The disclosure generally relates to mattress toppers, which may be placed on top of a mattress and may provide a level of comfort or warmth to a user.
A mattress topper is designed to be placed on top of a mattress. Some toppers are made from foam.
Adjustable foam-filled bladders have been known in the art. See WO2003041538A1 by Karen Boss. See also Noel Daly's UK Patent Application (GB 2413487). A foam-filled bladder may be filled with a core of a visco-elastic foam material and an external envelope covering the core. The external envelope may have upper and lower material layers. The upper and lower material layers may be the same or different. Most preferably the upper and lower material layers comprise an air impermeable material whereby the said material layers together define an airtight chamber.
Visco-elastic foams per se are known and widely available in a variety of grades and types. Visco-elastic foams are also known as “memory foams”, “slow recovery foams” or simply “slow foams”. By contrast, conventional high resilience foams (HR foams) are known as immediate recovery foams. This terminology derives from the response of the particular foam to compression. HR foams return immediately to their original state when the compression force ceases; visco-elastic foams have a longer recovery time.
In one arrangement, the external envelope forms a sealed chamber including the visco-elastic foam core and the overlay further comprises at least one valve operable to allow air into or out of the sealed chamber. This enables the overlay to be at least partially “self inflating”, as will be explained below. For purposes of this disclosure, “multi-valve” refers to “multivalve”, meaning “having a plurality of valves.”
Thus, in a most preferred form of the invention of the prior art the overlay is transformable from an extended or expanded state to a compressed state by opening said valve or valves, compressing the visco-elastic foam to expel air through said valve and closing said valve or valves to maintain the overlay in the compressed state.
Preferably also the overlay is transformable from a compressed or compact state in which the visco-elastic foam is compressed, to an expanded or extended state by opening said valve, or valves, whereby the viscoelastic foam expands from said compressed state and air is drawn into the overlay through said valve or valves, and closing said valve or valves to maintain the overlay in said expanded state. Preferably a plurality of valves is provided to increase the flow rate of air into or out of the envelope. For example one or two valves can be provided at each end of the envelope.
In another preferred arrangement, one or more bores or channels may be defined in the visco-elastic foam extending from the internal side of the, or each, valve into the interior of the foam core. This facilitates the flow of air into or out of the overlay, enhancing the speed at which the overlay can be inflated or deflated. These channels may, for example be arranged along a diagonal path through the overlay, extending from one valve located at a corner of the overlay to an opposite valve located at an opposite corner of the overlay or along a longitudinal path through the overlay, extending from one valve located at a corner of the overlay to another valve located at an opposite end of the overlay, at the same side thereof.
By means of these constructions the overlay can be compressed by rolling or folding after use, so expelling air through the valve or valves, and when so compressed, retained in the compressed state simply by closing the valve or valves. The reduced size or bulk of the overlay so achieved facilitates its transport between locations of use. In preferred forms of the invention of the prior art, the overlay can be compressed to the extent that, in its compressed state, a worker can conveniently carry it under his or her arm. The overlay is returned to its expanded state simply by opening the valve or valves and allowing air to be drawn into the overlay. If desired, air may be blown or pumped into the overlay, for example if a pressure within the overlay greater than atmospheric pressure is required, although this is not normally necessary.
Preferably the external envelope covering the core comprises a liquid impermeable material. In this way, in the unlikely event (considering the presence of the disposable protective cover) of any fluid spillage onto the overlay, the fluid will not penetrate the external envelope. The external envelope may desirably also be vapour and/or moisture impermeable.
Preferably in accordance with this first aspect of the invention of the prior art, the lower face in use of the body of visco-elastic foam material is attached to the inner surface of the lower material layer. Most preferably the said lower face is bonded to the said lower material layer. Preferably also at least a portion of the upper face in use of the body of visco- elastic foam material is similarly attached to the inner surface of the upper material layer. This is, however, not essential in all constructions. Movement between the upper material layer and the upper surface of the foam core may have therapeutic benefits by minimizing shear forces between the patient's skin and the upper material layer with which the skin is in contact (directly or indirectly).The visco-elastic foam material in the overlay of this aspect of the invention of the prior art may preferably have a thickness in the range of from about 5 cm to about 10 cm. The body of visco-elastic foam material may advantageously include a plurality of generally horizontal (in use) bores, such as transverse or longitudinal bores.
The upper surface of the foam material is most preferably planar but may be non-planar, for example a series of regularly arranged depressions and projections so that, in one form, the upper surface is provided with a waffle- like effect. Alternatively, or additionally, the visco-elastic foam may be provided with a series of generally vertical through bores or channels which also may achieve a waffle-like effect. The provision of the non-planar visco-elastic foam surface and/or generally vertical through bores may contribute to an improvement in ventilation for the patient, preventing excessive moisture build up. However, the provision of a vapor impermeable layer in the disposable cover is likely to be of much greater effect.
Preferably in accordance with the first aspect of the invention of the prior art the viscoelastic foam core is substantially co-extensive with the external envelope. In other words, the visco-elastic foam core preferably essentially fills the void defined by the external envelope. subject to the possible presence of vertical through channels or horizontal channels, as mentioned above.
The visco-elastic foam core may be joined to the external envelope over a major part of the area of its major (i.e. upper and lower) surfaces. This construction avoids movement of the external envelope with respect to the visco-elastic foam core. In this case the visco-elastic foam core is preferably bonded to the external envelope.
According to a third aspect there is provided an overlay for a mattress comprising: i) a core comprising a body of visco-elastic foam material; ii) an external envelope covering the core and comprising upper and lower material layers together defining an airtight chamber substantially filled by the core; and iii) at least one valve for allowing air communication between the interior and exterior of the chamber.
The prior art toppers are not fully-comfortable, given that the typical plastic covers of inflatable toppers are not as comfortable. Additionally, prior art toppers are unable to satisfy the desires of certain users who wish for varying levels of hardness for different areas of a topper. Some air mattresses require relatively complex electronic machinery, electricity, or blowers, which increase the cost and complexity.
Thus, a need exists for an inflatable topper assembly that may increase comfort, that may increase the number of areas with differences in the degree of hardness, and that may be relatively simple to use and also are energy-efficient.
For any inlet, air or liquid may enter in or also exit through the inlet.
Glue or some other affixing material may be applied between any foam piece of the topper body, including top panel 400 and the foam pieces below it, first short wall 410a, a head cushioning element 430, 410b, and 440.
The length and width of various pieces of the invention, such as the bladder assembly and portions of the topper body may be altered depending on the size of the topper model such as Twin, Full, Queen, split Queen, King, split King, Cal King. The apparatus may include an outer cushioning encasement that may have a head portion cushioning panel 430 of the middle layer 401 between 10″ and 25″ in length, a foot portion cushioning panel 440 of the middle layer 401 between 20″ and 35″ in length, one or more elongated cushioning panels, which may have a width between two inches to six inches inclusively, forming a perimeter around the middle layer (420a, 420b), and two cushioning panels (410a, 410b), having a length that maybe between 2 inches to 6 inches and may be depicted as running from the direction of the top of the page towards the bottom of the page, sandwiching the middle layer. Using a football field as a reference, if the top edge of the bottom panel was converted to a relative length based on a football field, such as the 0 yard line of a football field, then the beginning portion of the inflatable assembly would be aligned somewhere from the 10 yard line to the fifty yard line, and the end of the inflatable assembly would be somewhere inclusively on the 50 yard line to the 90 yard line. In one embodiment the top edge of the bladder assembly may be aligned at the relative “18 yard-line” of the back panel and the bottom edge of the bladder assembly aligned at the relative “61 yard line.”
For purposes of this disclosure, a foam-filled bladder is filled with foam such that the percentage of foam to other contents of the bladder is between 1% to 99.99%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 5% and 95%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 7% and 93%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 9% and 93%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 11% and 93%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 13% and 91%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 11% and 89%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 13% and 87%%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 15% and 85%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 17% and 83%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 19% and 81%, whereas in some preferred embodiments the percentage of foam to other contents of the bladder is between 21% and 79%.
For purposes of this disclosure, fused refers to two pieces that are one integral element. In some embodiments, a first element and a second element may be two separate pieces, but a fused element may replace the first element and second element such that a fused element has the dimensions substantially equal to the first element and the second element when the first and second are in frictional contact. Likewise, a plurality of elements could be replaced by a fused element.
For purposes of this disclosure, an inflatable bladder has two key metrics: 1) a relative length ratio, which may be expressed as a percentage, and 2) a laterally-aligned edge distance ratio, which may be expressed as a percentage. The relative length ratio of the inflatable bladder may be expressed as: the length of the inflatable bladder divided by the length of the bottom panel. The bottom panel may be made of foam, such as polyurethane regular foam, or other material, and may have thickness in the range of 0.1 inch to 5 inches, with a preferred thickness falling inclusively within the range of 0.75 inch to 1.5 inch. The laterally-aligned edge distance ratio may be expressed as the distance from the laterally-aligned edge of the inflatable bladder to the exterior edge of the first short wall divided by length of the bottom panel.
With respect to
Various types of foam may be used such as 1) TDI memory foam: 35 kg to 65 kg (2.1875 lbs-4.0625 lbs); MDI memory foam: 25 kg-50 kg (1.5625 lbs-3.125 lbs); TDI regular foam: 20 kg-35 kg (1.25 lbs-2.1875 lbs), or other types of foams. In some embodiments, other materials than foam are substituted for foam.
Infused is descriptive of materials to which an infusion has been performed. Additionally, in some embodiments, foam may be infused with elements or mixed elements such as bamboo and charcoal, gel, gel beads, gel swirls, charcoal, bamboo, lavender, aloe, green tea, chamomile, silver, copper, other types of infusions, or combinations thereof.
In one embodiment, a covered, adjustable topper assembly may have foam, such as memory foam or, polyurethane regular foam, that is disposed within a bladder, such as a supple-PVC bladder; the bladder may be surrounded by a foam casing; a nozzle may be configured to allow air flow in and out of the bladder. The nozzle may have a valve. The bladder of the adjustable topper assembly may be positioned so that a portion of the bladder is positioned below or substantially below the lumbar of a user that is lying supine on the covered, adjustable topper assembly.
In one related method of use of the covered, adjustable topper assembly, a user may exert pressure on or lie on top of the covered, adjustable topper assembly while keeping both valves closed. Then the user may press a trigger of a valve to release air from the foam-filled inflatable bladder; thus, the relative hardness1 of the portion of the topper above the foam-filled inflatable bladder will be decreased. When a user wants to increase the density of the foam-filled inflatable bladder, thereby affecting the density of the area of the topper above the foam-filled inflatable bladder, the user may then press the trigger to open a valve; if the user is not lying down or pressing down on the topper assembly, then opening the valve will result in communication between two areas of differing air pressure and the foam inside of the inflatable bladder will expand as air rushes into the inflatable bladder. The user may then release the trigger when the desired hardness of the inflatable bladder has been achieved. (Generally, when the foam becomes more dense then the foam is contracting or has contracted, and when the foam is becoming less dense then the foam is expanding or has expanded.)
Embodiments of covered, adjustable topper assembly may have memory foam; the covered, adjustable topper assembly may be adjustable by a user to fit a user's desired level of firmness, density, or plushness for a topper. The covered, adjustable topper assembly may be used as a mattress topper, thereby being placed on top of a mattress. The covered, adjustable topper assembly may feature the ability to adjust the comfortableness from firm to plush and in between, without the use of any electronics.
A cavity in a topper body is disclosed, and the cavity is sized so as to encase an inflatable bladder. The cavity length may be between 10% and 90% of the length of the topper body or covered adjustable topper assembly (205).
Unless specified, for any of the listed dimensions, the dimensions may between 0.05% to 500% of the listed dimensions; unless specified, in the preferred embodiments the dimensions ranges between 70% and 300% of the listed dimension. Ranges or ranging is inclusive.
The preferred embodiments of the present invention will be described in conjunction with the appended drawings. Like designations denote like elements, and:
Referring to the hand-adjustable valve (502) of
Referring to
In some preferred embodiments dimensions for elements fall between 70% to 300% of the listed dimension.
A middle panel (401) may be made of foam, Toluene diisocyanate (TDI) memory foam, methylene diphenyl diisocyanate (MDI) memory foam, or TDI regular foam. In the preferred embodiments the middle panel (401) of topper body (201) may have a vertical height between 2 inches to 3.5 inches and may be made from 1.5 lb., 25ILD Polyurethane Regular Foam. Middle panel (401) may have a first short wall (410a), ranging between 2.0 inches to 3.5 inches in thickness, and a second short wall (410b), ranging between 2.0 inches to 3.5 inches in thickness. Middle panel (401) may have a first long wall (420a) and a second long wall (420b). Middle panel (401) may have a head cushioning element (430) and a foot cushioning element (440). In some preferred embodiments head cushioning element (430) may be detachably or undetachably coupled to first short wall (410a). In some preferred embodiments foot cushioning element (440) may be detachably or undetachably coupled to the second short wall (420b).
As shown in
In some embodiments, elements of the middle panel (401) are replaced with a filler other than foam or a combination of foam and a filler other than foam.
In some embodiments, the length of the multi-valve inflatable bladder assembly (100) plus the length of the first short wall 248 and the length of the second short wall 250 is substantially equal to the length of the top panel (400). In some embodiments, at least one of head cushioning element (430) and foot cushioning element (440) is replaced with a filler of the type that is known in the art for being used to fill a mattress or topper. Although not shown in
A bottom panel may be 0.75″ thick and may be made from 1.51b., 34ILD Polyurethane Memory Foam. Any portion of the topper body may be made from 1.51b., 34ILD Polyurethane Memory Foam.
Although a twistable hand-adjustable valve is not shown in
Referring again to
Referring again to
The topper body may have a section that is 5 inches thick and 2.5 inches high that may surround a bladder assembly. Other dimensions are of the topper body are contemplated and within the scope of this disclosure. The perimeter of the topper body may be denser than the foam that is used to flank the inflatable bladder, thereby providing greater support if a user sits on the edge of the topper.
The following nonlimiting embodiments are disclosed:
Referring to
a multi-valve inflatable foam-filled bladder assembly (100);
an outer cover (300);
a topper body (201), the topper body (201) may define a cavity (150), wherein the multi-valve inflatable bladder assembly (100) may be disposed within the cavity (150), wherein the topper body (201) may be disposed within the outer cover (300), the topper body (201) may comprise a
A second embodiment which may inclide the adjustable mattress topper assembly of the first embodiment, and may also include the first multi-valve inflatable bladder assembly (100) which may further comprise
a multi-valve inflatable foam-filled bladder (101);
a first inlet (504) that may be coupled to the multi-valve inflatable bladder (100);
an openable-closable first valve (500) that may be coupled to the first inlet (504);
a second inlet (506) that may be coupled to the multi-valve inflatable bladder (100); and,
a hand-adjustable valve (502) that may be operable to be in an open position or a closed position so as to cause the inflatable foam-filled bladder (101) to be substantially airtight when the hand-adjustable valve (502) is in a closed position, wherein the hand-adjustable valve (502) may be coupled to the second inlet (506).
A third embodiment which may include the adjustable mattress topper assembly of the second embodiment, wherein the
first short wall (410a) may be fused to the head cushioning element (430) and the second short wall (410b) may be fused to the foot cushioning element (440).
A fourth embodiment of the adjustable mattress topper assembly may include the second embodiment, wherein an average density of a sum of the first density, the second density, the third density, and the fourth density may be less than an average density of a sum of the fifth density and the sixth density.
A fifth embodiment the adjustable mattress topper assembly may include the second embodiment, and may further comprise a hose (470) that may have a first end (472) and may have a second end (474), wherein the first end (472) may be coupled to the second inlet (506) and the second end (474) may be coupled to the hand-adjustable valve (502); wherein the hand-adjustable valve (502) may further comprise a finger-operable trigger (514) that may be operable to open the valve when the finger-operable trigger (514) is depressed and operable to close the valve when the finger-operable trigger is released.
A sixth embodiment may include the adjustable mattress topper assembly of the fifth embodiment wherein the topper body (201) may comprise foam selected from the group consisting of polyurethane regular foam having an average density ranging between 19 kg to 66 kg, toluene diisocyanate memory foam having an average density ranging between 34 kg to 66 kg, toluene diisocyanate regular foam having a density range between 19 kg to 36 kg, methylene diphenyl diisocyanate memory foam having a destiny range of 24 kg to 51 kg and combinations thereof.
A seventh embodiment of the adjustable mattress topper assembly may include the sixth embodiment, wherein the foam of the topper body (201) may further comprise an infusion element selected from the group consisting of gel, gel beads, gel swirls, charcoal, bamboo, lavender, aloe, green tea, chamomile, silver, copper, and combinations thereof. Other infusion elements may be used.
An eighth embodiment may include the adjustable mattress topper assembly of the sixth embodiment, wherein the multi-valve inflatable foam-filled bladder may have a length and a position describable by a set of key metrics selected from the group consisting of a) relative length ratio equal to 43% and a laterally-aligned edge distance ratio equal to 18%, b) relative length ratio equal to 40% and a laterally-aligned edge distance ratio equal to 15%, c) relative length ratio equal to 37% and a laterally-aligned edge distance ratio equal to 18%, d) relative length ratio equal to 46% and a laterally-aligned edge distance ratio equal to 18%, e) relative length ratio equal to 46% and a laterally-aligned edge distance ratio equal to 21%, f) relative length ratio equal to 49% and a laterally-aligned edge distance ratio equal to 18%, g) relative length ratio equal to 46% and a laterally-aligned edge distance ratio equal to 19%, h) relative length ratio equal to 46% and a laterally-aligned edge distance ratio equal to 20%, i) relative length ratio equal to 40% and a laterally-aligned edge distance ratio equal to 10%, j) relative length ratio equal to 45% and a laterally-aligned edge distance ratio equal to 15%, and k) relative length ratio equal to 43% and a laterally-aligned edge distance ratio equal to 40%. Other sets of key metrics are contemplated.
A ninth embodiment of the adjustable mattress topper assembly may include the sixth embodiment, the multi-valve inflatable foam-filled bladder may have a length and a position describable by a set of key metrics, wherein a) the relative length ratio of the foam-filled bladder may inclusively range between 1% and n %, b) the laterally-aligned edge distance ratio may inclusively range between 10% and 50%, and c) the sum of the relative length ratio and the laterally-aligned edge distance ratio may be between 11% and 99.5%.
A tenth embodiment of the adjustable mattress topper assembly may include the second embodiment wherein the multi-valve foam-filled inflatable bladder (100) may comprise foam selected from the group selected from the group consisting of polyurethane regular foam that may have an average density ranging between 19 kg to 66 kg, toluene diisocyanate memory foam that may have an average density ranging between 34 kg to 66 kg, toluene diisocyanate regular foam may have a density range between 19 kg to 36 kg, methylenediphenyl diisocyanate memory foam may have a density range of 24 kg to 51 kg and combinations thereof.
An eleventh embodiment of the adjustable mattress topper assembly of may include the seventh embodiment, wherein the foam of the foam-filled bladder further may comprise an infusion element selected from the group consisting of gel, gel beads, gel swirls, charcoal, bamboo, lavender, aloe, green tea, chamomile, silver, copper, and combinations thereof.
A twelfth embodiment of the adjustable mattress topper assembly may include the eleventh embodiment, wherein the first short wall (410a) may have a width inclusively within the range of 2 inches to 6 inches, the second short wall (410b) may have a width inclusively within the range of 2 inches to 6 inches, the first long wall (420a) may have a width inclusively within the range of 2 inches to 6 inches, the second long wall (420b) may have a width inclusively within the range of 2 inches to 6 inches, the head cushioning element (430) may have a length inclusively within the range of 10 inches to 25 inches, the foot cushioning element (440) may have a length inclusively within the range of 20 inches to 35 inches, the multi-valve inflatable foam-filled bladder (101) may have a width inclusively within the range of 20 inches to 34 inches, and the multi-valve inflatable foam-filled bladder (101) may have a length inclusively within the range of 20 inches to 40 inches.
Referring to the disclosure found in the schematics of
a second hose (470b) having a first end (472b) and a second end (474b), wherein the first end (472b) of the second hose (470b) may be coupled to a third inlet (506b) and the second end (474b) of the second hose (470b) may be coupled to a second hand-adjustable valve (502b);
wherein the second hand-adjustable valve (502b) may further comprise a second finger-operable trigger (514b) operable to open the valve when the second finger-operable trigger (514b) is depressed and operable to close the valve when the second finger-operable trigger (514b) is released.
A fourteenth embodiment of the embodiment of embodiment 13, wherein a combined width of width of the multi-valve inflatable foam-filled bladder assembly and a width of the second multi-valve inflatable foam-filled bladder assembly may be a value inclusively within a range of 40 inches to 76 inches.
One method of many methods for using the topper assembly or assemblies are described herein.
A method of using a multi-valve inflatable foam-filled bladder assembly;
providing
a multi-valve inflatable foam-filled bladder assembly; the multi-valve inflatable foam-filled bladder assembly comprising
providing an outer cover;
providing a topper body, the topper body defining a cavity, wherein the multi-valve inflatable bladder assembly may be disposed within the cavity, wherein the topper body is disposed within the outer cover, the topper body comprising a
a second short wall having a second density;
a first long wall having a third density;
a second long wall having a fourth density;
a head cushioning element having a fifth density; and,
a foot cushioning element having a sixth density;
applying pressure directly to the outer cover and indirectly to the top panel while simultaneously activating the hand-adjustable valve via pressing the finger-operable trigger, thereby deflating the inflatable foam-filled bladder.
It will be readily understood that the components of the present invention, as generally described with reference to the drawings herein, could be implemented in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, is not intended to limit the scope of the invention, but is merely representative of various embodiments of the invention. Unless explicitly stated, the use of “or” means and/or, that is, this the non-exclusive meaning of or.
Although several variations and embodiments have been described in detail above, various modifications may be made without departing from the scope and spirit of the invention.
This present application claims the benefit, and incorporates by reference, U.S. Nonprovisional patent application Ser. No. 16/735,682, which was filed on 2020 Jan. 6; U.S. Nonprovisional patent application Ser. No. 16/735,682 claims the benefit, and incorporates by reference, U.S. Provisional Patent Application No. 62/788,785, which was filed on 2019 Jan. 5.
Number | Date | Country | |
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62788785 | Jan 2019 | US |
Number | Date | Country | |
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Parent | 16735682 | Jan 2020 | US |
Child | 17686399 | US |