress and inhibit sag even after prolonged useO

Referring now to Figure 7, another embodiment of the mattress is shown. In this embodiment, like reference numbers will be used to indicate like components with a "B" added in clarity. In this embodiment, the upper and lower surfaces 14B, 16B of the mattress lOB are substantially smooth to provide generally flat upper and lowe~r surfaces as opposed to convoluted surfaces.

The present mattress provides advantages in that the design of the inner core region increases the lifetime of the mattress and inhibits sag by providing greater support along the axis or axes on which users typically lie. Moreover, since an inner high I.F.D. co-efficient foam is used to form the inner core, the mattress provides a firmer overall feel. Furthermore, the provision of the inner core having a high I.F.D. co-, , :

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~272~3 efficient allows the performance of the mattress to be increased at a relatively low cost.

It should be apparen~ to one of skill in the art that various modifications can be made to the present invention without departing from the scope thereof as defined by the appended claims.

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Claims (19)

We claim:
1. A mattress formed from foam material comprising:

a foam body having an upper surface for supporting a user and a lower surface for resting on a support, said foam body including an inner core region formed from one type of foam material, said one type of foam material being firmer than the remainder of said foam body, said inner core region extending substantially along the length of said mattress and providing support in said mattress along an axis substantially parallel to the longitudinal axis of said mattress.
2. A mattress as defined in claim 1 wherein the inner core region provides substantially continuous and even support along the entire axis.
3. A mattress as defined in claim 2 wherein said inner core region decreases in thickness in a direction transverse to said axis.
4. A mattress as defined in claim 3 wherein the inner core region is symmetrical about a substantially horizontal axis and includes upper and lower surfaces, said upper and lower surfaces being generally sinusoidal in configuration and defining at least one region of increased thickness, said region being positioned on said axis and extending therealong.
5. A mattress as defined in claim 4 wherein said inner core region includes two regions of increased thickness separated by a region of reduced thickness, said region of reduced thickness being located on the longitudinal axis and extending therealong, said regions of increased thickness being equidistantly spaced from the longitudinal axis and providing increased support along an axis extending substantially parallel to said longitudinal axis.
6. A mattress as defined in claim 4 wherein said axis and said longitudinal axis are coincident.
7. A mattress as defined in claim 1 wherein said upper and lower surfaces have convolutions formed thereon.
8. A mattress as defined in claim 1 wherein said inner core region is formed from foam material having a 25% Indentation Force Deflection co-efficient approximately two times greater than the 25% Indentation Force Deflection co-efficient of the foam material forming the remainder of said mattress.
9. A mattress as defined in claim 5 wherein the thickness of said regions of increased thickness with respect to said region of reduced thickness is in the ratio of about 2 to 1.
10. A mattress as defined in claim 4 wherein the thickness of said regions of increased thickness with respect to the thickness of said mattress is in the ratio of about 1 to 4.
11. A mattress as defined in claim 1 wherein said inner core region is formed from 1830 polyurethane foam material and wherein the remainder of said foam body is formed from 2060 polyurethane foam material.
12. A mattress as defined in claim 6 wherein said inner core region is formed from foam material having a 25% Indentation Force Deflection co-efficient approximately two times greater than the 25% Indentation Force Deflection co-efficient of the foam material forming the remainder of said mattress.
13. A mattress as defined in claim 6 wherein said inner core region includes a single region of increased thickness disposed between regions of reduced thickness positioned adjacent the sides of the mattress, the thickness of said region of increased thickness with respect to said regions of reduced thickness being in the ratio of about 2 to 1.
14. A mattress as defined in claim 13 wherein the thickness of said region of increased thickness with respect to the thickness of said mattress is in the ratio of about 1 to 4.
15. A mattress formed from foam material comprising:
a foam body having an upper surface for supporting a user and a lower surface to contact a support, said foam body having a longitudinal axis and including an inner core region formed from one type of foam material, said one type of foam material being firmer than the remainder of said foam body, said inner core region extending substantially along the length of said mattress and providing increased support in said mattress along an axis substantially parallel to longitudinal axis of said mattress, said inner core region further decreasing in thickness in a direction transverse to said axis.
16. A mattress as defined in claim 15 wherein said inner core region provides substantially continuous and even support along said axis.
17. A mattress as defined in claim 16 wherein said upper and lower surfaces have convolutions formed thereon.
18. A mattress as defined in claim 16 wherein said inner core region is formed from foam material having a 25% indentation force deflection co-efficient approximately two times greater than the 25% indentation force deflection co-efficient of the foam material forming the remainder of said mattress.
19. A mattress as defined in claim 16 wherein said inner core region is formed from 1830 polyurethane foam material and wherein the remainder of said foam body is formed from 2060 polyurethane foam material.
CA000614938A 1989-09-29 1989-09-29 Mattress Expired - Fee Related CA1327243C (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CA000614938A CA1327243C (en) 1989-09-29 1989-09-29 Mattress
US07/416,464 US4975996A (en) 1989-09-29 1989-10-03 Mattress

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA000614938A CA1327243C (en) 1989-09-29 1989-09-29 Mattress
US07/416,464 US4975996A (en) 1989-09-29 1989-10-03 Mattress

Publications (1)

Publication Number Publication Date
CA1327243C true CA1327243C (en) 1994-02-22

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA000614938A Expired - Fee Related CA1327243C (en) 1989-09-29 1989-09-29 Mattress

Country Status (2)

Country Link
US (1) US4975996A (en)
CA (1) CA1327243C (en)

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CA2086391C (en) * 1992-04-14 1996-09-24 Patrick J. Coyne Adjustable seat and back cushion
US5265295A (en) * 1992-11-02 1993-11-30 Sturgis William G Cushion construction and method
US5636397A (en) * 1994-03-01 1997-06-10 Boyd; Terence J. Futon mattress
US6044506A (en) * 1995-06-01 2000-04-04 Valene; Murray S. Water/foam wheelchair pad
US6115861A (en) * 1997-10-09 2000-09-12 Patmark Company, Inc. Mattress structure
US5701623A (en) * 1996-03-11 1997-12-30 Latex Foam Products, Inc. Composite mattress and mattress topper having a latex foam core
US6249924B1 (en) 1997-02-14 2001-06-26 Earl Sanderson Kluft Anti-roll off mattress construction
CA2313793A1 (en) 1997-12-11 1999-06-17 Hill-Rom, Inc. Mattress structure
US6256822B1 (en) * 1999-01-29 2001-07-10 Span-America Medical Systems, Inc. Patient support system with side bolster features
US6839929B2 (en) 2001-12-13 2005-01-11 Hill-Rom Services, Inc. Self-sealing mattress structure
US6601253B1 (en) * 2002-07-08 2003-08-05 Peter Tarquinio Multilayer foam mattress with side supports
US6988286B2 (en) * 2002-08-01 2006-01-24 Carpenter Co. Cushioning device and method of producing the same
US6782575B1 (en) 2003-09-05 2004-08-31 Steven J. Antinori Mattress core and mattress providing pressure relief and minimizing body pressure
US20050246839A1 (en) * 2004-05-10 2005-11-10 Niswonger Alan L Bed foundation having a structural foam perimeter utilizing mechanical interlocking
US7240386B1 (en) * 2004-05-20 2007-07-10 King Koil Licensing Company, Inc. Multi-layer mattress with an air filtration foundation
US7640611B1 (en) * 2005-01-25 2010-01-05 Kluft Earl S Mattress design
GB0513286D0 (en) * 2005-06-29 2005-08-03 Seating Design & Dev Ltd A mattress
PL1904570T3 (en) 2005-07-01 2019-01-31 Latexco Nv Latex based composite foams
US20080083069A1 (en) * 2006-10-06 2008-04-10 Dell Accio Giacomo Foam mattress
MD3586C2 (en) * 2006-12-22 2008-12-31 Василий АРАБАДЖИ Orthopedic mattress for bed
US20100024127A1 (en) * 2008-08-01 2010-02-04 E&E Company, Ltd. Body support mattress pad
MD3951C2 (en) * 2009-02-11 2010-03-31 Василий АРАБАДЖИ Orthopedic mattress for bed
US20110145996A1 (en) * 2009-12-22 2011-06-23 Kara Johan Reversible Foam Mattress and Method of Construction
US10694874B2 (en) * 2013-03-08 2020-06-30 Sealy Technology, Llc Latex foam pillow

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US3319274A (en) * 1965-01-25 1967-05-16 Raymond R Upton Mattress with sag-resistant insert
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Also Published As

Publication number Publication date
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