Patent Application
20230292930
The present disclosure generally relates to mattress assemblies, and more particularly, to mattress assemblies including an orthotic layer providing a contoured sleeping surface personalized for a specific end user and processes for personalized fitting of an end user to define the contours of the mattress assemblies.
Mattress assemblies are typically rectangular shaped having planar top and bottom surfaces. These types of mattress assemblies often exhibit uneven pressure distribution and spinal misalignment depending on the quality of mattress construction. Relief can often be addressed with different foams and/or coil systems used in the mattress construction, which can add manufacturing complexity and significant cost increases. Still, even with these types of modifications, relief is generalized and somewhat optimized for all consumers of the mattress assemblies. Personalization is generally not provided, and for most constructions, not economically practical to the bedding manufacturer. Moreover, existing mattress assemblies do a poor job in zoning for different regions of the body. Compression can be a culprit of pain points being created while tension strives to distribute the load.
Disclosed herein are [to be completed once claims are finalized].
In one or more other embodiments, a mattress assembly includes [to be completed once claims are finalized].
In still one or more other embodiments, a mattress assembly includes [to be completed once claims are finalized].
The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.
Referring now to the figures wherein the like elements are numbered alike:
Disclosed herein are mattress assemblies including an orthotic layer providing the mattress assemblies with a contoured surface that is translatable to the sleeping surface and processes for personalized fitting of an end user to define the orthotic foam layer. The orthotic layer is personalized to the end user and generally includes a contoured upper surface, a planar or contoured bottom surface, and vertically oriented sidewalls extending from the bottom planar surface to the contoured upper surface. The contoured upper surface is configured to minimize pressure points based on a deformation map personalized to the end user, which is likely different from other end users. One or more comfort layers can overlay the orthotic layer, wherein the contoured surface is translatable to the sleeping surface. The one or more comfort layers can be configured to have a relatively low firmness and thickness so that upon compression by a prone end user, the contoured surface provided by the orthotic layer can be felt by the end user even if the contour is not visibly apparent because of the presence of the one or more comfort layers. The mattress assemblies including the orthotic layer advantageously provide a reduction in pressure points experienced by the end user.
The processes for generating the mattress assemblies including the orthotic layer for providing the contoured surface generally includes generating a deformation map associated with an end user positioned on a test mattress. By way of example, the test mattress can include a plurality of pressure sensors configured to measure and generate the deformation map specific to the end user on the test mattress. A processor is configured to receive the signals from each of the various pressure sensors to generate the deformation map. The deformation map is then used to generate the orthotic layer including a contoured surface personalized to a particular end user. The orthotic layer generated from the deformation map can be configured for back sleepers, side sleepers, and/or stomach sleepers.
Mattress assemblies are then fabricated including at least the orthotic layer, which can further include one or more overlaying comfort layers or underlying layers as may be desired. The resulting mattress assemblies provide a personalized contoured sleeping surface with minimal pressure points for a particular end user. The orthotic layer is generally rectangular shaped having dimensions approximating the width and length of the mattress assembly such as a twin, queen, oversized queen, king, or California king sized mattress assembly, as well as custom or non-standard sizes constructed to accommodate a particular user or a particular room.
In one or more embodiments, the orthotic layer is generally rectangular shaped having dimensions less than the width and/or length of the mattress assembly. As such, the orthotic layer can be positioned in the mattress layer at a location corresponding to a desired sleeping area. For example, in a mattress assembly configured to accommodate two end users, orthotic layers can be customized for at least one or both end users and generally positioned under the respective end location on the mattress when sleeping.
Conventional techniques related to manufacturing processes such as the use of stitching, application of adhesives assembly steps, and the like are well known and so, in the interest of brevity, many conventional steps will only be mentioned briefly herein or will be omitted entirely without providing the well-known process details.
For the purposes of the description hereinafter, the terms “upper”, “lower”, “top”, “bottom”, “left,” and “right,” and derivatives thereof shall relate to the described structures, as they are oriented in the drawing figures. The same numbers in the various figures can refer to the same structural component or part thereof. Additionally, the articles “a” and “an” preceding an element or component are intended to be nonrestrictive regarding the number of instances (i.e., occurrences) of the element or component. Therefore, “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.
Spatially relative terms, e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.
The following definitions and abbreviations are to be used for the interpretation of the claims and the specification. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains” or “containing,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a composition, a mixture, process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus.
As used herein, the term “about” modifying the quantity of an ingredient, component, or reactant of the invention employed refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or solutions. Furthermore, variation can occur from inadvertent error in measuring procedures, differences in the manufacture, source, or purity of the ingredients employed to make the compositions or carry out the methods, and the like.
It will also be understood that when an element, such as a layer, region, or substrate is referred to as being “on” or “over” another element, it can be directly on the other element or intervening elements can also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, there are no intervening elements present, and the element is in contact with another element.
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The orthotic layer is not intended to be limited to a specific material so long as it is fairly rigid and maintains the contour surface. Exemplary materials include elastomeric solid materials, foams, or the like. These materials are relatively rigid and in one or more embodiments, have some flexibility. Suitable foams include but are not limited to, polyurethane foams, latex foams including natural, blended and synthetic latex foams; polystyrene foams, polyethylene foams, polypropylene foam, polyether-polyurethane foams, and the like. Likewise, the foam can be selected to be viscoelastic or non-viscoelastic foams. Some viscoelastic materials are also temperature sensitive, thereby also enabling the foam layer to change hardness/firmness based in part upon the temperature of the supported part. Unless otherwise noted, any of these foams may be open celled or closed cell or a hybrid structure of open and closed cells. Likewise, the foams can be reticulated, partially reticulated or non-reticulated foams. The term reticulation generally refers to removal of cell membranes to create an open cell structure that is open to air and moisture flow. Still further, the foams may be gel infused in some embodiments. The different layers can be formed of the same material configured with different properties or different materials.
The various foams suitable for use as the orthotic layer may be produced according to methods known to persons ordinarily skilled in the art. For example, polyurethane foams are typically prepared by reacting a polyol with a polyisocyanate in the presence of a catalyst, a blowing agent, one or more foam stabilizers or surfactants and other foaming aids. The gas generated during polymerization causes foaming of the reaction mixture to form a cellular or foam structure Latex foams are typically manufactured by the well-known Dunlap or Talalay processes. Manufacturing of the different foams are well within the skill of those in the art.
The different properties defining the orthotic layer may include, but are not limited to, density, hardness, thickness, support factor, flex fatigue, air flow, various combinations thereof, and the like Density is a measurement of the mass per unit volume and is commonly expressed in pounds per cubic foot. The density of the layers can generally range from about 1 to 2.5 pounds per cubic foot for non-viscoelastic foams and 1.5 to 6 pounds per cubic foot for viscoelastic foams. The hardness properties of foam are also referred to as the indention load deflection (ILD) or indention force deflection (IFD) and is measured in accordance with ASTM D-3574 The hardness of the layers generally have an indention load deflection (ILD) of 7 to 16 pounds force for viscoelastic foams and an ILD of 7 to 45 pounds force for non-viscoelastic foams. ILD can be measured in accordance with ASTM D 3575.
The orthotic layer can be molded, cut and/or manually slotted to form the desired contoured upper surface.
Turning now to
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
