This disclosure relates to beds and mattresses.
In general, a bed is a piece of furniture used as a location to sleep or relax. Many modern beds include a soft mattress on a bed frame. The mattress may include springs, foam material, and/or an air chamber to support the weight of one or more occupants. The mattress may include a mattress cover.
This specification describes technologies relating to hybrid mattresses, such as mattresses with coils in combination with other materials as shown and described herein.
An example embodiment of the subject matter described within this disclosure is a mattress with a mattress top, a mattress bottom, and a mattress perimeter. The mattress included the following features. An air chamber has an air chamber perimeter. A coiled spring perimeter includes a first set of coiled springs surrounding the air chamber perimeter. A topper portion has a support layer between the air chamber and the mattress top.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The topper portion includes a layer of foam and a second set of coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The support layer include at least a first portion of the second set of coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. A scrim is located between the layer of foam and the second plurality of springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The second plurality of springs is below the layer of foam.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The topper portion includes a topper portion perimeter including at least a second portion of the second set of coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The first portion of the second set of coiled springs and the second portion of the second set of coiled springs have different spring rates.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The first set of coiled springs have a different spring rate than the second set of coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The topper portion is inset such that an upper surface of the topper portion is substantially in line with an upper surface of the coiled spring perimeter.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. A scrim is between the topper portion and the air chamber.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The top of the coiled spring perimeter is connected to a bottom of the topper portion.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. A mattress cover encloses the topper portion, the coiled spring perimeter, and the air chamber.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The coiled spring perimeter includes a pocketed coil system, wherein coiled springs of the first set of coiled springs are individually pocketed.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The first set of coils includes an inner ring of coils positioned proximate the air chamber perimeter and an outer ring of coils positioned proximate the mattress perimeter.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The air chamber includes a first air chamber positioned in the mattress for supporting a first user. The mattress further includes a second air chamber positioned in the mattress for supporting a second user. Both the first and second air chambers are positioned inside the coiled spring perimeter.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The coiled spring perimeter and the topper portion combine to form an upside-down tub that covers the air chamber.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The topper portion includes a first layer comprising a foam and a second layer including a second plurality of coiled springs positioned below the first layer. The second layer is positioned above both the air chamber and the coiled spring perimeter.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The topper portion includes a first layer including a first foam and a second layer including a second foam different than the first foam. Both the first and second layers are positioned above both the air chamber and the coiled spring perimeter.
An example embodiment of the subject matter described within this disclosure is a system with the following features. A bed has a mattress including an air chamber with an air chamber perimeter. A coiled spring perimeter includes a first set of coiled springs surrounding the air chamber perimeter. A topper portion has a support layer between the air chamber and a top mattress of the mattress.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. A foundation is sized and configured to support the mattress.
An example embodiment of the subject matter described within this disclosure is a method with the following features. A mattress with a mattress top, a mattress bottom, and a mattress perimeter is formed. The mattress includes an air chamber with an air chamber perimeter. A coiled spring perimeter includes a first set of coiled springs surrounding the air chamber perimeter. A topper portion has a support layer between the air chamber and the mattress top.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The topper portion includes a foam layer and a second set of coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The support layer includes at least a first portion of the second set of coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The topper portion includes a topper portion perimeter comprising at least a second portion of the second set of coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The first portion of the second set of coiled springs and the second portion of the second set of coiled springs have different spring rates.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. Forming the mattress includes positioning the topper portion inside an interior space defined by the coiled spring perimeter. The topper portion has a geometry such that an upper surface of the topper portion is substantially in line with an upper surface of the coiled spring perimeter.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. Forming the mattress further includes receiving a scrim between the topper portion and the air chamber.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The mattress is received by an adjustable foundation. The mattress is retained to the adjustable foundation platforms of the adjustable foundation so as to retain the air chamber, coiled spring perimeter, and topper portion on the adjustable foundation.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The coiled spring perimeter is compressed to a compressed state and the coiled spring perimeter is stored in the compressed state prior to forming the mattress.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The mattress is compressed to a compressed state that compresses the coiled spring perimeter and storing the mattress in the compressed state after forming the mattress.
An example embodiment of the subject matter described within this disclosure is a mattress with a mattress top, a mattress bottom, and a mattress perimeter. The mattress includes the following features. A mattress core has a core perimeter. A coiled spring perimeter includes a first set of coiled springs surrounding the core perimeter. A topper portion is positioned above the mattress core.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. The mattress core includes no coiled springs.
Aspects of the example embodiment, which can be combined with any of the example embodiments alone or in combination, include the following. A cover encloses the mattress core, the coiled spring perimeter, and the topper.
Particular embodiments of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages. The mattresses described herein can facilitate quality and efficient mattress construction. For example, a mattress with a coiled spring perimeter as described herein can provide support around the edge of the mattress with springs while using one or more other materials such as foam and/or one or more air chambers at other locations of the mattress. The mattresses described herein can allow additional air-flow, for both static and dynamic air flow options, through the mattress when compared to other mattresses. The increased air flow allows for improved breathability and removal of built-up heat.
The details of one or more embodiments of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
Like reference numbers and designations in the various drawings indicate like elements.
This disclosure relates to a mattress using coiled springs in combination with other mattress materials. The mattress can include a mattress core with a perimeter around the mattress core. The mattress core can include one or more air chambers. A set of coiled springs surrounds the mattress core perimeter to form a coiled spring perimeter. Atop the mattress core is one or more mattress layers integrated with the mattress. The mattress layers can include one or more layers of foam and/or one or more layers of coiled springs. The coiled spring perimeter and the mattress topper can be attached to one another to form an upside-down, or inverted, tub that encompasses the mattress core.
In one example, the topper portion 116 can include a first layer 118 and a second layer 120. The first layer 118 can include a first foam and the second layer 120 can include a second foam different than the first foam. Regardless of composition, both the first layer 118 and second layer 120 are positioned above the mattress core and the coiled spring perimeter 112. While illustrated as having a two layer topper portion 116, the mattress 102 can include more or fewer support layers without departing from this disclosure. Alternatively or in addition, the layers of the topper portion 116 can include other materials, such as one or more layers or zones of ticking, spacer material, air chambers, down, down alternative, or springs without departing from this disclosure. A cover 122 can enclose the internal components of the mattress 102, such as enclosing the topper portion 116, the coiled springs 114, and the core. The cover 112 is pulled aside in
The mattress core 304 can include one or more air chambers 306 having an air chamber perimeter 308. The spring perimeter 112 surrounds the air chamber perimeter 308 of the one or more air chambers 306. The air chambers 306 can be inflatable air chambers that are fluidically connected to one or more pumps or blowers controlled by one or more controllers (not shown in
In some embodiments, other mattress cores can be used without departing from this disclosure. For example, in one embodiment the mattress core 304 can be formed of one or more foam members without any inflatable air chambers. In such an embodiment, the mattress core 304 can be positioned within the spring perimeter 112 and under the topper portion 302 to provide support for one or more users resting on the mattress 300. In other embodiments, the mattress core 304 can include a combination of one or more foam members and one or more air chambers. In still other embodiments, the mattress core 304 can include other mattress components, for example, such as one or more of a water-filled core portion, a foam core portion, a spring core portion, an air chamber core portion, and/or other core portions suitable for the application.
In some embodiments, a top of the coiled spring perimeter 112 can be connected to a bottom of the topper portion 302 to form an inverted (or upside-down) tub that covers the mattress core 304. In some embodiments, the coiled spring perimeter 112 includes a pocketed coil system. The springs can be individually pocketed or pocketed in groups by being sewn or glued in one or more layers of fabric. The coiled spring perimeter 112 can include one, two, or more rings of coiled springs. For example, as shown in
The topper portion 302 in
In one embodiment, the topper portion 402 can be connected to the coiled spring perimeter 112. For example, the topper portion 402 and the coiled spring perimeter 112 can be combined as a single unit during manufacturing as an inverted tub. The topper portion 402 and the coiled spring perimeter 112 can be stored separately from the first and second cores 404a and 404b until it is time for assembly of the mattress 400, either at an assembly facility or in a home of the user. At the time of assembly, the inverted tub that includes the topper portion 402 and the coiled spring perimeter 112 can be placed over the first and second cores 404a and 404b and a cover 410 of the mattress 400 can be closed around the internal components (such as by zipping, buttoning, or otherwise fastening the cover 410 closed, for example).
In some embodiments of the mattress 400 (as well as some embodiments of the other mattress variations described herein), the coiled spring perimeter 112 can be stored in a compressed state during the time between manufacture of the coiled spring perimeter 112 and the assembly of the mattress 400. In other embodiments, the mattress 400 can be stored in a compressed state after assembly. In some of the various embodiments, the springs of the coiled spring perimeter can be configured to be compressed for an extended period of time and spring back to shape after becoming uncompressed. Accordingly, the coiled spring perimeter can be configured to resist permanent deformation during compression for extended periods. By using the coiled spring perimeter 112 in combination with the topper portion 404 (having one or more layers of foam and/or coiled springs) and one or more cores 404a and 404b, the mattress 400 can be manufactured with materials that are high quality and high performance for the specific functions those materials are needed to perform within the mattress 400 while using lower quality components in other areas. For example, a high quality foam material can be used for the top layer of foam 406 without having to use lower quality foam material for the perimeter of the mattress 400 around the cores 404a and 404b.
Atop the coil spring perimeter 112 is the topper portion 508. As illustrated, the topper portion 508 includes a second set of perimeter springs 510 and a foam topper portion core 512. The second set of perimeter springs 510 rests above and has similar top-down dimensions as the main spring perimeter 112. The second set of perimeter springs 510 can have a different vertical height as well as a different spring rate as the coiled spring perimeter 112. In such an embodiment, the main spring perimeter 112 is attached to an underside of the scrim fabric, for example, with an adhesive. The second set of perimeter springs 510 and the foam topper portion core 512 can similarly be attacked to an upper side of the scrim fabric, for example, with adhesive
In some embodiments the foam 712 can be positioned above the spring layer 710. In other embodiments, the foam layer 712 can be positioned underneath the spring layer 710. In some embodiment, each group of springs (the spring perimeter 112, the topper portion perimeter springs 709, and the spring layer 710) can all have a different spring parameters (e.g. spring rates and/or geometries).
During manufacturing of the embodiments described herein, a mattress with a mattress top, a mattress bottom, and a mattress perimeter is formed. The finished mattress includes a core, such as an air chamber having an air chamber perimeter. A coiled spring perimeter of coiled springs surrounds the air chamber perimeter. A topper portion with a support layer is positioned between the air chamber and the mattress top. In some embodiments, the topper portion is received by a chamber defined by the coiled spring perimeter and the air chamber. In some embodiments, the topper portion has a geometry such that an upper surface of the topper portion is substantially in line with an upper surface of the coiled spring perimeter within standard manufacturing tolerances. During manufacture, a scrim is received under the topper portion. After the mattress is completed, the mattress is received by a foundation or other base that supports the mattress.
While this specification contains many specific embodiment details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. For example, while individual layers of certain embodiments may have been illustrated or described in a certain order, other arrangements can be used without departing from this disclosure. In some embodiments, the supporting spring layer can be separated into zones by changing the spring constant (i.e., firmness) of the coils throughout different areas of the layer. Also, forced air flow through ducting/zoning/wrapping of sections can be added without departing from this disclosure. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.
Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results.
This application claims the benefit of U.S. Provisional Application Ser. No. 63/191,086, filed May 20, 2021. The disclosure of the prior application is considered part of (and is incorporated by reference in) the disclosure of this application.
Number | Date | Country | |
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63191086 | May 2021 | US |