TECHNICAL FIELD
This application relates to the bonding of performance fabric to microfiber micro hooks and microfiber hook and loop ties and to modular mattress system technology.
BACKGROUND OF THE INVENTION
Some patents and patent applications have addressed the issue of modular mattresses.
Garshfield, in U.S. Pat. No. 3,950,800, “Modular Mattress Structure”, taught a layered modular mattress that was enclosed by a large zippered assembly.
Wu, in 20 2012 101 932 U1, “Gebrauchsmusterschrift (Modular Mattress Arrangement),” taught the use of three connection units in a single plane that were connected to each other on their outer perimeters and to the top of an underlying lower mattress body using Velcro.
Al-Hazeem, in WO 2017/072577 A1, “Mattresses with Multiple Customizable and Replaceable Levels and Sections and Methods Thereof,” taught a split top layer modular mattress enclosed by a customizable and replaceable fabric panel.
Prochazka, in US 2016/0100697 A1, “Field Adjustable Mattress System and Method,” taught a multi-layer mattress system having layers that could be secured together by zippers.
Iskeceli, in WO 2020/022978 A1, “Multipiece and Multifunctional Bed,” taught a single-layer three part bed, the three parts of which were joined together internally with hook-and-loop fasteners.
Alletto, in WO 2020/154372 A1, “Bedding System, Kit and Method,” taught the use of belts and buckles to secure the side walls (that defined a cavity) in the system relative to one another.
Vesey, in U.S. Pat. No. 10,531,746 B2, “Modular Mattress,” taught a multi-layer modular mattress with a top surface and a bottom surface that are distinct in firmness and feel with nonslip sheets or Velcro to prevent one layer from slipping on the other layer.
However, these references do not teach the apparatus that is disclosed and described in this application.
SUMMARY OF INVENTION
Technical Problems
A problem exists regarding what textile can be used that is comfortable enough to be used in bedding that has the ability to securely attach to a microfiber hook system such as that used on microfiber hook and loop cable ties, the strength to withstand significant force from said microfiber hook system, and sufficient structural resiliency to avoid aesthetic and structural damage such as tears or runs.
A problem exists as to how to create a modular mattress system that will avoid the problem of the tendency of a top mattress layer to separate upward away from a lower layer when a person lies on the top layer. This undesirable phenomenon is known as “hammocking.” Hammocking results in an inferior sleep experience when a layered mattress system is compared to a single, non-layered mattress because it generally results in less support to the person lying on the mattress. Therefore, resolving this problem is important to advancing the art of modular mattress systems.
Another problem that exists is what materials to use to resolve the hammocking problem. It would be highly desirable to be able to use materials that are not rough and which do not irritate human skin and which are easy to manipulate, assemble and disassemble while still being sufficiently powerful to be able to bind the various layers of a modular mattress system together under the weight of a human.
Still another problem is how to be able to customize a modular mattress system to be able to accommodate the preferences of a wide variety of sleepers regarding firmness and other mattress characteristics.
Solutions to the Problems
One solution to the problem of hammocking is to use microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, to vertically connect the ticking of the outer perimeter of a top comfort layer to the outer perimeter of the ticking of either a lower interchangeable comfort layer or a mattress core layer.
One solution to the problems of (a) what textile can be used that is comfortable enough to be used in bedding that has the ability to securely attach to a microfiber hook system such as that used on microfiber hook and loop cable ties, the strength to withstand significant force from said microfiber hook system, and sufficient structural resiliency to avoid aesthetic and structural damage such as tears or runs, and (b) what materials to use to resolve the hammocking problem, is to use a performance fabric either as the entire outer perimeter of the ticking of a mattress core layer, as a portion of some or all of the outer perimeters of said ticking, or as the entire outer perimeter of comfort layer covers (or a portion of some or all of the outer perimeters of said comfort layer covers) that encase the top comfort layer and any or all lower interchangeable comfort layers. This performance fabric not only is pleasant to the touch, but possesses the surprising and unexpected characteristic of attaching strongly to microfiber hook and loop cable ties and microfiber micro hooks without tearing or running and having sufficient strength to bind the various layers of a modular mattress system together under the weight of a human, while simultaneously being easy to manipulate, assemble and disassemble, i.e., easy to apply to and remove from such performance fabric.
A solution to the problem of how to customize a modular mattress system to be able to accommodate the preferences of a wide variety of sleepers regarding firmness and other mattress characteristics is disclosed in the variety of exemplary embodiments set forth in this application, which will allow the construction of a wide variety of modular mattresses that vary from soft to firm.
Advantageous Effects of the Disclosed Embodiments
One advantage of the disclosed embodiments is that the disclosed performance fabric has the unexpected and surprising property of not running or tearing when used in conjunction with the disclosed microfiber micro hooks or with microfiber hook and loop cable ties.
Another advantage of the disclosed embodiments is that they disclose a performance fabric with unexpected properties that can be used in conjunction with microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks to securely join objects together securely by using a cloth that is comfortable to human touch without the need for a rough surface such as is often used with Velcro or other similar hook and loop counterpart surfaces.
Another advantage of the disclosures contained in this document is that they teach how to avoid the problem of hammocking when constructing multi-layer modular mattress systems.
Yet another advantage of the disclosures contained in this document is that they teach how to customize a modular mattress system to be able to accommodate the preferences of a wide variety of sleepers regarding firmness and other mattress characteristics.
Although certain specific products are identified in the examples provided below, a person having ordinary skill in the art will appreciate that the combinations taught herein of microfiber hook and loop cable ties or microfiber micro hooks to the specific performance fabric disclosed herein is applicable to a wide range of consumer goods and durable goods as demonstrated by the diversity of the types of products referenced herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top right front perspective view of a first exemplary embodiment of a modular mattress system that uses anti-hammocking bonding strips.
FIG. 2 is a top plan view of a microfiber hook and loop cable tie that is capable of functioning as an anti-hammocking bonding strip.
FIG. 3 is a right elevational view of a microfiber hook and loop cable tie that is capable of functioning as an anti-hammocking bonding strip.
FIG. 4 is a bottom plan view of a microfiber hook and loop cable tie that is capable of functioning as an anti-hammocking bonding strip.
FIG. 5 is a top right close-up perspective of a first cooperating surface comprising a plurality of strands capable of linking to micro hooks.
FIG. 6 is a top right close-up perspective of a plurality of micro hooks.
FIG. 7 is a top plan view of a second cooperating surface of performance fabric comprising woven parallel rows of fiber strands.
FIG. 8 is a right elevational sectional view of the mattress core layer to the first exemplary embodiment.
FIG. 9 is a top plan sectional view of the mattress core layer to the first exemplary embodiment.
FIG. 10 is a right elevational sectional view of the interchangeable comfort layer to the first exemplary embodiment.
FIG. 11 is a top plan sectional view of the interchangeable comfort layer to the first exemplary embodiment.
FIG. 12 is a top right front perspective view of a second exemplary embodiment of a modular mattress system that uses anti-hammocking bonding strips.
FIG. 13 is a right elevational sectional view of the mattress core layer to the second exemplary embodiment.
FIG. 14 is a top plan sectional view of the mattress core layer to the second exemplary embodiment.
FIG. 15 is a right elevational sectional view of an interchangeable comfort half layer to the second exemplary embodiment.
FIG. 16 is a top plan sectional view of the interchangeable comfort half layer to the second exemplary embodiment.
FIG. 17 is a right elevational sectional view of the third exemplary embodiment.
FIG. 18 is a right elevational sectional view of the fourth exemplary embodiment.
FIG. 19 is a right elevational sectional view of the fifth exemplary embodiment.
FIG. 20 is a right elevational sectional view of the sixth exemplary embodiment.
FIG. 21 is a right elevational sectional view of the seventh exemplary embodiment.
FIG. 22 is a right elevational sectional view of the eighth exemplary embodiment.
FIG. 23 is a right elevational sectional view of the ninth exemplary embodiment.
FIG. 24 is a right elevational sectional view of the tenth exemplary embodiment.
FIG. 25 is a right elevational sectional view of the eleventh exemplary embodiment.
FIG. 26 is a right elevational sectional view of the twelfth exemplary embodiment.
FIG. 27 is a right elevational sectional view of the thirteenth exemplary embodiment.
FIG. 28 is a right elevational sectional view of the fourteenth exemplary embodiment.
FIG. 29 is a right elevational sectional view of an exemplary embodiment of a mattress core layer comprising a plurality of wrapped coils.
FIG. 30 is a top plan sectional view an exemplary embodiment of a mattress core layer comprising a plurality of wrapped coils.
DESCRIPTION OF THE DISCLOSED EMBODIMENTS
The following exemplary embodiments are intended to provide further description of the invention so as to enable a person of ordinary skill in the art to make and use the full scope of the invention. They are not intended to be limiting. Where any preferred depth of any mattress core layer or interchangeable comfort layer is disclosed as part of any of the embodiments below, they are intended to be approximate as well as only to reflect the depth that has been found to be optimal at the present time.
First Exemplary Embodiment
FIG. 1 discloses a modular mattress system for facilitating human sleep. That figure illustrates a plurality of interchangeable comfort layers (20) and a mattress core layer (10).
FIG. 1 further illustrates a comfort layer cover (24) that encases the interchangeable comfort layers (20), and that the interchangeable comfort layer covers' outer perimeters (25) are comprised of a performance fabric (40).
Additionally, FIG. 1 illustrates the mattress core layer's (10) ticking's outer perimeter (16) comprising performance fabric (40).
The modular mattress system disclosed in the First Exemplary Embodiment is further comprised in part of a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising a performance fabric or a patch of performance fabric (40).
FIG. 1 further depicts an anti-hammocking bonding strip (30) that connects the top interchangeable comfort layer cover's outer perimeter (25) to a lower interchangeable comfort layer cover's outer perimeter (25) and to the mattress core layer ticking's outer perimeter (16). The purpose of this is to prevent the outer perimeter of the top interchangeable comfort layer from raising up, i.e., hammocking, when a person lies in the middle of the top interchangeable comfort layer.
Although the anti-hammocking bonding strip (30) in FIG. 1 is depicted as extending all of the way from the top of the top interchangeable comfort layer cover's outer perimeter (25) to the bottom of the mattress core layer ticking's outer perimeter (16), anti-hammocking bonding strips can be deployed in alternative placements and configurations to accomplish the same objective, that is, to prevent the outer perimeter of the top interchangeable comfort layer from raising up, i.e., hammocking, when a person lies in the middle of the top interchangeable comfort layer. Some such alternative placements and configurations are shown in FIG. 1, such as:
- a second anti-hammocking bonding strip (31) that is deployed from below the top of the top interchangeable comfort layer cover's outer perimeter (25) to the bottom of the mattress core layer ticking's outer perimeter (16);
- a third anti-hammocking bonding strip (32) that is deployed from below the top of the top interchangeable comfort layer cover's outer perimeter (25) to above the bottom of a lower interchangeable comfort layer cover's outer perimeter (25); and
- a fourth anti-hammocking bonding strip (33) that is deployed from the top interchangeable comfort layer cover's outer perimeter (25) to a point above the bottom of the mattress core layer ticking's outer perimeter (16).
Thus, the First Exemplary Embodiment teaches anti-hammocking bonding strips (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the tip interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: a lower interchangeable comfort layer cover's outer perimeter (25) or the mattress core layer ticking's outer perimeter (16).
All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
An exemplary embodiment of anti-hammocking bonding strips such as elements (30), (31), (32), and (33) of FIG. 1 is depicted in FIGS. 2 through 4. FIG. 2 is a top plan view of a microfiber hook and loop cable tie that is capable of functioning as an anti-hammocking bonding strip. FIG. 2 shows a micro loop surface (32). Although many microfiber hook and loop cable ties contain a micro loop surface, a micro loop surface is not necessary for an anti-hammocking bonding strip to function as illustrated by this application.
FIG. 3 is a right elevational view of a microfiber hook and loop cable tie that is capable of functioning as an anti-hammocking bonding strip. FIG. 3 shows the micro loop surface (32) of FIG. 2 on the top surface of the anti-hammocking bonding strip (30) and a micro hook surface (31) on the bottom surface of the anti-hammocking bonding strip (30).
FIG. 4 is a bottom plan view of a microfiber hook and loop cable tie that is capable of functioning as an anti-hammocking bonding strip. FIG. 4 shows the micro hook surface (31) on the bottom surface of the anti-hammocking bonding strip (30).
FIG. 5 is a top right close-up perspective of a portion of a surface comprising a plurality of micro hooks (33), such as the micro hook surface (31) on the bottom surface of the anti-hammocking bonding strip (30) depicted in FIG. 4.
FIG. 6 is a top right close-up perspective of a plurality of micro hooks showing them in alternating ranks with the open portion of every other micro hook (33) facing the same direction, such as the micro hook surface (31) on the bottom surface of the anti-hammocking bonding strip (30) depicted in FIG. 4 and FIG. 5.
FIG. 7 is a top plan view of a second cooperating surface of woven parallel rows of fiber strands (34) comprising performance fabric.
FIG. 7 also provides additional detail regarding the performance fabric (40) of FIG. 1, illustrating a surface comprising performance fabric of woven parallel rows of fibers.
Collectively, FIGS. 3 through 7 illustrate a separable fastening apparatus comprising a first cooperating surface comprising a plurality of micro hooks arranged in alternating ranks with the open portion of every other micro hook [FIGS. 3 and 4 (31) and FIG. 6 (33)] facing the same direction and a second cooperating surface [FIG. 1 (40)] of a performance fabric (40) comprising woven parallel rows of fibers [FIG. 7 (34)].
FIG. 8 reveals further detail regarding the mattress core layer (10) of FIG. 1. FIG. 8 is a right elevational sectional view of the mattress core layer depicted in FIG. 9. FIG. 8 makes it clear that an interior core (11) of the mattress core layer (10) is encased by the ticking (15) of FIG. 9. The ticking's outer perimeter (16) is made of performance fabric (40).
The material comprising the interior core (11) of a mattress core layer (10) such as those depicted in FIG. 8 may be selected from the following: solid foam, solid latex, a plurality of wrapped coils, base foam, support foam, polyurethane foam, and high density poly core foam.
FIG. 9 shows in greater detail the mattress core layer (10) of FIG. 1. FIG. 9 discloses that the mattress core layer (10) is encased by a ticking (15) that encases the mattress core layer and that the sides of the ticking as viewed from the top plan view are the ticking's outer perimeter (16).
FIG. 10 makes it clear that interior core (21) of each interchangeable comfort layer (20) is encased by the comfort layer cover (24) of FIG. 11 and that the interchangeable comfort layer cover's outer perimeter (25) is made of a performance fabric (40).
FIG. 11 shows in greater detail the interchangeable comfort layers (20) of FIG. 1. FIG. 11, a top plan sectional view of the interchangeable comfort layer, discloses that each interchangeable comfort layer (20) is comprised of an interior core (21) that is encased by a comfort layer cover (24) and that the sides of the ticking as viewed from the top plan view are the interchangeable comfort layer cover's outer perimeter (25).
The material comprising the interior core (21) of an interchangeable comfort layer (20) such as those depicted in FIGS. 10 and 11 may be selected from the following: low ILD soft foam, microcoils, polyurethane foam, ultra-dense memory foam, memory foam, avena foam, foam, hyper-elastic polymer foam, latex, minicoils, nanocoils, flexible polyurethane foam, viscoelastic foam, latex foam, felt, polyester fiber, cotton fiber, wool fiber, non-woven fiber pads, gel-infused foams, soft-solid gels layered over foam, and poured gels.
FIG. 29 illustrates another exemplary embodiment of the mattress core layer (10) of FIG. 1. FIG. 29 is a right elevational sectional view of the mattress core layer depicted in FIG. 30. FIG. 29 makes it clear that an interior core (11) of the mattress core layer (10) is encased by the ticking (15) of FIG. 30. The ticking's outer perimeter (16) is made of performance fabric (40).
The material comprising the interior core (11) of a mattress core layer (10) in FIGS. 29 and 30 is depicted in those figures as a plurality of wrapped coils (14).
FIG. 30 shows in greater detail the exemplary embodiment of the mattress core layer (10) of FIG. 1 that is disclosed in FIG. 29. FIG. 30 discloses that the mattress core layer (10) is encased by a ticking (15) that encases the mattress core layer and that the sides of the ticking as viewed from the top plan view are the ticking's outer perimeter (16).
A person of ordinary skill in the art will appreciate that, although the foregoing separable fastening apparatus has been described in FIG. 1 with respect to connecting top interchangeable comfort layer cover's outer perimeter (25) to either a lower interchangeable comfort layer cover's outer perimeter (25) or the mattress core layer ticking's outer perimeter (16) of a modular mattress system, the foregoing process is also suitable to other products and home fixtures. Such products are by way of example only and the foregoing process is suitable not only to the production of such durable home goods, but is equally suitable to a variety of durable goods and consumer products.
Second Exemplary Embodiment
FIG. 12 discloses another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a mattress core layer (10), an interchangeable comfort layer (20), a first interchangeable comfort half layer (26) and a second interchangeable comfort half layer (22).
FIG. 13 and FIG. 14 provide more detail regarding the mattress core layer to the second exemplary embodiment, FIG. 13 depicting a right elevational sectional view of the mattress core layer to the second exemplary embodiment and FIG. 14 depicting a top plan sectional view of the mattress core layer to the second exemplary embodiment.
FIG. 13 shows in greater detail the mattress core layer (10) of FIG. 12. FIG. 13 is a right elevational sectional view of the mattress core layer that discloses that the mattress core layer (10) contains an interior core (11) and is encased by a ticking [FIG. 14 (15)] that encases the mattress core layer and that the sides of the ticking as viewed from the top plan view (FIG. 14) are the ticking's outer perimeter (16). FIG. 13 further illustrates that the ticking's outer perimeter (16) contains a patch (41) made of performance fabric.
FIG. 14's top plan view of the mattress core layer to the second exemplary embodiment makes it clear that an interior core (11) of the mattress core layer (10) is encased by a ticking (15).
An interior core (11) of a mattress core layer (10) as depicted in FIG. 13 and FIG. 14 may be selected from the following: solid foam, solid latex, a plurality of wrapped coils, base foam, support foam, polyurethane foam, and high density poly core foam.
FIG. 15 and FIG. 16 provide more detail regarding the interchangeable comfort layer (20) and each of the interchangeable the comfort half layers (22) & (26) to the second exemplary embodiment illustrated in FIG. 12, FIG. 15 being a right elevational sectional view of an interchangeable comfort half layer to the second exemplary embodiment and FIG. 16 being a top plan sectional view of the interchangeable comfort half layer to the second exemplary embodiment.
Although FIG. 15 and FIG. 16 depict only sectional views of an interchangeable comfort half layer to the second exemplary embodiment, the interchangeable comfort layer (20) of FIG. 12 may be identical, in some embodiments, to the interchangeable comfort half layers (22) & (26) of FIG. 12, except that a single interchangeable comfort layer covers the entire surface of the mattress core layer (10) of FIG. 12, whereas a plurality of interchangeable comfort half layers (22) are needed to cover the entire surface of the mattress core layer (10) of FIG. 12.
FIG. 15 makes it clear that the interchangeable comfort half layer (26) to the second exemplary embodiment illustrated in FIG. 12 is comprised of an interior core (21) which is encased by the comfort layer cover (24). Further, the comfort layer cover (24) of FIG. 15 contains a patch (41) comprising a performance fabric, said patch extending from the top to the bottom of the comfort layer cover (24) on an outer perimeter [FIG. 16 (25)] of the interchangeable comfort half layers (26).
Thus, a comfort layer cover [FIG. 16 (24)] encases each interchangeable comfort layer and each of the interchangeable comfort half layers [FIG. 12 (22) & (26)], said interchangeable comfort layer cover's outer perimeter [FIG. 16 (25)] or a patch [FIG. 15 (41)] on said outer perimeter comprising performance fabric.
FIG. 16 shows in greater detail the first interchangeable comfort half layer (26) of FIG. 12. FIG. 16, a top plan sectional view of an interchangeable comfort half layer (26), discloses that said interchangeable comfort half layer (26) is comprised of an interior core (21) that is encased by a comfort layer cover (24) and that the sides of the ticking as viewed from the top plan view are the interchangeable comfort layer cover's outer perimeter (25). FIG. 15 makes it clear that the interior core (21) of interchangeable comfort half layer (26) is encased by comfort layer cover (24) of FIG. 16. The interchangeable comfort half layer cover's outer perimeter (25) contains a patch (41) made of performance fabric.
Thus the modular mattress system of the Second Exemplary Embodiment is comprised, in part, of a plurality of comfort layer covers [FIGS. 15 and 16 (24)] with one said comfort layer cover encasing the interchangeable comfort layer and each of the interchangeable comfort half layers, the outer perimeter [FIG. 16 (25)] of each said comfort layer cover comprising performance fabric or a patch of performance fabric [FIG. 15 (41)] (40)].
FIG. 12 illustrates that anti-hammocking bonding strips and performance fabrics can be deployed in alternative placements and configurations to prevent the outer perimeter of the top interchangeable comfort half layers (22) & (26) from raising up, i.e., hammocking, when a person lies in the middle of the top interchangeable comfort half layers. Some such alternative placements and configurations are shown in FIG. 12, such as:
- a first anti-hammocking bonding strip (30) that is deployed on a patch (41) of performance fabric (40)
- from below the top of the top interchangeable comfort half layer cover's (26) outer perimeter (25)
- then onto another patch (41) of said performance fabric on the interchangeable comfort layer (20) cover's outer perimeter (25) and
- then onto another patch (41) of said performance fabric on the mattress core layer's (10) ticking's [FIG. 14 (15)] outer perimeter (16);
- a second anti-hammocking bonding strip (31) that is deployed on a patch (41) of performance fabric (40)
- from below the top of the top interchangeable comfort half layer cover's (26) outer perimeter (25)
- then across the interchangeable comfort layer (20) cover's outer perimeter (25) and
- then onto another patch (41) of said performance fabric on the mattress core layer's (10) ticking's [FIG. 14 (15)] outer perimeter (16);
- a third anti-hammocking bonding strip (32) that is deployed on a patch of performance fabric
- from below the top of the top interchangeable comfort half layer cover's outer perimeter (25) to a patch of said performance fabric on the interchangeable comfort layer cover's outer perimeter (25);
- a fourth anti-hammocking bonding strip (33) that is attached to performance fabric
- on the top interchangeable comfort half layer cover's (26) outer perimeter (25)
- to said performance fabric on the interchangeable comfort layer cover's outer perimeter (25) and
- then onto another patch (41) of said performance fabric on the mattress core layer's (10) ticking's [FIG. 14 (15)] outer perimeter (16);
- a fifth anti-hammocking bonding strip (35) that is deployed on a patch (41) of performance fabric (40)
- from below the top of the top interchangeable comfort half layer cover's (22) outer perimeter (25)
- then across the interchangeable comfort layer (20) cover's outer perimeter (25) and
- then onto another patch (41) of said performance fabric on the mattress core layer's (10) ticking's [FIG. 14 (15)] outer perimeter (16).
Thus, the Second Exemplary Embodiment teaches anti-hammocking bonding strips [FIGS. 2-7, (30) (31) (32) (33) & FIGS. 12 (30) (31) (32) (33) & (35)] comprising microfiber micro hooks (31), such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect either the top interchangeable comfort layer cover's outer perimeter (25) or the patch (41) on the interchangeable comfort layer cover's outer perimeter to at least one of the following: a lower interchangeable comfort layer cover's outer perimeter (25) or the patch (41) on the interchangeable comfort layer cover's outer perimeter; or the mattress core layer ticking's outer perimeter (16) or the patch (41) on the mattress core layer ticking's outer perimeter.
All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application. The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
Third Exemplary Embodiment
FIG. 17 discloses yet another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), and a plurality of interchangeable comfort layers (20), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 17 is comprised of a mattress core layer comprising an interior core of from four through ten inches of solid base foam (312) with the mattress core layer being encased by a ticking, with said ticking's outer perimeter (16) being comprised of performance fabric (40).
FIG. 17 further discloses a plurality of interchangeable comfort layers (20) comprising a top interchangeable comfort layer comprising two inches of low ILD soft foam (321); a middle interchangeable comfort layer comprising a plurality of wrapped microcoils that may be from ½ through 4 inches in height (14); a bottom interchangeable comfort layer comprising two inches of high-density polyurethane foam (317); and a comfort layer cover that encases each interchangeable comfort layer, said interchangeable comfort layer cover's outer perimeter (25) comprising performance fabric (40).
Thus the modular mattress system of the Third Exemplary Embodiment is further comprised, in part, of a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 17 further discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
Thus, the Third Exemplary Embodiment teaches an anti-hammocking bonding strip (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the tip interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the middle interchangeable comfort layer cover's outer perimeter (25), the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top, middle or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Fourth Exemplary Embodiment
FIG. 18 discloses yet another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), and a plurality of interchangeable comfort layers (20), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 18 is comprised of a mattress core layer comprising an interior core of four inches of solid base foam (412), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 18 further discloses a plurality of interchangeable comfort layers (20) comprising a top interchangeable comfort layer comprising two inches of polyurethane foam (421); a middle interchangeable comfort layer comprising a plurality of wrapped 2.4 inch microcoils (14); a bottom interchangeable comfort layer comprising two inches of low ILD soft foam (417); and a comfort layer cover that encases each interchangeable comfort layer, said interchangeable comfort layer cover's outer perimeter (25) comprising performance fabric (40).
Thus the modular mattress system of the Fourth Exemplary Embodiment is comprised, in part, of a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 18 further discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
Thus, the Fourth Exemplary Embodiment teaches anti-hammocking bonding strips (30) comprising microfiber micro hooks, such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the middle interchangeable comfort layer cover's outer perimeter (25), the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top, middle or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Fifth Exemplary Embodiment
FIG. 19 discloses yet another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), and a plurality of interchangeable comfort layers (20), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 19 is comprised of a mattress core layer comprising an interior core of four inches of solid base foam (512), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 19 further discloses a plurality of interchangeable comfort layers (20) comprising a top interchangeable comfort layer comprising two inches of low ILD soft foam (521); a middle interchangeable comfort layer comprising two inches of high-density polyurethane foam (517); a bottom interchangeable comfort layer comprising a plurality of wrapped 2.4 inch microcoils (14); and a comfort layer cover that encases each interchangeable comfort layer, said interchangeable comfort layer cover's outer perimeter (25) comprising performance fabric (40).
Thus the modular mattress system of the Fifth Exemplary Embodiment is comprised, in part, of a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 19 further discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
Thus, the Fifth Exemplary Embodiment teaches anti-hammocking bonding strips (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the middle interchangeable comfort layer cover's outer perimeter (25), the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top, middle or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Sixth Exemplary Embodiment
FIG. 20 discloses yet another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), and a plurality of interchangeable comfort layers (20), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 20 is comprised of a mattress core layer comprising an interior core of four inches of solid base foam (612), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 20 further discloses a plurality of interchangeable comfort layers (20) comprising a top interchangeable comfort layer comprising a plurality of interchangeable comfort layers (20) comprising a top interchangeable comfort layer comprising two inches of high-density polyurethane foam (617); a middle interchangeable comfort layer comprising two inches of low ILD soft foam (621); a bottom interchangeable comfort layer comprising a plurality of wrapped 2.4 inch microcoils (14); and a comfort layer cover that encases each interchangeable comfort layer, said interchangeable comfort layer cover's outer perimeter (25) comprising performance fabric (40).
Thus the modular mattress system of the Sixth Exemplary Embodiment is further comprised, in part, of a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 20 further discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
Thus, the Sixth Exemplary Embodiment teaches anti-hammocking bonding strips (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the following: the middle interchangeable comfort layer's outer perimeter (25); the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the middle interchangeable comfort layer cover's outer perimeter (25), the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top, middle or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Seventh Exemplary Embodiment
FIG. 21 discloses still another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), and a plurality of interchangeable comfort layers, including a top comfort layer (70), a bottom comfort layer (71), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 21 is comprised of a mattress core layer (10) comprising an interior core of seven inches of support foam (712), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 21 further discloses a plurality of interchangeable comfort layers comprising a top comfort layer (70) comprising two inches of ultra-dense memory foam (700); a bottom comfort layer (71) comprising two inches of ultra-dense memory foam (700); and a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 21 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer cover's outer perimeter (25) to at least one of the following: the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Eighth Exemplary Embodiment
FIG. 22 discloses still another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), a top comfort layer (800), a bottom comfort layer (71), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 22 is comprised of a mattress core layer comprising an interior core of seven inches of polyurethane foam (812); a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 22 further discloses a top comfort layer (800) comprising three inches of ultra-dense memory foam (820); a comfort layer cover that encases the bottom comfort layer, said comfort layer cover's outer perimeter (16) comprising performance fabric (40).
FIG. 22 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer cover's outer perimeter (25) to the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
Ninth Exemplary Embodiment
FIG. 23 discloses still another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10); a plurality of interchangeable comfort layers (900) (940) and (980); and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 23 is comprised of a mattress core layer (10) comprising an interior core of five inches of base foam (912), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 23 further discloses a plurality of interchangeable comfort layers comprising a top comfort layer (900) comprising one and a half inches of polyurethane foam (920); a middle comfort layer (940) comprising one and a half inches of memory foam (960); a bottom comfort layer (980) comprising one and a half inches of polyurethane foam (990); a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 23 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer cover's outer perimeter (25) to at least one of the following: the middle comfort layer ticking's outer perimeter (25); the bottom comfort layer ticking's outer perimeter (25); or the mattress core layer ticking's outer perimeter (25).
The anti-hammocking bonding strips (30) in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the middle interchangeable comfort layer cover's outer perimeter (25), the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top, middle or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Tenth Exemplary Embodiment
FIG. 24 discloses still another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), and a plurality of interchangeable comfort layers, including a top comfort layer (1000); a bottom comfort layer (1080); a plurality of comfort layer covers; and an anti-hammocking bonding strip (30).
FIG. 24 discloses still another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10) comprising an interior core of ten inches of support foam (1012), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 24 further discloses a plurality of interchangeable comfort layers comprising a top comfort layer (1000) comprising two inches of avena foam (1020); a bottom comfort layer (1080) comprising two inches of memory foam (1090); a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 24 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer cover's outer perimeter (25) to at least one of the following: the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Eleventh Exemplary Embodiment
FIG. 25 discloses still another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), a top comfort layer (1100), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 25 is comprised of a mattress core layer comprising an interior core of seven and a half inches of support foam (1112), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 25 further discloses a top comfort layer (1100) comprising three inches of memory foam (1120); a comfort layer cover that encases the top comfort layer, said comfort layer cover's outer perimeter (25) comprising performance fabric (40).
FIG. 25 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer's cover's outer perimeter (25) to the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
Twelfth Exemplary Embodiment
FIG. 26 discloses yet another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), a plurality of interchangeable comfort layers comprising a top comfort layer (1200), a bottom comfort layer (1280), a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 26 is comprised of a mattress core layer (10) comprising an interior core of seven and a half inches of support foam (1212), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 26 further discloses a plurality of interchangeable comfort layers comprising a top comfort layer (1200) comprising one and a half inches of aerated latex foam (1220); a bottom comfort layer (1280) comprising two inches of gel memory foam (1290); a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 26 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer cover's outer perimeter (25) to at least one of the following: the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Thirteenth Exemplary Embodiment
FIG. 27 discloses still another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10), a top comfort layer (1300), and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 27 is comprised of a mattress core layer (10) comprising an interior core of six inches of high density poly core foam (1312), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 27 further discloses a top comfort layer (1300) comprising four inches of memory foam (1320); and a comfort layer cover that encases the top comfort layer, said comfort layer cover's outer perimeter (25) comprising performance fabric (40).
FIG. 27 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30) comprising microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer cover's outer perimeter (25) to the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
Fourteenth Exemplary Embodiment
FIG. 28 discloses yet another exemplary embodiment of a modular mattress system for facilitating human sleep. That figure illustrates a modular mattress system comprising a mattress core layer (10); a plurality of interchangeable comfort layers comprising a top comfort layer (1400), a bottom comfort layer (1480) and a plurality of comfort layer covers with one said comfort layer cover encasing each interchangeable comfort layer; and an anti-hammocking bonding strip (30).
The exemplary embodiment depicted in FIG. 28 is comprised of a mattress core layer (10) comprising an interior core of four inches of polyurethane foam (1412), and a ticking that encases the mattress core layer, said ticking's outer perimeter (16) comprising performance fabric (40).
FIG. 28 further discloses a plurality of interchangeable comfort layers comprising a plurality of interchangeable comfort layers comprising a top comfort layer (1400) comprising two inches of hyper-elastic polymer foam (1420); a bottom comfort layer (1480) comprising three and a half inches of polyurethane foam (1490); a plurality of comfort layer covers, with one said comfort layer cover encasing each interchangeable comfort layer, the outer perimeter (25) of each said comfort layer cover comprising performance fabric or a patch of performance fabric (40).
FIG. 28 also discloses that the modular mattress system is further comprised of an anti-hammocking bonding strip (30). This anti-hammocking bonding strip (30) is comprised of microfiber micro hooks [FIGS. 3 & 4 (31)], such as a microfiber hook and loop cable ties or a strip or plurality of strips of microfiber micro hooks, that vertically connect the top comfort layer cover's outer perimeter (25) to at least one of the following: the bottom interchangeable comfort layer's outer perimeter (25); or the mattress core layer ticking's outer perimeter (16).
The anti-hammocking bonding strips in this exemplary embodiment are the same as those described in the First Exemplary Embodiment and the description of the anti-hammocking bonding strips contained in the First Exemplary Embodiment are hereby incorporated by reference into this exemplary embodiment.
A person of ordinary skill in the art will appreciate that the anti-hammocking bonding strips can also be placed to vertically connect the top interchangeable comfort layer cover's outer perimeter (25) to at least one of the bottom interchangeable comfort layer cover's outer perimeter (25), the ticking that encases the mattress core layer or to a patch of performance fabric (40) that is on the outer perimeter of the top or bottom comfort layer covers or the ticking that encases the mattress core layer. All alternative placements and configurations of anti-hammocking bonding strips are claimed by this application.
Definitions
Certain definitions are provided below. At no time are any of these definitions intended to modify or restrict the knowledge of a person having ordinary skill in the art or to limit the scope of the claims unless such definition is expressly adopted in the claim language itself. Similarly, reference to particular examples within each definition are exemplary and non-limiting.
“Elastane” means a manufactured fiber in which the fiber-forming substance is any long chain synthetic polymer composed of at least 85% by weight of a segmented polyurethane.
Foams:
“Avena foam” means the flexible, latex-like polyurethane foam having the “feel” and comfort of a latex foam and an Indentation Force Deflection (25% IFD as low as 3 lbs.) disclosed and claimed in U.S. Pat. No. 6,521,674 B1 to Haley et al. “Latex-like flexible polyurethane foam and process for making same.” The name Avena is registered as U.S. Trademark 3897846.
“Base foam” means support foam, as defined elsewhere in this application.
“Foam” means a suspension of a gas in a solid, such as for example, soft rubber full of small holes.
“Flexible polyurethane foam” means a polyurethane foam (defined elsewhere in this application) that has a density ranging from 12 to 50 kg/m3.
“Gel” means a colloidal system having a honeycomb-like structure in which the dispersed phase is liquid and the dispersion medium is a solid.
“Gel-infused foams” means memory foams which have liquid gel beads or particles within the foam and said gel beads can either absorb or release heat, thereby making the foam less warm than viscoelastic foam.
“High density poly core foam” means viscoelastic foam or memory foam, said foams having a density of greater than 5 pounds per cubic foot (“PCF”) up to and less than 6 PCF.
“High-density polyurethane foam” means polyurethane foam that has a density of greater than 1.7 pounds per cubic foot (“PCF”).
“Hyper-elastic polymer foam” means the plasticized elastomeric gel material sold as an integral component of cushioned products, namely, mattresses, that is used in the Purple Grid mattress sold by Purple Innovation, LLC and that is described in U.S. Trademark Registration Number 5,224,883.
“Low ILD soft foam” means natural or synthetic foam rubber with an Impression Load Deflection (ILD) rating from 1.2 ILD through 3.0 ILD.
“Memory foam” means viscoelastic foam as defined elsewhere in this application, with a bulk density range from 1.5 through 9.0 pounds per cubic foot (“PCF”).
“Polyurethane foam” means an air permeable open cell-structured thermosetting plastic material containing a high percentage of air by volume and further consisting of molecules with the chemical formula of C27H36N2O10 with an Impression Load Deflection (ILD) rating from 15 ILD to 70 ILD.
“Poured gels” means viscoelastic foam into which gels other than liquid beads have been infused and also includes foams that consist entirely of gel.
“Soft-solid gels” means gels comprised of non-Newtonian fluids which can behave either like a solid or like a liquid, depending upon what type of stress is affecting the gel.
“Solid foam” means a polyurethane foam with a density of at least 1.2 pounds per cubic foot.
“Solid latex” means natural or synthetic foam rubber with an Impression Load Deflection (ILD) rating from 14 ILD to 44 ILD.
“Support foam” means polyurethane foam that has an indentation force deflection (IFD) from 30 to 45 IFD.
“Ultra-dense memory foam” means viscoelastic foam or memory foam, said foams having a density of 6 pounds per cubic foot (“PCF”) or greater.
“Viscoelastic foam” means materials that absorb and reduce a high proportion of the compressive forces when under pressure load and corresponding deformation (“stress relaxation”), that with subsequent pressure relief, return to their original form with a time delay (recovery time), thus behaving like a damped spring, and that have the following property characteristics: a bulk density range of 35-80 kg/m3; compression hardness (initial hardness after a loading cycle) between 1.0 and 4.0 kPa; rebound or point elasticity not greater than 15% when measured as rebound resilience according to DIN EN ISO 8307; and a recovery time as a visible characteristic for pressure relief in the range of 5 through 13 sec.
“Microcoils” means springs that are at least ¾″ high and less than 2″ high.
“Microfiber” means fiber formed from nylon, polyester, polyethylene, vinyl or polypropylene that contain a plurality of micro hooks on at least one side.
“Minicoils” means springs from 2″ to 4″ high.
“Micro hooks” means hooks with a total height of 0.03 inches or less such as, for example Velcro Brand High Technology Hook Styles 22 or 29, said micro hooks being comprised of nylon, polyester, polyethylene, vinyl or polypropylene.
“Nanocoils” means springs less than ¾″ high.
“Performance fabric” means a stretchable textile comprised of 89 percent polyamide fiber and 11 percent elastane fiber by weight with a density from 145 grams per square meter through 295 grams per square meter, such as Rosset Textil's Ketten Sport branded athletic fabric.
“Polyamide” means a polymer with repeating units linked by amide bonds.
“Rosset Textil” means Rosset & Cia. Ltda., a Brazil Limited Liability Company, which was the applicant in U.S. Trademark Registration Number 3936388, U.S. Ser. No. 77/909,551.
“Ticking” means a fabric case that encloses a mattress.
“Ticking's outer perimeter” means the part of a ticking that is oriented vertically on the side of a mattress extending from the bottom of the mattress to the top of the mattress.
“Wrapped coils” means wire springs that are compressed within a fabric encasement, also sometimes known as pocketed coils, encased coils, encased springs, or Marshall coils.
While the present exemplary embodiments are shown in the drawings and fully described above with particularity and detail, it will be apparent to those of ordinary skill in the art that many modifications thereof may be made without departing from the principles and concepts set forth herein, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly, and use.
Hence, the proper scope of the present application should be determined only by the appended claims to encompass all such modifications as well as all relationships equivalent to those illustrated in the drawings and described in the specification.
Finally, it will be appreciated that the purpose of the annexed Abstract is to enable various patent offices throughout the world, the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of this application. Accordingly, the Abstract is not intended to define the invention or the application, which are defined only by the claims, and the Abstract is not intended to limit the scope of the invention in any way.
INDUSTRIAL APPLICABILITY
The disclosed embodiments and the methods associated therewith have applicability to the area of separable fastening apparatuses and modular mattress systems for facilitating human sleep.
CITATION LIST
Patent Literature
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- Iskeceli, WO 2020/022978 A1, “Multipiece and Multifunctional Bed.”
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Patent Application
20250000272
