Mattress structure

Information

  • Patent Grant
  • 6460209
  • Patent Number
    6,460,209
  • Date Filed
    Tuesday, January 18, 2000
    25 years ago
  • Date Issued
    Tuesday, October 8, 2002
    22 years ago
Abstract
A mattress (900) provides a user with three-dimensional firmness zoning, the mattress (900) cooperating with a mattress shell (720). The mattress (900) includes a plurality of longitudinally spaced, transversely extending resilient blocks (910) being independently movable relative to one another, an inflatable bladder (914) positioned to lie upon the top side of at least one of the blocks (910), and a topper (912) positioned to lie upon the inflatable bladder (914), the topper including opposite ends configured for attachment to the shell (720).
Description




BACKGROUND AND SUMMARY OF THE INVENTION




The present invention relates to bed and mattress structures and particularly to mattress structures that may be customized for individual users. The mattress of the present invention may be delivered to the user in a variety of forms assembled from kits provided at the point of sale to accommodate the musculoskeletal condition of the user. The mattress may also be customized at the factory or at some assembly location other than the point of sale based on a customer's reaction to a test mattress used at the point of sale.




It is well known to provide foam support pads or mattresses for supporting a user reclining on the pad. For example, U.S. Pat. Nos. 4,879,776, 5,038,433; 5,077,849; 5,111,542; and 5,172,439, all to Farley, disclose mattress overlays and pads for supporting a user. In addition, U.S. Pat. No. 4,449,261 to Magnusson and U.S. Pat. No. 4,991,244 to Walker disclose mattress borders for receiving core mattresses, and U.S. Pat. No. 5,105,488 to Hutchinson et al.; U.S. Pat. No. 4,803,744 to Peck et al.; and U.S. Pat. Nos. 4,424,600 and 4,435,864 to Callaway, disclose supporting surfaces having selectively adjustable firmness.




A mattress structure in accordance with the present invention is suitable for use with a conventional mattress positioned to lie upon an articulating deck. The conventional mattress includes a head portion for supporting the scapula and the lumbar of the a seat portion for supporting the user's sacrum, a thigh portion for supporting the thighs of the user, and a foot portion. Each named mattress portion is associated respectively with the head, seat, thighs, and feet of the person resting on the sleeping surface of the bed as well as with the underlying head, seat, thigh, and foot sections of the deck.




The mattress further includes a mattress cover having a top mattress cover and a bottom mattress cover coupled to the top mattress cover. The top and bottom mattress covers define a mattress interior receiving a plurality of mattress structure components. The bottom cover can be placed on a surface and used as a template for building the mattress with a “bottom up” assembly technique placing the components on the bottom of the mattress on top of the bottom cover and building the other components thereon. The top cover may also be positioned to facilitate a “top down” assembly by starting with the top cover and first adding the components on the top of the mattress to the top cover and building the other components thereon.




The mattress structure components include a frame made from a relatively firm foam rubber such as a high resiliency, high density urethane foam. The frame is positioned generally along the perimeter of the mattress. Use of a relatively firm foam provides support characteristics that aid users as they ingress and egress to and from an upwardly-facing sleeping surface of the mattress and that prevent the user from rolling off of the sleeping surface. The frame is formed to include a central opening beneath the sleeping surface above which the user will rest.




A plurality of cores including an air bladder, “zone foam” elements, “sculptured foam” shaped from foam blocks, and combinations thereof are provided for filling the central opening. The cores are selected to customize the firmness, support, and interface pressure characteristics to meet the individual desires of each user. To customize the mattress in such a fashion requires considering the combination of each individual's height, weight, body type, weight distribution, health conditions, and preferences.




The preferred method for customizing the mattress is initiated when a potential user completes a questionnaire to aid in the analysis of that user's “sleep profile.” The sleep profile assesses such factors as the user's general health and sleep habits. A firmness recommendation is computed either in terms of a pressure for various zones of a “test mattress” containing an air bladder or in terms of a foam type and density for each zone. In addition, a surface recommendation is established based on the user's responses to a surface recommendation questionnaire.




Once the surface and hardness recommendations are established, the user lies on a test sleeping surface containing an air bladder that is pressurized to match the firmness recommendation. Zones of the air bladder are then adjusted to match the preferences of the user and the resulting preferred firmness readings are recorded. An algorithm has been developed that translates the preferred firmness readings into a customized bed configuration. For example, the preferred firmness readings can be translated to establish the foam density that, if incorporated into a mattress, will provide the firmness and support characteristics similar to those provided by the test sleeping surface having the preferred firmness readings.




Once the customized bed configuration is established, a mattress can be assembled from a kit at the point of sale containing the plurality of cores for the user to test and verify that the mattress meets his or her preferences. If the mattress is not satisfactory, it can be adjusted at the point of sale. Once the user is satisfied, he or she can immediately take delivery of the completed customized mattress if desired. In the alternative, once the customized bed configuration is established, the data describing this configuration can be transmitted to a factory at which the mattress is assembled for delivery to the user.




The mattress structure in accordance with the present invention can be sized for a twin bed, a double bed, a queen-sized bed, or a king-sized bed. When the mattress is sized for queen-sized and king-sized beds, both sides of the mattress can be individually customized if desired to provide the firmness and support characteristics desired by individual sleep partners by customizing the core and customizing the topper to provide the desired firmness and support for each side of the bed. In such a “side-by-side” customization, the core and toppers supporting each user on separate halves of the mattress are distinct and separate. Having distinct and separate cores and toppers facilitates this customization while also serving to minimize the transmission of motion from one half of the mattress to the other when one of the sleeping partners moves.




As will be discussed in greater detail later in the specification, the mattress structure can be provided with an air bladder adjacent a foam block that is selectively adjustable by the user to provide varied firmness and support characteristics. If the same mattress is used on a bed having an articulating deck, the mattress can be provided with a hand held controller for use by the user that controls the adjustment of both the position of the deck and the bladder. In addition, the hand held controller can include a “memory set” feature that allows the user to establish preferred deck and mattress combination settings.




For example, the user may desire a first set of support characteristics at a pre-selected zone of the mattress when the deck is in a generally planar sleeping position. The user could establish this set of characteristics as the first memory setting. The user may also desire a different set of support characteristics at that zone of the mattress when the deck is positioned in a reclining position away from the generally planar sleeping position. If the user establishes this second set of characteristics as the second memory setting, the user can automatically move the bed and mattress structure to either of the first or second set of characteristics by pressing a button. Of course, even with these memory settings established, the user can move the bed and mattress to other positions as desired.




In addition, the mattress structure can be provided with combinations of air bladders, zone foam elements, and sculptured foam to produce a “combination mattress.” For example, the mattress structure can be provided having an air bladder supporting the scapula, foam supporting the lumbar, an air bladder in the seat portion supporting the sacrum, and foam supporting the thighs and legs. If desired, the air bladders can be in fluid communication so that they inflate and deflate at the same times and to the same pressures or the air bladders can be independent of one another and independently controlled by the user so that they user can establish different characteristics of support and firmness for each of the scapula and the sacrum.




According to one embodiment of the present invention, a mattress structure is provided that may be customized at the point of sale to accommodate the musculoskeletal condition and interface pressure preference of the user. The mattress structure includes a frame that defines a central opening and a foam core being positioned to lie within the central opening of the frame. The foam core comprises a head-end foam block, a foot-end foam block, and a seat foam block positioned to lie between the head and foot foam blocks. Each of the foam blocks has a top side and an opposite bottom side. The mattress structure further comprises a first block that has a first block firmness and is positioned to lie between the head-end foam block and the seat foam block and a second block that has a second block firmness and is positioned to lie between the foot-end foam block and the seat foam block. The second block firmness is different than the first block firmness and may be pre-selected by the user. Further, the mattress comprises a first cover having a first cover firmness and formed for extension across the frame and between the head-end and foot-end foam blocks and a second cover having a second cover firmness and formed for extension across an opposite side of the frame between the head-end and foot-end foam blocks. The second cover firmness is different than the first cover firmness to provide the user with a plurality of firmness configurations.




In another embodiment of the present invention, a mattress core is provided that comprises a frame that defines an interior region and that has a top end and an opposite bottom end and first and second covers. The first cover is coupled to the top end of the side wall and has a first cover firmness. The second cover is coupled to the bottom end of the side wall and has a second cover firmness that is greater than the first cover firmness. The mattress core further comprises a seat-support section positioned to lie within the interior region, a first foam block, and a second foam block. The seat-support section has a top side facing the first cover, an opposite bottom side facing the second cover, and opposite walls extending between the top and bottom sides. The first foam block is positioned to lie adjacent one side of the seat-support section and has a first core firmness and the second foam block is positioned to lie adjacent the opposite side of the seat-support section and has a second core firmness that is different than the first core firmness.




In yet another embodiment of the present invention a mattress is provided that comprises a frame that defines an interior region, a one-piece inflatable bladder positioned to lie within the interior region of the frame, and a plurality of foam blocks. The foam blocks are positioned to lie upon the inflatable bladder within the interior region of the frame. In addition, the foam blocks are configured to move upon the inflatable bladder relative to one another.




In still another embodiment of the present invention a mattress is provided that comprises a frame that includes a head-end section, a foot-end section and opposing sides that extend between the head-end section and the foot-end section and define an interior region therebetween and a plurality of foam blocks positioned to lie within the interior region of the frame. The foam blocks include opposite ends that are coupled to the opposite sides of the frame by an adhesive positioned to lie between the frame and the blocks.




Further, in another embodiment of the present invention a mattress is provided that comprises a frame defining an interior region, a plurality of foam blocks positioned to lie within the interior region of the frame, and an inflatable bladder positioned to lie adjacent one of the foam blocks.




In yet another embodiment of the present invention, a mechanism for attaching a pillow top on a mattress is provided. The attachment mechanism comprises a pillow top handle coupled to the pillow top, a mattress handle coupled to the mattress vertically adjacent the pillow top handle, and a strap. The pillow top handle includes opposite ends and a handle portion that extends between the opposite ends and defines a gripping aperture. The mattress handle includes opposite ends and a handle portion that extends between the opposite ends and defines a griping aperture. The strap is sized for extension through the gripping apertures of the pillow top and mattress handles and includes opposite ends and a fastening mechanism thereon. The fastening mechanism is configured to coupled the opposite ends of the strap together.




According to the present invention a pillow top assembly is provided suitable to lie upon a top cover of a mattress so that the pillow top assembly is configured to lie between the mattress and a user resting upon the mattress. The pillow top assembly comprises first and second fabric layers and a series of zoned blocks therebetween. The first fabric layer has an external side, an opposite internal side, a head end, and an opposite foot end. The second fabric layer is coupled to the first fabric layer and has an external side and an opposite internal side that cooperates with the internal side of the first fabric layer to define an internal region therebetween. The series of zoned blocks is positioned to lie within the internal region and is configured to extend between the head end and the foot end of the first fabric layer.




According to another embodiment of the present invention, a pillow top assembly is provided suitable for use on a top cover of a mattress. The pillow top assembly comprises a fabric shell and a series of zoned blocks. The fabric shell includes a top layer, a bottom layer spaced apart from the top layer to define an interior region therebetween, a head end, and an opposite foot end. The series of zoned blocks is positioned to lie within the interior region and extends between the head and foot ends of the fabric shell. Each of the zoned blocks in the series has a first end and an opposite second end and the second end of the first zoned block in the series is movably coupled to the first end of the adjacent zoned block in the series.




According to still another embodiment of the present invention, a pillow top assembly is provided suitable for use on a mattress. The pillow top assembly includes a fabric shell and a series of zoned blocks. The fabric shell includes a top layer having a first thermal resistance and a bottom layer spaced apart from the top layer to define an interior region therebetween and having a second thermal resistance that is greater than the first thermal resistance of the top layer, a head end, and an opposite foot end. The series of zoned blocks are positioned to lie within the internal region to extend between the head end and the foot end of the fabric shell.




Additional objects, features, and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of the preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived.











BRIEF DESCRIPTION OF THE DRAWINGS




The detailed description particularly refers to the accompanying figures in which:




FIG.


1


(


a


) is an exploded perspective view of a mattress in accordance with the present invention showing a bottom cover positioned beneath a foam bottom and a frame, a plurality of cores receivable above the foam bottom in a central opening formed in the frame, the plurality of cores including either a sculptured foam core, transversely extending zone foam blocks, an air bladder, or a combination thereof, the mattress also including a foam topper positioned to lie above the frame and the core, a top cover surrounding the topper, the frame, and the foam bottom, the top cover including a zipper half engaging a zipper half on the bottom cover to attach the top cover thereto, and a pillow top attached to the top of the top cover;




FIG.


1


(


b


) is a view similar to FIG.


1


(


a


) showing a mattress including a core having a combination of zone foam blocks and air bladders with zone foam blocks positioned to support the lumbar region of the back of the user and the thighs and legs of the user and air bladders positioned to support other portions of the user;




FIG.


1


(


c


) is a view similar to FIG.


1


(


b


) showing a mattress including a core having a combination of zone foam blocks and air bladders with air bladders positioned to support the lumbar region of the back of the user and the thighs of the user and zone foam blocks positioned to support other portions of the user;





FIG. 2

is an exploded perspective view of a king-sized mattress similar to the mattress of FIG.


1


(


a


) showing the bottom cover, the foam bottom, the frame, a foam divider received in the central opening of the frame to divide the central opening into two equally-sized side openings, the plurality of cores being alternatively receivable in the two side openings, the king-sized bed also including the topper, the top cover, and the pillow top;





FIG. 3

is an exploded perspective view of a mattress and bed structure in accordance with the present invention including a foundation and the mattress and showing the mattress positioned to lie above the foundation and a pillow top positioned to lie above the mattress, the mattress being attached to the foundation by a pair of elongated hook and loop type fasteners attached to the foundation and to the mattress at a foot end of the mattress to allow relative longitudinal motion at a head end of the mattress and foundation during articulation of the mattress and foundation, the pillow top being connected to the top cover of the mattress by a pair of elongated hook and loop type fasteners attached to a top cover of the mattress and attached to the pillow top, the pillow top also being coupled to the mattress by a pair of elongated straps fixed to the head end of the top cover of the mattress to form longitudinal loops and short straps which feed through the loops and are attached to the pillow top so that the head end of the pillow top can slide longitudinally relative to the top cover of the mattress while remaining generally fixed in the transverse direction relative to the pillow top;





FIG. 4

is a diagrammatic view of an articulating deck for carrying the mattress in accordance with the present invention showing the deck moved to a position other than a generally planar sleeping position;





FIG. 5

is a diagrammatic sectional view taken along line


5





5


of FIG.


1


(


a


) showing a sculptured foam core resting on an articulating deck of a bed, the deck being in a generally planar sleeping position;





FIG. 6

is a view similar to

FIG. 5

showing the deck in a position having the head section lifted to an upward raised position, the thigh section lifted slightly to an upward raised position, and the foot section elevated above and generally parallel to the seat section, cuts formed in the sculptured foam core on the surface opposite the folds allowing the sculptured foam core to generally conform to the shape of the deck;





FIG. 7

is a perspective view of the frame and the foam divider of

FIG. 2

showing the frame and the foam divider rail moved by an articulating deck (not shown) to a position other than the generally planar sleeping position, cuts formed in side foam sections of the frame on the surface opposite the bends and cuts formed in the foam divider rail on the surface opposite the bends allowing the frame and foam divider rail to generally conform to the shape of the deck;




FIG.


8


(


a


) is a diagrammatic bottom view of a “four-zone” air bladder and pressurized air supply with portions broken away showing the pockets formed in the air bladder by I-beams (not shown) attached to the interior of the air bladder, and showing each I-beam having first and second transverse ends, the first and second ends of a first set of I-beams being spaced-apart from the edge of the air bladder to form openings allowing fluid communication between pockets, and a diagrammatic manifold of the pressurized air supply;




FIG.


8


(


b


) is a view similar to FIG.


8


(


a


) of a four-zone air bladder in which zones of the air bladder which are not adjacent to one another are in fluid communication showing an upper back zone in fluid communication with a seat zone through a first tube positioned outside of an internal region of the air bladder and a lower back zone in fluid communication with a foot zone through a second tube positioned outside of an internal region of the air bladder;





FIG. 9

is a diagrammatic illustration of a sectional view taken along line


9





9


of FIG.


8


(


a


) showing the four-zone air bladder having pockets separated by I-beams with the selected I-beams defining the zones of the air bladder, the ends of a second set of I-beams sealingly engaging the edge of the air bladder to separate pockets adjacent to the I-beams to form separate and independently inflatable and deflatable zones of the air bladder;





FIG. 10

is a schematic view of a valve manifold for a one-zone air bladder showing a compressed air line, an exhaust line, an air line in fluid communication with the interior region of the air bladder, and a transducer for transducing a pressure measurement to an electronic output signal;





FIG. 11

is a diagrammatic sectional view of the bladder taken along line


11





11


of FIG.


8


(


a


) showing an interior region of the partially inflated air bladder including I-beams of generally uniform height with one I-beam being significantly taller than the remaining I-beams;





FIG. 12

is a view similar to

FIG. 11

showing the air bladder fully inflated so that the air bladder adjacent to the pockets defined by the significantly taller I-beam project above the air bladder adjacent to the other pockets so that the mattress adjacent to the projecting pockets provides a user with additional support and firmness;





FIG. 13

is a diagrammatic sectional view taken along line


13





13


of FIG.


8


(


a


) showing an interior region of the partially inflated air bladder including I-beams of generally uniform height with two I-beams being significantly taller than the remaining I-beams;





FIG. 14

is a view similar to

FIG. 13

showing the air bladder fully inflated so that the air bladder adjacent to the pockets defined by the significantly taller I-beams project above the air bladder adjacent to the other pockets so that the mattress adjacent to the projecting pockets provides a user with additional support and firmness;





FIG. 15

is a view similar to

FIG. 9

showing the air bladder having a plurality of significantly taller I-beams so that the air bladder adjacent to pockets adjacent to the lumbar region of the user, pockets adjacent to the thigh of the user, and pockets adjacent to the ankles of the user project above the air bladder adjacent to the other pockets to provide a user with additional support and firmness near portions of the mattress adjacent to the projecting pockets and to provide additional pressure relief to the heels of the user;





FIG. 16

is a view of the mattress of FIGS.


1


(


a


) and


2


showing an air supply providing pressurized air to an air bladder inside of the mattress and to an enclosed channel formed along the perimeter of the upwardly-facing sleeping surface of the mattress and an air heater interposed between the air supply and the channel to heat the air received by the channel, the material enclosing the channel being formed to include small openings that direct a small volume of air from the channel across the sleeping surface to warm or cool the user;





FIG. 17

is a perspective view of an arm rest in accordance with the present invention;





FIG. 18

is a sectional view of taken along line


18





18


of

FIG. 17

showing a cover surrounding the arm rest and showing a cup (in phantom) received in a cup holder formed in the arm rest;





FIG. 19

is a view similar to

FIG. 18

showing a bed having an articulated deck moved to a position away from the generally planar sleeping position, a mattress received on the deck, and the arm rest in a first orientation;





FIG. 20

is a view similar to

FIG. 19

showing the deck moved to a different position away from the generally planar sleeping position, the mattress on the deck, and the arm rest in a second orientation;





FIG. 21

is a perspective view of the hand held controller of

FIG. 16

for controlling the positions of the articulating portions of the articulating deck of the bed, controlling the pressure of air in the four zones of the bladder, and for pre-setting in memory air pressures selected by the user corresponding to deck positions selected by the user so that by pressing a single button the deck will adjust to the preselected position and the bladder will adjust pressures in the four zones to the preselected pressures;





FIG. 22

is a plan view of a portion of the hand held controller of

FIG. 21

showing the indicia on the hand held controller and showing “bed position buttons” on a first end, the buttons being arranged in a “use-frequency arrangement” having the most frequently used buttons positioned to lie adjacent to the first end, the least frequently used buttons positioned to lie adjacent to the second end which is opposite the first end, and the remaining buttons positioned to lie therebetween arranged in order of the frequency of use with the more frequently used buttons being positioned closer to the first end than the less frequently used buttons;





FIG. 23

is a schematic block diagram illustrating the electrical components of a control system for controlling features of the bed and mattress structure in accordance with the present invention;





FIG. 24

is an exploded perspective view of an alternative embodiment of a mattress apparatus of the present invention, with portions broken away showing a top quilted panel, a bottom quilted panel, a frame defining a central opening positioned between the top and bottom quilted panels, a mattress core positioned in the central opening and including a head-end block, a foot-end block, and a seat block, a first zone block having a first block firmness and positioned to lie between the head-end block and the seat block, and a second zone block having a second block firmness and positioned to lie between the foot-end block and the seat block;





FIG. 25

is a perspective view with portions broken away of the mattress apparatus of

FIG. 24

that is configured to accommodate two users, showing a first set of blocks and a second set of blocks positioned to lie in a side-by-side relationship;





FIG. 25



a


is a cross-sectional view taken along line


25




a





25




a


of

FIG. 25

showing an anti-shear coating positioned upon the first zone block and the seat block;





FIG. 26

is a perspective view with portions broken away of an alternative embodiment of the present invention showing a mattress including a frame that defines an interior opening, a one-piece bladder positioned to lie in the interior opening, and a plurality of zone blocks positioned to lie upon the one-piece bladder;





FIG. 27

is a cross-sectional view of the mattress of

FIG. 26

showing the mattress including a lower quilted panel and an upper quilted panel and showing the one-piece bladder resting upon the lower quilted panel and the zone blocks positioned to lie between the one-piece bladder and the upper quilted panel;





FIG. 28

is an enlarged perspective view of a portion of a slip cover in accordance with another embodiment of the present invention showing the slip cover including a top member, a bottom member, and a plurality of pockets that are spaced apart by fabric spacer regions, the pockets being sized to receive zone blocks therein;





FIG. 29

is a cross-sectional view taken along lines


29





29


of

FIG. 28

after insertion of the zone blocks in the pockets and showing the individual compression of the zone blocks relative to one another;





FIG. 30

is an exploded perspective view of an alternative embodiment of the present invention showing a shell, a frame, a topper, sleeve each including a top cover, a bottom cover, a plurality of pockets therebetween defined by seams, and a slot formed in the top cover and zoned blocks sized for insertion through the slots into the pockets of the sleeves;





FIG. 31

is a perspective view with portions broken away of an alternative embodiment of the present invention showing a frame that defines an interior region and includes a head-end, a foot-end, and opposite sides extending between the head-end and the foot-end, a plurality of zoned blocks positioned to lie within the interior region, each of the blocks including opposite ends coupled to the opposite sides of the frame by an adhesive;





FIG. 32

is a cross-sectional view taken along lines


32





32


of

FIG. 31

showing one zone block including an end coupled to the frame by an adhesive;





FIG. 33

is a cross-sectional view taken along lines


33





33


of

FIG. 31

showing a sleeve positioned to lie between adjacent zone blocks of the mattress;





FIG. 34

is a perspective view with portions broken away of an alternative embodiment of the present invention showing a frame defining an interior region and a modular block component portioned within the interior region, and the block component includes a zone block and a bladder positioned adjacent the zone block to selectively increase or decrease the firmness of the zone block;





FIG. 35

is an exploded perspective view of an alternative embodiment of the present invention showing a super pillow top having a fabric shell with handles and a plurality of zoned blocks positioned to lie within the shell, an attachment mechanism, and a foundation;





FIG. 35



a


is an exploded perspective view of the super top, mattress, foundation, and attachment mechanism of

FIG. 35

showing the attachment mechanism including a strap with hook and loop type fasteners and the mattress having a handle;





FIG. 35



b


is a cross-sectional view of the mattress, pillow top and attachment mechanism of

FIG. 35



a


showing the strap extending through the handles of the pillow top and mattress and coupled to hook and loop type fasteners on the foundation;





FIG. 35



c


is a perspective view of a sleeve receiving the blocks of

FIG. 35

for use in a super top in accordance with an alternative embodiment of the present invention;





FIG. 36

is an enlarged view of one strap of

FIG. 35



b


showing the strap including opposite ends with hook and loop type fasteners;





FIG. 37

is an exploded perspective view of a bed in accordance with yet another embodiment of the present invention showing the bed including a frame, a plurality of zone foam blocks, a seat block, a lumbar block, a topper, and a pillow topper;





FIG. 38

is a cross-section taken along lines


38





38


of

FIG. 37

showing the seat block including a thin upper layer, a thick inner core, and a thin lower layer of different firmness;





FIG. 38



a


is a view similar to

FIG. 38

showing the seat block when the user is lying down on block to distribute the load across block;





FIG. 38



b


is a view similar to

FIG. 38

showing the seat block when the user weight is directed toward the core of seat block;





FIG. 39

is a cross-section taken along lines


39





39


of

FIG. 37

showing the lumber block including a thick center core and spaced-apart thin side layers of different firmness sandwiching the center core therebetween;





FIG. 40

is an exploded perspective view of a mattress structure in accordance with still another embodiment of the present invention showing the mattress structure including shell, a plurality of zone blocks, a topper, and a thin air chamber positioned to lie between the zone blocks and the topper;





FIG. 41

is a cross-section of the mattress structure of

FIG. 40

showing the air chamber including a plurality of inner supports defining tube-like cavities therein;





FIG. 42

is an exploded perspective view of a pillow top assembly in accordance with the present invention showing the pillow top assembly positioned to lie upon a top surface of a mattress and including a shell having a first and second cover defining an interior region therebetween, a foam block held within the interior region, and handles extending from the first cover for engagement with the mattress to hold the assembly upon the mattress;





FIG. 43

is a cross-sectional view of the pillow top assembly of

FIG. 42

, showing the first and second covers coupled together with the zoned blocks positioned therebetween and an anti-slip sheet positioned to lie between a seat portion of the pillow top assembly and the mattress to prevent motion between the seat portion of the pillow top assembly and the mattress;





FIG. 44

is a view similar to

FIG. 42

of an alternative pillow top assembly in accordance with the present invention showing the pillow top assembly including a shell defining an interior region, a series of zoned blocks held within the interior region, and handles extending from the shell;





FIG. 45

is a cross-sectional view of a heat-dispersement apparatus in accordance with the present invention positioned upon a mattress and showing the heat-dispersement apparatus engaging a heating element and supporting the pillow top assembly of

FIG. 42

;





FIG. 46

is an exploded perspective view of a pillow top assembly in accordance with the present invention showing the pillow top assembly positioned to lie upon a top surface of a mattress and including a shell having a first and second layer defining an interior region therebetween and two series of zoned blocks held within the interior region and showing an anti-skid material positioned to lie between the pillow top assembly and the mattress;





FIG. 47

is a cross section of the pillow top assembly of

FIG. 46

, showing the first and second layers of the shell coupled together with the zoned blocks positioned therebetween and an anti-slip sheet positioned between a middle region of the pillow topper and the mattress to prevent motion between the middle region of the pillow topper and the mattress during articulation of the mattress;





FIG. 48

is a cross section of another pillow top assembly of the present invention showing the pillow top assembly positioned to lie upon an anti-slip material, which lies upon a top surface of a mattress and showing the pillow top assembly including a shell, a first series of generally rectangular zone blocks positioned to lie within the shell and a second series of generally rectangular zone blocks positioned to lie upon the first series of blocks within the shell;





FIG. 49

is a cross-sectional view of the pillow top assembly of

FIG. 47

positioned to lie upon an anti-slip material, which lies upon a heat-dispersement of

FIG. 45

;





FIG. 50

is a cross section of another pillow top assembly of the present invention showing the pillow top assembly positioned to lie on a top surface of a mattress and including a shell defining an interior region and a series of transversely extending trapezoidal-shaped zoned blocks held within the interior region, each of the zoned blocks including angled first and second ends and showing the second end of a first block in the series overlapping the first end of an adjacent block in the series;





FIG. 51

is a view similar to

FIG. 50

of yet another pillow top assembly of the present invention, showing the pillow top assembly including a first series of generally trapezoidal shaped zoned blocks and a second series of generally trapezoidal shaped zoned blocks positioned to lie upon the first series of zoned blocks;





FIG. 52

is a perspective view of a slip cover in accordance with the present invention having a plurality of pockets sized to receive the zoned blocks and showing a zoned block before insertion into one of the pockets;





FIG. 53

is a cross-sectional view of the slip cover of

FIG. 52

following insertion of the zoned blocks into the pockets;





FIG. 54

is a perspective view of a sleeve in accordance with the present invention showing the sleeve having slots and pockets and showing generally trapezoidal-shaped zoned blocks positioned to lie in the pockets and showing one zoned block being inserted through a slot of the sleeve into the pocket;





FIG. 55

is an exploded assembly view of a conversion mattress structure of the present invention showing the mattress structure including a fabric shell, resilient blocks, and a sleeve formed to receive the blocks and showing a first configuration of the mattress structure wherein convoluted foam is configured to rest upon the sleeve;





FIG. 56

is an exploded assembly view of a second configuration of the mattress structure of

FIG. 55

showing the mattress structure including an air bladder and a foam topper that are configured to rest upon the sleeve within the fabric shell;





FIG. 57

is a cross-sectional view of the mattress structure of

FIG. 55

in an assembled position showing the fabric shell having a pre-determined height and the foam core positioned upon the sleeve;





FIG. 58

is a cross-sectional view of the mattress structure of

FIG. 56

in an assembled position showing the foam topper situated upon the air bladder and the air bladder situated upon the sleeve and also showing the fabric shell having generally the same predetermined height so that the mattress structure is interchangeable between the first and second configurations;





FIG. 59

is an exploded assembly view of an alternative embodiment of the present invention showing a mattress structure including a fabric shell, anti-skid material affixed to fabric shell, opposite end foam blocks, a center block that includes three symmetric zoned foam blocks (in phantom), foam side rails and toppers coupled to end and center blocks, and a sleeve formed to receive the end and center blocks;





FIG. 60

is a perspective view of mattress structure of

FIG. 59

in a folded position showing (in phantom) the relative positioning of the end foam blocks in the unfolded position and the symmetry of the end foam blocks to aid the manufacturer in storing and shipping the mattress structure,





FIG. 61

is an exploded assembly view of the center block of

FIG. 59

showing three symmetric zoned foam blocks therein that are separated by a polyethylene film to enable the blocks to move relative to one another;





FIG. 62

is an exploded assembly view of a mattress structure of the present invention showing the mattress structure including a fabric shell, composite foam blocks, and a sleeve formed to receive the composite foam blocks;





FIG. 63

is a perspective view of one composite block showing the block coupled to top and bottom foam toppers and to opposite foam end rails;





FIG. 64

is an exploded perspective view of a mattress retention bracket in accordance with the present invention showing the bracket including a retainer configured for extension into a block and a support frame configured to be coupled to a foundation and to the retainer; and





FIG. 65

is an exploded perspective view of a mattress retention apparatus that prevents an associated mattress structure from sliding laterally upon a foundation having a solid deck and the retainer of

FIG. 64

configured to be coupled the solid support of the foundation.











DETAILED DESCRIPTION OF THE INVENTION




A bed and mattress structure


50


includes a mattress


52


in accordance with the present invention as illustratively shown in FIGS.


1


(


a


)-(


c


). As used in this description, the phrase “head end


46


” will be used to denote the end of any referred-to object that is positioned to lie nearest head end


46


of bed and mattress structure


50


. Likewise, the phrase “foot end


48


” will be used to denote the end of any referred-to object that is positioned to lie nearest foot end


48


of bed and mattress structure


50


.




Mattress


52


includes a bottom cover


54


having a perimeter edge


56


and a first zipper half


58


attached to perimeter edge


56


as shown in FIGS.


1


(


a


) and


2


. Mattress


52


also includes a top cover


60


that cooperates with bottom cover


54


to define a mattress interior


72


.




Top cover


60


includes an upwardly-facing top portion


62


and a downwardly-extending side portion


66


as shown in FIGS.


1


(


a


) and


2


. Side portion


66


includes a bottom edge


68


and a second zipper half


64


attached to bottom edge


68


, second zipper half


64


attaching to first zipper half


58


to form zipper


70


that connects top cover


60


and bottom cover


54


.




Although zipper


70


is positioned to lie adjacent to bottom edge


68


, a bottom cover could be provided having an upwardly-extending side portion


67


as shown in FIGS.


1


(


b


) and


1


(


c


) defining a mattress side and the second zipper half could be attached to side portion


67


of the bottom cover so that zipper


70


could be positioned along the mattress side or the upper perimeter edge of mattress


52


. Zipper


70


can therefore be positioned to lie adjacent to bottom edge


68


or at any position along the mattress side, which in preferred mattress


52


includes side portion


66


, without exceeding the scope of the invention as presently perceived. However, positioning zipper


70


adjacent bottom edge


68


provides certain assembly related advantages described below while also improving the appearance of mattress


52


by allowing zipper


70


to be easily hidden.




A frame


74


having a head end foam section


76


, a foot end foam section


78


, and longitudinally extending side foam sections


80


joining head end and foot end foam sections


76


,


78


is received in mattress interior


72


as shown in FIGS.


1


(


a


) and


2


. Frame


74


is formed with rounded corners to enhance the appearance of mattress


52


. In addition, joints


83


connect head end foam section


76


to side foam sections


80


and foot end foam section


78


to side foam sections


80


. Joints


83


are lap joints having portions of head end and foot end foam sections


76


,


78


overlapping and fastened to respective portions of side foam sections


80


. Forming joints


83


in this manner results in additional support provided to head end foam section


76


when mattress


52


slides past head end


46


of foundation


120


during articulation of deck


138


.




Head end, foot end, and side foam sections


76


,


78


,


80


of frame


74


cooperate to define a central opening


82


as shown best in FIGS.


1


(


a


) and


2


above which a user (not shown) will rest. A foam bottom


84


is received in central opening


82


and foam bottom


84


and frame


74


lay against bottom cover


54


. A topper


86


rests against top of frame


74


and above central opening


82


to engage top portion


62


of top cover


60


. A core or core structure


88


is received in central opening


82


and is positioned to lie between foam bottom


84


and topper


86


. Having topper


86


sized to cover both frame


74


and core


88


minimizes the ability of the user to perceive the interface between frame


74


and core


88


.




A pillow top


90


is attached to the top of top portion


62


of top cover


60


and is positioned to lie outside of mattress interior


72


as shown in FIGS.


1


(


a


) and


2


to define a sleeping surface


122


on which a user will rest. Top cover


60


is made from a material having a low coefficient of friction such as a polypropylene anti-shear material to allow for the sliding movement of pillow top


90


relative to top cover


60


near head end


46


of mattress


52


. In addition, top cover


60


should be somewhat elastic so that the user can “sink into” mattress


52


allowing mattress


52


to conform to the user's shape, thereby relieving interface pressure.




Pillow top


90


includes a foam pad (not shown) covered by fabric and adorned, for example, by buttons


124


, ornamental stitching, or the like to enhance the appearance of pillow top


90


. Pillow top


90


can be attached to top cover


60


using any suitable method such as by a zipper (not shown), adhesive (not shown), straps (not shown), or even sewing pillow top


90


to top cover


60


. However, as described below with reference to

FIG. 3

, pillow top


90


is attached to top cover


60


using hook and loop type fasteners so that pillow top


90


is easily removable and replaceable. Mattress


52


can alternatively be provided without pillow top


90


, in which case the upwardly-facing surface of top portion


62


of top cover


60


serves as sleeping surface


122


.




Core


88


can alternatively include either a set of zone foam blocks


92


, a sculptured foam core


94


, an air bladder


96


, or a combination thereof as shown in FIGS.


1


(


a


)-(


c


) and


2


. Frame


74


, foam bottom


84


, topper


86


, zone foam blocks


92


, sculptured foam core


94


, and an interior portion (not shown) of pillow top


90


may be made from a foam rubber such as urethane foam. The firmness and support characteristics of the foam rubber can be varied in accordance with the desires of the user of mattress


52


. The firmness and support characteristics of the foam rubber is varied by varying either the density of the foam or the shape of the outer surfaces of the foam.




Although urethane foam is the preferred material for these components, any material providing support and firmness characteristics similar to those provided by foam rubber can be used without exceeding the scope of the invention as presently perceived. For example, topper


86


can be made from latex foam or urethane foam, or in the alternative it can include an air bladder, a water bladder, or a bladder for other fluids without exceeding the scope of the invention as presently perceived.




Mattress


52


rests on a foundation


120


, as shown in

FIG. 3

, such as box springs, a stationary deck of a bed, an articulating deck of a bed, or the like. Mattress can also rest on a floor or any other generally planar, upwardly facing surface without exceeding the scope of the invention as presently perceived.




Foundation


120


and the underside of bottom cover


54


are provided with elongated mating portions of hook and loop type fasteners


164


so that mattress


52


is removably attached to foundation


120


as shown in FIG.


3


. Fasteners


164


prevent lateral movement of mattress


52


relative to foundation


120


. However, fasteners


164


are spaced apart from head end


46


of bed and mattress structure


50


so that head end


46


of mattress


52


can slide longitudinally relative to head end


46


of foundation


120


as described below.




In addition, the underside of pillow top


90


and the upper side of top portion


62


of top cover


60


of mattress


52


are both provided with elongated mating portions of hook and loop type fasteners


168


as shown in

FIG. 3

so that pillow top


90


is removably attached to mattress


52


. Mattress


52


is also provided with a pair of longitudinally extending long loops


170


and pillow top


90


is provided with a pair of transversely extending short loops


172


. Each short loop


172


includes a first end


174


that is fixed to pillow top


90


and a second end


176


that is attached to pillow top


90


using hook and loop type fasteners


178


. Second end


176


of each short loop


172


is received by one of long loops


170


respectively so that short loops


172


cooperate with long loops


170


to prevent transverse movement of pillow top


90


relative to mattress


52


while allowing the longitudinal sliding of pillow top


90


relative to mattress


52


during articulation of deck


138


.




As described above, mattress


52


is configured for use on both stationary, generally planar, and upwardly facing surfaces on which mattress


52


rests during use by a user, as well as on a bed, table, or other device (not shown) having an articulating deck


138


as shown diagrammatically in FIG.


4


. Illustrative articulating deck


138


includes a head section


144


, a seat section


146


, a thigh section


148


, and a foot section


150


. A light (not shown) or other illuminating device can be provided having an arm (not shown) or extending bracket attached to head section


144


so that the light extends to a position illuminating mattress


52


. By attaching the arm to head section, the relative position of user's head and the light will remain generally fixed.




Seat section


146


of deck


138


is fixed relative to the bed having a generally horizontal upwardly-facing surface carrying mattress


52


and head, thigh, and foot sections


144


,


148


,


150


are movable with respect to the bed (not shown) and with respect to each other to move mattress


52


so that the position of mattress


52


and the position of the user on top of mattress


52


changes. Drivers for moving head, thigh, and foot sections


144


,


148


,


150


are diagrammatically indicated by arrows


152


in FIG.


4


. In the preferred articulating deck


138


, foot section


150


is movable only to positions in which foot section


150


is generally parallel to seat section


146


. In addition, the movement of preferred thigh section


148


is limited to positions between the generally horizontal sleeping position and positions upwardly from the sleeping position so that the feet of the user (not shown) remain generally vertically even with or elevated above the torso of the user.




It will be appreciated that various mechanical and electromechanical actuators and drivers may be used to raise and lower individual deck sections


144


,


146


,


148


,


150


relative to the bed as shown in

FIGS. 4-6

. It is well known in the hospital bed art that electric drive motors with various types of transmission elements including lead screw drives and various types of mechanical linkages may be used to cause relative movement of portions of hospital beds. It is also well known to use pneumatic actuators including various types of air bladders powered by pressurized air to actuate and/or move individual portions of hospital beds. The terms “means for raising or lowering” in the specification and in the claims, therefore, are intended to cover all types of mechanical, electromechanical, hydraulic, and pneumatic mechanisms, including manual cranking mechanisms of all types, for raising and lowering portions of chair bed


50


of the present invention.




As indicated above, mattress


52


is attached to foundation


120


and pillow top


90


is attached to mattress


52


to allow sliding movement of head end


46


of mattress


52


relative to foundation


120


and of pillow top


90


relative to mattress


52


. It will be apparent to those skilled in the art, that fixing one end of mattress


52


and pillow top


90


and then moving articulating deck


138


will cause shear forces between mattress


52


and foundation


120


and between pillow top


90


and mattress


52


. Connecting mattress


52


to foundation


120


and pillow top


90


to mattress


52


as described above with respect to

FIG. 3

will alleviate the shear forces by allowing head end


46


of mattress


52


and pillow top


90


to slide longitudinally relative to foundation


120


and relative to each other.




As described above, core


88


can include zone foam blocks


92


. A set of zone foam blocks


92


found in mattress


52


includes a plurality of transversely extending zone foam blocks


92


that longitudinally abut one another. If mattress


52


is for use in a single bed as shown in FIG.


1


(


a


) so that central opening


82


is a first width


110


, each block


92


extends full width


110


of central opening


82


to engage opposing side foam sections


80


. Plurality of zone foam blocks


92


fills the entire central opening


82


so that a first of blocks


92


engages head end foam section


76


, a last of zone foam blocks


92


engages foot end foam section


78


, and zone foam blocks


92


therebetween engage one another.




If mattress is for use in a queen-sized bed (not shown), central opening


82


is a second width and each block


92


extends only one-half of the second width. In such instance, core


88


can alternatively include side-by-side combinations including a set of zone foam blocks


92


, sculptured foam core


94


, and air bladder


96


. For example, sculptured foam core


94


can be received in opening


82


engaging one of side foam sections


80


and zone foam blocks


92


can be received in opening


82


engaging sculptured foam core


94


on one side and the other of side foam sections


80


.




For another example, central opening


82


can receive side-by-side left and right sets of zone foam blocks


92


. A first of the zone foam blocks


92


of the left set of zone foam blocks


92


engages head end foam section


76


, a last of the zone foam blocks


92


of the left set of zone foam blocks engages foot end foam section


78


, and each zone foam block


92


of the left set of zone foam blocks


92


engages one of side foam sections


80


. A first of the zone foam blocks


92


of the right set of zone foam blocks


92


also engages head end foam section


76


, a last of the zone foam blocks


92


of the right set of zone foam blocks engages foot end foam section


78


, and each zone foam block


92


of the right set of zone foam blocks


92


engages the other of side foam sections


80


. In addition, zone foam blocks


92


of the left set of zone foam blocks engage zone foam blocks


92


of the right set of zone foam blocks


92


. Thus, in a queen-sized bed, zone foam blocks


92


abut one another longitudinally and side-by-side.




If mattress


52


is for use in a king-sized bed as shown in

FIG. 2

, central opening


82


is a third width


112


and each block


92


extends less than one-half of the full width


112


of central opening


82


. In such an instance, core


88


can additionally include a foam divider rail


114


. Foam divider rail


114


divides central opening


82


into a first side opening


116


and a second side opening


118


.




First and second side openings


116


,


118


have equal widths, and foam divider rail


114


is sized so that the widths of first and second side openings


116


,


118


are the same as first width


110


as shown in FIG.


2


. Thus, blocks


92


, sculptured foam core


94


, and air bladder


96


can interchangeably fit in each of opening


82


of a single or twin bed as shown in FIG.


1


(


a


) and first and second side openings


116


,


118


and engage one of side rails


80


and foam divider rail


114


as shown in FIG.


2


.




First opening


116


can receive any of zone foam blocks


92


, sculptured foam core


94


, and air bladder


96


and second opening


118


can receive any of the zone foam blocks


92


, sculptured foam core


94


, and air bladder


96


as shown in FIG.


2


. The selection of pieces of core


88


received by first opening


116


is independent of the selection of pieces of core


88


of second opening


118


, so that core


88


for a mattress for use with a king-sized bed can include foam divider rail


114


, zone foam blocks


92


, sculptured foam core


94


, air bladder


96


, or a combination thereof.




For example, if core


88


includes two sets of zone foam blocks


92


as described above for a queen-sized mattress, each block


92


will extend the full width of the respective first or second opening


116


,


118


to engage foam divider rail


114


and opposing side foam section


80


. Each set of zone foam blocks


92


fills the entire first or second opening


116


,


118


so that a first of blocks


92


engages head end foam section


76


, foam divider rail


114


, and one of the side foam sections


80


, a last of zone foam blocks


92


engages foot end foam section


78


, foam divider rail


114


, and the same of the side foam sections


80


, and blocks


92


therebetween engage one another, foam divider rail


114


, and the same of the side foam sections


80


.




Each zone foam block is provided with an anti-shear coating so that each zone foam block


92


can move in a vertical direction independently of adjacent zone foam blocks


92


and independently of frame


74


. The anti-shear coating can be a coating formed on or applied to zone foam blocks


92


as well as a sleeve


98


having an interior


100


receiving zone foam block


92


as shown in FIGS.


1


(


a


) and


2


. Sleeve


98


is made from a material having a low coefficient of friction such as “parachute material” or nylon.




The firmness of zone foam blocks


92


can vary from zone foam block


92


to zone foam block


92


. The firmness ranges approximately between an average indention load deflection (ILD) of 15 to 98. Preferred zone foam blocks


92


are provided with ribbed upper and lower surfaces as shown in FIGS.


1


(


a


)-(


c


) and


2


. Ribs on the surfaces result in less force being required to compress zone foam blocks


92


than would be required without the ribs. This means that even when little weight is applied to zone foam blocks


92


, blocks


92


will compress and contour to user's shape, thereby reducing interface pressures, and essentially reducing the ILD so that the ILD can be “fine-tuned” by the addition of ribs.




As described above, core


88


can also include sculptured foam core


94


as shown in FIGS.


1


(


a


),


2


,


5


, and


6


. Sculptured foam core


94


is a unitary piece of foam of uniform firmness that has been sculptured to a desired shape. However, sculptured foam core


94


can be formed from a piece of foam having firmness that varies along its length or across its width without exceeding the scope of the invention as presently perceived.




Sculptured foam core


94


is formed to include transversely extending troughs


130


along a top surface


132


of sculptured foam core


94


as well as transversely extending cuts


134


extending inwardly from both top surface


132


and a bottom surface


136


of sculptured foam core


94


, as shown best is

FIGS. 5 and 6

that show sculptured foam core


94


resting on a diagrammatic articulating deck


138


of a bed (not shown). Each cut


134


includes a transversely-extending slit


140


extending inwardly from the respective surface


132


,


136


and terminating in a transversely-extending cylindrical opening


142


.




As described above, each of the head, thigh, and foot sections


144


,


148


,


150


of articulating deck


138


typically move relative to seat section


146


, relative to one another, and relative to the bed as shown in

FIGS. 5 and 6

. Portions of sculptured foam core


94


adjacent to each of sections


144


,


146


,


148


,


150


are configured to move with each respective section


144


,


146


,


148


,


150


. Slits


140


allow for folding movement of sculptured foam core


94


in a direction inwardly away from slits


140


as shown, for example, in

FIG. 6

, and openings


142


prevent the inadvertent tearing of sculptured foam core


94


when sculptured foam core


94


is folded.




Cuts


134


are positioned so that at least one of cuts


134


lies generally between the head and seat sections


144


,


146


, at least one of cuts


134


lies generally between the seat and thigh sections


146


,


148


, and at least one of cuts


134


lies generally between the thigh and foot sections


148


,


150


as shown in

FIGS. 5 and 6

. Sculptured foam core


94


is provided with a plurality of cuts


134


at each position as shown best in

FIGS. 5 and 6

so that the above holds true when sculptured foam core


94


is used with a variety of beds having articulating decks, the longitudinal lengths of the head, seat, thigh, and foot sections


144


,


146


,


148


,


150


of which may vary from bed to bed.




As mentioned above, sculptured foam core


94


is also provided with transversely extending troughs


130


formed on top surface


132


shown best in

FIGS. 5 and 6

. Troughs


130


can be positioned to facilitate the folding of sculptured foam core


94


as shown in

FIG. 6

by providing additional space for the surface


132


,


136


opposite cuts


134


to compress upon itself. However, troughs


130


are not necessary for the portions of sculptured foam core


94


to move with the head, seat, thigh, and foot sections


144


,


146


,


148


,


150


or articulating deck


138


.




Each trough


130


is formed to include a depth


160


and a width


162


as shown best in

FIGS. 5 and 6

, and both of depth


160


and width


162


can be varied to vary the characteristics of support and firmness exhibited by sculptured foam core


94


adjacent to troughs


130


. For example, by increasing depth


160


of troughs


130


, sculptured foam core


94


adjacent to troughs


130


provides the user (not shown) with support and firmness characteristics that would be expected from a non-sculptured foam mattress having foam that is less firm than the foam comprising sculptured foam core


94


. Likewise, by increasing width


162


of troughs


130


, sculptured foam core


94


adjacent to troughs


130


provides the user (not shown) with support and firmness characteristics that would be expected from a non-sculptured foam mattress having foam that is less firm than the foam comprising sculptured foam core


94


. Thus, by varying depth


160


and width


162


of troughs


130


, the support and firmness characteristics of portions of sculptured foam core


94


can be varied.




Troughs


130


are formed in top surface


132


of sculptured foam core


94


. It has been found, however, that by sculpturing troughs


130


onto the surface of sculptured foam core


94


engaging the bed so that sculptured foam core


94


presents a generally planar top surface


132


provides for decreases of the firmness and support characteristics of mattress


52


carrying sculptured foam core


94


, these decreases being less than the decreases experienced when the sculptured surface faces upwardly. Thus, by sculpturing sculptured foam core


94


on the downward surface engaging the bed, the firmness and support characteristics of mattress


52


can be further adjusted. It is within the scope of the invention as presently perceived to sculpt the sculptured foam core to include troughs


130


only on top surface


132


, only on the downwardly-facing surface of sculptured foam core


94


engaging the bed, and on both above-mentioned surfaces.




Side foam sections


80


of frame


74


and foam divider rail


114


can also be sculptured to allow for each of these members


80


,


114


to move as shown in

FIG. 7

along with head, seat, thigh, and foot sections


144


,


146


,


148


,


150


of articulating deck


138


. Foam divider rail


114


is typically sculptured to have the same pattern of troughs


130


and cuts


134


as described above with respect to sculptured foam core


94


.




Frame


74


is formed from foam having a significantly greater firmness than core


88


so that frame


74


provides additional support along the sides and ends of mattress


52


. Such additional support is particularly useful when a user enters and exits the bed. However, use of such additionally firm side foam sections


80


requires that side foam sections


80


are sculptured to ensure that side foam sections


80


move with the head, seat, thigh, and foot sections


144


,


146


,


148


,


150


of deck


138


.




As with sculptured foam core


94


, side foam sections


80


of frame


74


are provided with transverse cuts


134


having slits


140


and cylindrical openings


142


as shown in FIG.


7


. Side foam sections


80


can also be provided with troughs


130


to vary the firmness and support characteristics of side foam sections


80


as described above with respect to sculptured foam core


94


.




Core


88


can also include air bladder


96


as shown in FIGS.


1


(


a


),


2


, and


8


(


a


)-


15


. Air bladder


96


is preferably inflated and deflated using air, however any acceptable fluid such as other gasses or liquids such as water and water having additives to adjust the viscosity of the resultant liquid can be used to inflate air bladder


96


without exceeding the scope of the invention as presently perceived. Thus, throughout the specification and claims such fluid will be referred to as air, although it is understood that other fluids may be used.




Air bladder


96


can be a “one-zone” air bladder (not shown) having one continuous air pocket extending through the air bladder so that the entire air bladder is uniformly inflated and deflated each time air is added to or removed from the air bladder. Air bladder


96


is a multiple-zoned air bladder having independently inflatable zones. Preferred and illustrative air bladder


96


is a “four-zone” air bladder


96


as shown in FIGS.


8


(


a


) and


9


having independently inflatable zones including an upper back zone


192


supporting the scapula, a lower back zone


194


supporting the lumbar region, a seat zone


196


supporting the sacrum, and a foot zone


198


supporting the thighs, legs, and feet of the user.




Air bladder


96


is constructed from an upper sheet


210


of an air impermeable material that is adhesively connected to a lower sheet


212


of an air impermeable material by a perimetral bead


214


of adhesive applied therebetween as shown in FIGS.


8


(


a


),


8


(


b


), and


9


to form an air-tight perimetral seal. Upper and lower sheets


210


,


212


cooperate with bead


214


to define an internal region


216


of air bladder


96


that is air impermeable. Bead


214


is slightly spaced apart from outer edges of upper and lower sheets


210


,


212


forming a two-layered perimetral flange


217


.




Transversely extending I-beams


218


,


219


are received inside of internal region


216


as shown in FIGS.


9


and


11


-


15


. Each I-beam


218


,


219


includes a top lip


220


sewn and adhesively attached to upper sheet


210


and a lower lip


222


sewn and adhesively attached to lower sheet


212


as shown best in

FIGS. 11 and 14

. The adhesive forms an air impermeable seal between top lip


220


and upper sheet


210


and between lower lip


222


and lower sheet


212


. Each I-beam


218


,


219


cooperates with upper sheet


210


, lower sheet


212


, and each adjacent I-beam


218


,


219


to define a pocket


224


so that when air bladder


96


is inflated it defines a longitudinally extending series of transverse pockets


224


as shown best in FIGS.


8


(


a


),


8


(


b


),


9


, and


11


-


15


. Each pocket


224


is a predetermined size when pocket


224


is inflated to its full capacity.




Each I-beam


218


,


219


has a transverse first end


226


and a transverse second end


228


as shown in FIG.


8


(


a


). First and second ends


226


,


228


of I-beams


218


are spaced apart from bead


214


to define openings


230


in fluid communication with adjacent pockets


224


defined by I-beams


218


, thereby allowing the passage of air therebetween. However, first and second ends


226


,


228


of I-beams


219


are adhesively attached to bead


214


to form air impermeable seals between adjacent pockets


224


defined by I-beams


219


. Thus, adjacent pockets


224


defined by I-beams


219


are not in fluid communication through I-beams


219


. I-beams


219


are placed to define each of the separate and distinct upper back, lower back, seat, and foot zones


192


,


194


,


196


,


198


of air bladder


96


as shown in FIGS.


8


(


a


),


8


(


b


), and


9


.




Each zone


192


,


194


,


196


,


198


is provided with a tube


232


in fluid communication with pockets


224


of each respective zone


192


,


194


,


196


,


198


, and tubes


232


are each in fluid communication with a pressurized air supply


234


as shown diagrammatically in FIG.


8


(


a


). Preferred pressurized air supply


234


includes a source of compressed air


236


such as an air compressor, a pressurized air tank, or the like, a manifold


238


connecting each tube


232


to source of compressed air


236


, and valves


240


individually controlling the flow of compressed air to and from each tube


232


as shown in FIGS.


1


(


a


),


2


, and


8


(


a


). Manifold


238


is positioned to lie in an opening


243


formed in foot end foam section


78


of frame


74


as shown in FIGS.


1


(


a


) and


2


.




Valves


240


include a three-way normally open source/exhaust valve


260


connecting manifold


238


to source of compressed air


236


when source/exhaust valve


260


is open, as shown in FIGS.


8


(


a


) and


8


(


b


), and connecting manifold


238


to an exhaust line


258


when source/exhaust valve


260


is energized. An upper back valve


262


is a normally closed valve that connects upper back zone


192


to manifold


238


when upper back valve


262


is energized. A lower back valve


264


is a normally closed valve that connects lower back zone


194


to manifold


238


when lower back valve


264


is energized. A seat valve


266


is a normally closed valve that connects seat zone


196


to manifold


238


when seat valve


266


is energized. A foot valve


268


is a normally closed valve that connects foot zone


198


to manifold


238


when foot valve


268


is energized.




To increase the support and firmness characteristics of mattress


52


having four-zone air bladder


96


adjacent to upper back zone


192


, the user energizes upper back valve


262


to bring upper back zone


192


into fluid communication with manifold


238


as shown in FIG.


8


(


a


). Source/exhaust valve


260


is normally open so that when upper back zone


192


is in fluid communication with manifold


238


, upper back zone


192


is also in fluid communication with source of compressed air


236


so that upper back zone


192


inflates. Likewise, to increase the firmness and support characteristics of matters


52


adjacent to lower back, seat, or foot zones


194


,


196


,


198


, the user simply energizes lower back valve, seat valve, or foot valve


264


,


266


,


268


respectively to bring the respective zone


194


,


196


,


198


of air bladder


96


into fluid communication with source of compressed air


236


. To increase the firmness and support characteristics of the entire mattress


52


simultaneously, the user simply energizes all four of the upper back, lower back, seat, and foot valves


262


,


264


,


266


,


268


simultaneously to bring all four zones


192


,


194


,


196


,


198


into fluid communication with source of compressed air


236


at the same time.




To decrease the support and firmness characteristics of mattress


52


having four-zone air bladder


96


adjacent to upper back zone


192


to provide the user with a more plush feel, the user energizes source/exhaust valve


260


to bring manifold


238


into fluid communication with exhaust line


258


as shown in FIGS.


8


(


a


) and


8


(


b


), and then energizes upper back valve


262


to bring upper back zone


192


into fluid communication with manifold


238


. Typically, exhaust line


258


vents directly to the atmosphere, so that energizing both source/exhaust valve


260


and upper back valve


262


brings upper back zone


192


into fluid communication with the atmosphere, causing upper back zone


192


to deflate and providing mattress


52


with a more plush feel for the user.




Likewise, to decrease the firmness and support characteristics of mattress


52


adjacent to lower back, seat, or foot zones


194


,


196


,


198


, the user simply energizes lower back valve, seat valve, or foot valve


264


,


266


,


268


respectively to bring the respective zone


194


,


196


,


198


of air bladder


96


into fluid communication with manifold


238


, and thus the respective zone


194


,


196


,


198


, and at the same time energizes source/exhaust valve


258


to bring manifold


238


, and thus the respective zone


194


,


196


,


198


, into fluid communication with exhaust line


258


as shown in FIGS.


8


(


a


) and


8


(


b


). To decrease the firmness and support characteristics of the entire mattress


52


simultaneously, the user simply energizes all five of the upper back, lower back, seat, foot, and source/exhaust valves


262


,


264


,


266


,


268


,


260


simultaneously to bring all four zones


192


,


194


,


196


,


198


into fluid communication with exhaust line


258


at the same time so that all four zones


192


,


194


,


196


,


198


simultaneously vent to the atmosphere.




If desired, manifold


238


and valves


240


can be rearranged to “link” the performance of separate zones of four zone air bladder


96


as shown in FIG.


8


(


b


). For example, tube


232


communicating with upper back zone


192


can also be brought into fluid communication with tube


232


communicating with seat zone


196


by connector tube


263


communicating with both upper back zone


192


and seat zone


196


. Connector tube


263


can be brought into fluid communication with source of compressed air


236


through an upper back and seat valve


267


and manifold


238


so that both upper back and seat zones


192


,


196


are inflated generally simultaneously and to the same extent to increase the firmness and support characteristics of these zones


192


,


196


of mattress


52


. Connector tube


263


can also be brought into fluid communication with exhaust line


258


to simultaneously and to the same extent deflate both upper back and seat zones


192


,


196


, and decrease the firmness and support characteristics of mattress


52


accordingly.




As can be seen, any two or more of zones


192


,


194


,


196


,


198


can be linked by a connector tube to cause separate portions of mattress


52


to provide similar firmness and support characteristics. Likewise, a second connector tube


265


can be formed to bring tubes


232


not connected to the first common line into fluid communication. For example, if upper back and seat zones


192


,


196


are in fluid communication through connector tube


263


, tube


232


communicating with lower back zone


194


can be brought into fluid communication with tube


232


communicating with foot zone


198


by second connector tube


265


so that lower back zone


194


is in fluid communication with foot zone


198


. By bringing second connector tube


265


into fluid communication with source of compressed air


236


, both lower back and foot zones


194


,


198


will simultaneously inflate, increasing the firmness and support characteristics of mattress


52


adjacent to lower back and foot zones


194


,


198


at the same time and to the same extent. Likewise, by bringing the second connector tube


265


into fluid communication with exhaust line


258


, the firmness and support characteristics of mattress


52


adjacent to lower back and foot zones


194


,


198


will decrease generally simultaneously and generally to the same extent. Thus, independent zones of air bladder


96


can be linked so that the support and firmness characteristics of mattress


52


adjacent to the linked zones change at the same time to the same extent when adjusted by the user.




In mattress


52


that has four-zone or one-zone air bladder


96


, the pressure of each zone


192


,


194


,


196


,


198


can be automatically controlled by placing air bladder


96


into “computer” mode. Once a user establishes a desired pressure for each zone


192


,


194


,


196


,


198


that results in the desired firmness and support characteristics, the pressure in one or more of the zones


192


,


194


,


196


,


198


can change. For example, if the user moves so that a heavier or lighter portion of the user's body is supported by the affected zone, the pressure in the affected zone will change, changing the firmness and support characteristics of the affected zone.




Each zone


192


,


194


,


196


,


198


of air bladder


96


is provided with a transducer


296


for providing an output signal in response to the pressure of each respective zone


192


,


194


,


196


,


198


so that the pressure in each zone


192


,


194


,


196


,


198


can be monitored, and bed and mattress structure


50


can be configured to compensate for these changes in pressure. For example, if the pressure in upper back zone


192


decreases from a set point established by the user, upper back valve


262


can be automatically energized to bring upper back zone


192


into fluid communication with source of compressed air


236


until the pressure in upper back zone


192


increases back to the set point, thus increasing the firmness and support characteristics of mattress


52


to the selected level. Likewise, if the pressure in seat zone


196


increases above the set point established by the user, seat valve


266


and source/exhaust valve


260


can be automatically energized to bring seat zone


196


into fluid communication with exhaust line


258


, deflating seat zone


196


until the pressure is reduced back to the set point, thus returning the support and firmness characteristics of mattress


52


adjacent to seat zone


196


to the selected level. By monitoring and adjusting the pressure in each zone


192


,


194


,


196


,


198


of air bladder


96


, the user's selected support and firmness characteristics can be maintained.




When mattress


52


is sized for a king- or queen-sized bed as shown in FIG.


2


and core


88


includes two side-by-side air bladders


96


, one source of compressed air


236


can be used to inflate and deflate both air bladders


96


. Typically, each air bladder


96


is provided with manifold


238


and valves


240


, with each source/exhaust valve


260


being in fluid communication with a “T-connector” (not shown) bringing each source/exhaust valve


260


into fluid communication with source of compressed air


236


.




As described above, both air bladders


96


can operate in a “computer” mode wherein the pressure of each respective zone


192


,


194


,


196


,


198


is maintained by automatically inflating and deflating each zone to compensate for movement of the user that changes the load carried by each respective zone. The above-described valve configuration in accordance with the present invention prevents a “continuous run” condition. A continuous run condition is present in side-by-side air bladders


96


, both of which are on computer mode, when one air bladder


96


is exhausting so that one manifold


238


is in fluid communication with exhaust line


258


at the same time the other air bladder


96


is inflating so that the other manifold


238


is in fluid communication with source of compressed air


236


. Since both manifolds


238


are connected by the T-connector, the possibility exists that compressed air source


236


might be in fluid communication with exhaust line


258


so that neither air bladder


96


reaches the desired state, causing the system to run continuously as it attempts to inflate and deflate each air bladder.




However, each source/exhaust valve


260


is a three-way valve that positively blocks the flow between exhaust line


258


and manifold


238


when source/exhaust valve


260


is open to bring manifold


238


into fluid communication with source of compressed air


236


. In addition, source/exhaust valve


260


blocks the flow from source of compressed air


236


when source/exhaust valve


260


is energized to bring manifold


238


into fluid communication with exhaust line


258


. Thus, use of a three-way valve for source/exhaust valve


260


eliminates the possibility of inadvertently achieving a continuous run condition when operating two side-by-side air bladders.




The operation of a one-zone air bladder


96


as shown in

FIG. 10

is simpler than the operation of four-zone air bladder


96


. An inlet valve


292


is normally closed to block the fluid communication between source of compressed air


236


and manifold


238


. Likewise, an exhaust valve


294


is normally closed to block the fluid communication between exhaust line


258


and manifold


238


. Manifold


238


is in fluid communication with air bladder


96


and a transducer


296


for converting a measured pressure to an output signal for use by a controller


370


is in fluid communication with air bladder


96


through manifold


238


. To increase the firmness and support characteristics of mattress


52


having one-zone bladder


96


, user simply energizes inlet valve


292


to restore fluid communication between source of compressed air


236


and air bladder


96


through manifold


238


to inflate air bladder


96


. To decrease the firmness and support characteristics of mattress


52


, user energizes exhaust valve


294


to restore fluid communication between exhaust line


258


and air bladder


96


through manifold


238


to deflate air bladder


96


.




I-beams


218


,


219


are generally of similar height so that pockets


224


are generally uniform in size and shape as shown in FIG.


9


. The height of I-beams


218


,


219


can be varied as shown in

FIGS. 11-14

for I-beams


218


′ which are taller than I-beams


218


,


219


to produce pockets


224


′ defined by I-beam


218


′ that inflate to a size larger than pockets


224


that are not adjacent to I-beam


218


′. Pockets


224


′ produce a portion on mattress


52


adjacent to pockets


224


′ at which the user perceives additional support and firmness. By placing I-beam


218


′ as shown in

FIGS. 11-15

, air bladder


96


will provide additional support and firmness for the lumbar portion of the user's adjacent to the lower back zone


194


.




Typically, I-beams


218


,


219


are generally the same height so that pockets


224


are generally uniform in size and shape as shown in FIG.


9


. Air bladder


96


can be made, however, having selected I-beams


218


′ which are taller than I-beams


218


,


219


as shown in

FIGS. 11-15

to produce pockets


224


′ defined by taller I-beams


218


′ that inflate to a size larger than pockets


224


defined only by I-beams


218


,


219


so that upper and lower sheets


210


,


212


adjacent to pockets


224


′ project beyond upper and lower sheets


210


,


212


adjacent to pockets


224


defined only by I-beams


218


,


219


when pockets


224


,


224


′ are fully inflated, as shown best in FIG.


15


. By including isolated pockets


224


′ that project past the other surfaces of air bladder


96


, mattress


52


provides additional firmness and support characteristics at longitudinal zones adjacent to projecting pockets


224


′.




For example, a single I-beam


218


′ can be positioned to lie between two I-beams


218


,


219


as shown diagrammatically in

FIGS. 11 and 12

for air bladder


96


resting on a generally planar surface. When air bladder


96


is fully inflated, upper sheet


210


adjacent to two adjacent pockets


224


, which are both defined in part by I-beam


218


′, projects above upper sheet


210


adjacent to pockets


224


as shown in FIG.


11


. Likewise, two adjacent I-beams


218


′ can be positioned to lie between I-beams


218


,


219


as shown diagrammatically in

FIGS. 13 and 14

for air bladder


96


resting on a generally planar surface. When air bladder


96


is fully inflated, upper sheet


210


adjacent to three adjacent pockets


224


′, each of which are defined at least in part by I-beams


218


′, projects above upper sheet


210


adjacent to pockets


224


as shown in FIG.


14


. Although only one and two adjacent I-beams


218


′ that are taller than I-beams


218


,


219


are shown in

FIGS. 11-15

, the height of any number of adjacent I-beams


218


′ may be varied to cause a desired portion of upper and lower sheets


210


,


212


of air bladder


96


to project beyond the remaining portions of upper and lower sheets


210


,


212


.




Taller I-beams


218


′ can be used to provide firmness and support characteristics that vary longitudinally along mattress


52


including air bladder


96


as shown in

FIG. 15

, even if air bladder


96


is a one-zone air bladder. In addition, use of taller I-beams


218


′ can cause each zone of a multiple zone air bladder


96


to provide mattress


52


with multiple firmness and support characteristics adjacent to the zone.




For example, I-beams


218


′ can be used to form pockets


224


′ in foot zone


198


adjacent to seat zone


196


as shown in FIG.


15


. Mattress


52


including air bladder


96


with such pockets


224


′ will provide the user with additional firmness and support adjacent to his or her thighs. Thus foot zone


198


, which includes pockets


224


,


224


′ that are all in fluid communication so that the air pressure in each pocket


224


,


224


′ of foot zone


198


is generally equivalent, will simultaneously provide the portion of mattress


52


adjacent to foot zone


198


with multiple firmness and support characteristics.




For another example, I-beams


218


′ can be used to form pockets


224


′ in foot zone


198


adjacent to the ankles of the user as shown in FIG.


15


. Mattress


52


including air bladder


96


with such pockets


224


′ will provide the user with additional firmness and support adjacent to his or her ankles. In addition, by providing this additional support adjacent to the ankles of the user, mattress


52


will operate to relieve interface pressure against the heels of the user to help alleviate pressure ulcers that can develop on the heels of the user. Air bladder


96


can thus be used to adjust the support and firmness characteristics of mattress


52


both by having adjustable air pressure in one or multiple longitudinal zones, for example zones


192


,


194


,


196


,


198


, and by using I-beams


218


′ that are taller than other I-beams


218


,


219


so that portions of upper and lower sheets


210


,


212


of air bladder


96


project beyond portions of upper and lower sheets


210


,


212


adjacent only to I-beams


218


,


219


.




Flange


217


of air bladder


96


, which is positioned to lie outside of perimetral bead


214


as shown in FIGS.


8


(


a


),


8


(


b


), and


9


, is formed from outer portions of both the upper and lower sheets


210


,


212


. Flange


217


is formed to include a plurality of spaced-apart openings


244


that extend therethrough. Openings


244


are used during the manufacturing process to stabilize air bladder


96


as manufacturing operations are performed thereon.




Openings


244


can also be used, however, to stabilize air bladder


96


in mattress


52


. For example, when mattress


52


is provided for a queen-sized bed (not shown) so that core


88


includes elements in side-by-side abutting engagement, if core


88


includes side-by-side air bladders


96


, then openings


244


of the first air bladder


96


can be tied to openings


244


of the second air bladder


96


to prevent relative transverse movement of the first air bladder


96


relative to the second air bladder


96


. Even if core


88


includes side-by-side elements only one of which is an air bladder


96


, openings


244


can still be used to stabilize air bladder


96


if desired.




In bed and mattress structure


50


, top cover


60


of mattress


52


can be formed to include an enclosed “warm air release” channel


250


receiving air from source of compressed air


236


as shown in FIG.


16


. Enclosed channel


250


is preferably made from a light weight and air impermeable material so that air is directed along the length of channel


250


. The material is formed to include small openings (not shown) that allow a small amount of air to escape from channel


250


. The openings direct the air across the surface of mattress


52


as shown by arrows


252


in FIG.


12


.




An air heater


254


is interposed between source of compressed air


236


and channel


250


as shown in

FIG. 16

so that heated air can be provided to channel


250


. Air heater


254


can be selectively operated so that when air heater


254


is operating, air


252


is the warm air release warming the user and particularly warming the extremities of the user. When air heater


254


is not operating, air


252


is a room temperature air release cooling the user during operation of channel


250


. Of course, a valve is positioned between source of compressed air


236


and channel


250


so that channel


250


can be operated or not operated at the discretion of the user.




Channel


250


can be positioned about the perimeter of top cover


60


as shown in FIG.


16


. As mentioned above, the preferred material of construction of much of mattress


52


is foam rubber which is a thermal insulator. As such, it is important that channel


250


be as close as possible to sleeping surface


122


and the user. As a result, if mattress


52


includes pillow top


90


, then channel


250


can be formed around an outer edge of pillow top


90


rather than top cover


60


so that channel


250


is adjacent to sleeping surface


122


.




Also, a hand held controller


256


is provided for use by the user as shown in

FIG. 16

for controlling the operation of bed and mattress structure


50


. Hand held controller


256


can operate both source of compressed air


236


and air heater


254


as well as other mattress functions as described in detail below with reference to

FIGS. 21 and 22

.




Bed and mattress structure


50


can additionally be provided with arm rests


270


as shown in

FIGS. 17-20

. Arm rest


270


includes a curved top surface


272


, a curved bottom surface


274


, and generally planar sides


276


. Top and bottom surfaces


272


,


274


can each be formed to include openings


278


sized to receive drinking glasses, drinking cups, beverage cans, or the like (shown in phantom in FIG.


18


). The preferred arm rest


270


includes a foam rubber pad


280


and a fabric covering


282


conformingly shaped to fit around pad


280


as shown best in FIG.


18


. Top and bottom surfaces


272


,


274


are spaced apart by a first distance


284


near a first end


286


of arm rest


270


and taper together so that top and bottom surfaces


272


,


274


are spaced apart by a second distance


288


near a second end


290


of arm rest


270


.




Arm rest


270


is positioned between the elbow of the user (not shown) and sleeping surface


122


. The distance between the elbow and sleeping surface


122


varies somewhat between users resting on sleeping surface


122


. By moving arm rest


270


longitudinally relative to the elbow of the user, most users will find a position on arm rest


270


having a distance between top and bottom surfaces


272


,


274


at which the user can comfortably rest his or her elbow. If the user finds that it is most comfortable to rest his or her elbow nearer to first end


286


than to second end


290


, the user will most likely prefer to use arm rest


270


with top side


272


facing upwardly as shown in

FIG. 19

so that upwardly-facing opening


278


is on the portion of arm rest


270


extending longitudinally away from seat section


146


. Conversely, if the user finds that it is most comfortable to rest his or her elbow nearer to second end


290


than to first end


286


, the user will most likely prefer to use arm rest


270


with bottom side


274


facing upwardly as shown in

FIG. 20

so that once again upwardly-facing opening


278


is on the portion of arm rest


270


extending longitudinally away from seat section


146


. It can be seen in each instance that the shapes of top and bottom surfaces


272


,


274


generally conform to the shape of sleeping surface


122


of mattress


52


when deck


138


is articulated away from the generally planar sleeping position.




As mentioned above, hand held controller


256


is provided as shown in

FIGS. 16

,


21


, and


22


for controlling the operation of bed and mattress structure


50


. Hand held controller


256


includes a first end


310


, a second end


312


, a power and communication cord


314


extending away from second end


312


and toward bed and mattress structure


50


, an upper face


316


, and a key pad


318


carried on upper face


316


for receiving inputs from the user, bed and mattress structure


50


adjusting its various features in response to the inputs from keypad


318


as described below. When the user is holding hand held controller


256


to operate bed and mattress structure


50


, hand held controller


256


will typically be held in a generally upright orientation as shown in

FIG. 21

having first end


310


positioned to lie generally above second end


312


.




Illustrative key pad


318


includes a light emitting diode (LED) primary display


320


, memory buttons


322


, bed position buttons


324


, mattress control buttons


326


, massage control buttons


328


, and a bed select button


330


as shown in FIG.


22


. In addition, key pad


318


includes an LED computer on/off display


332


, an LED zone display


334


, and an LED bed select display


336


. As described below, illustrative key pad


318


is configured for use with a king- or queen-sized bed having an articulating deck


138


and having at least one four-zone air bladder


96


. Other beds having other features would include hand held controller


256


having a key pad


318


including at least some of these buttons.




Key pad


318


is arranged so that primary display


320


is positioned adjacent to first end


310


of key pad


318


as shown in FIG.


22


. The remaining buttons and displays are positioned to lie in longitudinally spaced-apart relation between primary display


320


and second end


312


. Memory buttons


322


are positioned adjacent to primary display


320


, bed position buttons


324


are positioned adjacent memory buttons


322


, mattress control buttons


326


are positioned adjacent bed position buttons


324


, massage control buttons


328


are positioned adjacent mattress control buttons


326


, and bed select button


330


is positioned adjacent massage control buttons


328


and adjacent second end


312


of key pad


318


.




Memory buttons


322


provide the user with the ability to establish one or more preferred “memory positions” of articulating deck


138


. In addition, the memory positions include a corresponding air pressure in zones


192


,


194


,


196


,


198


of air bladder


96


selected by the user to provide selected firmness and support characteristics to correspond to each preferred position of articulating deck


138


, as shown in

FIG. 22

in which illustrative key pad


318


allows the user to establish two memory positions. Once the user establishes the memory positions, the user simply presses the memory button corresponding to the desired position and articulating deck


138


will automatically move to its prescribed position while each zone


192


,


194


,


196


,


198


of air bladder


96


is automatically inflated or deflated to its prescribed pressure so that mattress


52


provides the preselected firmness and support characteristics selected by the user to correspond to the selected position of articulating deck


138


.




Bed position buttons


324


allow the user to manipulate the articulating sections of articulating deck


138


. In addition, certain of the individual LEDs of primary display


320


will be energized to indicate the relative position of articulating deck


138


. In addition, primary display


320


indicates the relative air pressure in zones


192


,


194


,


196


,


198


of air bladder


96


. Primary display


320


will provide an indication for the last button pressed. If more than one function is running at one time or if memory buttons


322


are pressed, primary display


320


will indicate the relative position of head section


144


of deck


138


. Also, bed position buttons


324


include a preset “lounge” button


338


and a preset “bed flat” button


340


which are additional memory keys that are set during assembly of mattress


52


in accordance with inputs from the customer profile sheet.




Mattress control buttons


326


shown in

FIG. 22

include a “zones” button


342


for selecting a zone


192


,


194


,


196


,


198


of air bladder


96


in response to user pressing zones button


342


, zone display


334


including LED indicators, one of which will be energized to indicate the selected zone


192


,


194


,


196


,


198


, a “firm” button


344


for increasing the air pressure in the selected zone in response to user pressing firm button


344


to increase the firmness of mattress


52


adjacent to the selected zone, and a “soft” button


346


for decreasing the air pressure in the selected zone in response to user pressing soft button


346


to decrease the firmness of mattress


52


adjacent to the selected zone. As described above, when the user presses zones button


342


to select a selected zone, primary display


320


will indicate the relative air pressure in the selected zone.




In addition, mattress control buttons


326


include a mattress computer on/off button


348


. Once a user has selected a desired air pressure for each zone


192


,


194


,


196


,


198


, the user may move relative to air bladder


96


. As the user moves, heavier or lighter body parts of the user may be supported by each respective zone


192


,


194


,


196


,


198


than were supported by the zone when the desired air pressure was originally selected. If the amount of air in zones


192


,


194


,


196


,


198


were fixed, this movement of user could change the forces exerted on each zone


192


,


194


,


196


,


198


, thus changing the air pressure in each zone and the support and firmness characteristics of mattress


52


adjacent to each zone


192


,


194


,


196


,


198


.




Mattress


52


preferably includes transducers


296


, described above with reference to FIGS.


8


(


a


),


8


(


b


), and


10


, for measuring the air pressure in each zone


192


,


194


,


196


,


198


. If, after selecting the desired firmness and support characteristics for each zone


192


,


194


,


196


,


198


the user presses computer on/off button


348


to turn on the “computer mode, ” an internal computer will monitor output signals provided from each transducer


296


in response to the air pressure in each zone


192


,


194


,


196


,


198


and will automatically operate valves


240


when necessary and in the manner described above with reference to FIGS.


8


(


a


) and


8


(


b


) to maintain the pressure in each respective zone


192


,


194


,


196


,


198


at a set point that corresponds to the firmness and support characteristics chosen by the user. If computer mode is turned on, the LED of computer on/off display


332


will be energized to indicate such status.




Mattress


52


can also be provided with a massage feature. The presently preferred massage feature is provided by first and second motors (not shown), the first motor being attached to articulating deck


138


adjacent to head section


144


and the second motor being attached to articulating deck


138


adjacent to foot section


150


. Each motor rotates a generally horizontally extending shaft. An off-center weight is fixed to each shaft so that as each shaft rotates, each shaft, each motor, and deck


138


adjacent to each motor vibrates. To increase the level of vibration felt by the user, the rotation speed of the shafts is increased and to decrease the level of vibration felt by the user, the rotation speed of the shaft is decreased.




As mentioned above, mattress control buttons


326


include massage control buttons


328


, including head end massage increase button


350


, head end massage decrease button


352


, foot end massage increase button


354


, foot end massage decrease button


356


, and wave buttons


358


. When the user presses head end massage increase button


350


, the motor attached to articulating deck


138


adjacent to head section


144


increases the rotational speed of its shaft until a maximum rotational speed is reached at which point the rotational speed of the shaft cannot be further increased.




When the user presses head end massage decrease button


352


, the motor attached to articulating deck


138


adjacent to head section


144


decreases the rotational speed of its shaft until a minimum rotational speed is reached. The motor will halt the rotation of the shaft if head end massage decrease button


352


is pressed when the shaft is rotating at the minimum rotational speed. Likewise, pressing foot end massage increase button


354


and foot end massage decrease button


356


causes the motor attached to articulating deck


138


adjacent to foot section


150


to increase and decrease the rotational speed of its shaft. Pressing wave buttons


358


causes the motors to operate together to provide a coordinate massage effect.




Finally, if mattress


52


is for a queen- or king-sized bed having side-by-side air bladders


96


, hand held controller


256


will control both halves of bed and mattress structure


50


. Pressing bed select button


330


, shown in

FIG. 22

, will toggle between the two halves of the bed and mattress structure


50


so that when the “left” LED of bed select display


336


is energized control inputs from the user to key pad


318


will operate to manipulate the left side of bed and mattress structure


50


, and when the “right” LED of bed select display


336


is energized, control inputs from the user to key pad


318


will operate to manipulate the right side of bed and mattress structure


50


.




Typically when the user operates bed and mattress structure


50


including articulating deck


138


and four-zone air bladder


96


using illustrative key pad


318


shown in

FIG. 22

, the user will press one of memory buttons


322


. However, on occasion, the user may choose to adjust the position of articulating deck


138


using bed position buttons


324


and may, probably less frequently, wish to adjust the support and firmness characteristics of mattress


52


by pressing mattress control buttons


326


. Occasionally, the typical user will utilize the massage feature by pressing massage control buttons


328


.




Thus, illustrative key pad


318


is arranged so that buttons are ordered from first end


310


to second end


312


, or from top to bottom, in order of the frequency of use of the buttons so that the most frequently used buttons are positioned to lie nearest the top or first end


310


of key pad


318


and the least frequently used buttons are nearest the bottom or second end


312


of key pad


318


. In addition, it can also be seen that illustrative key pad


318


is arranged so that buttons are ordered from first end


310


to second end


312


, or from top to bottom of key pad


318


, generally in the order that the user will use the buttons so that the first buttons generally used in a typical operation sequence are nearest the top of key pad


318


and the last buttons used in a typical operation sequence are nearest the bottom of key pad


318


.




Hand held controller


256


provides the man-machine interface for the user. By depressing buttons


322


,


324


,


326


,


328


,


330


(graphically displayed) the user can select various operations. These operations are bed position, mattress computer, memory, massage, mattress zones, and firm or soft controls. These commands are sent by way of an RS232 wire connection


372


to the compressor board


374


as shown in FIG.


23


. The compressor board


374


acts as an interconnection interface to the mattress control board


376


, massage and bed position motors


378


. Signals generated at hand held controller


256


pass through compressor board


374


to mattress control board


376


. Mattress controller operates valves


240


to control the flow of compressed air or exhaust from zone to zone. Mattress controller also receives signals from transducers


296


that monitor the air pressure at each zone and provides signals back to hand held controller


256


for display.




Hand held controller


256


is a microprocessor based control system capable of remotely controlling up to eight bladders or individual air zones of air bladders


96


via a serial link with pressure control system. The system will also receive and display relative pressure information by way of the serial link. The link itself is to be either a wire or a wireless link.




The system is based on a Microchip 16 C series surface mount one time programmable device. There are two microcontrollers used. One located in hand held controller


256


and the other is in mattress control board. They communicate VIA an RS232 serial link.




The primary benefit of the Microchip device is the implementation of control algorithms due to the controller's reduced instruction set. Additional benefits include:




Simplified memory requirement predictions, and timing calculations due to the single line, predominantly single cycle instructions.




Low Cost.




No additional program memory required.




Software is directly portable to other devices in the large family allowing for easier upgrades.




Specialized sleep capability, and external interrupts allow a power consumption savings.




Built in, independent watch dog timer prevents system crash due to an unresponsive controller.




Separate program and data memory prevents unintentional program corruption due to accidental program memory access.




A salient feature for this system is the implementation of a direct feed back display on key pad


318


at the man-machine interface. Primary display


320


presents the user with direct real time feed back of control operations. Mattress control board


376


receives signals from transducers


296


in response to the air pressure in each zone and uses that information to display pressure setting and the controlled zones of air bladder


96


on primary display


320


of hand held controller


256


.




Mattress


52


is ideally suited for providing a user with sleeping surface


122


that is customized to provide firmness and support characteristics established by and for the user. As described above, mattress


52


can include air bladder


96


having either one zone or multiple zones, and within each zone air bladder


96


can be provided with I-beams of varying height to provide multiple firmness and support characteristics within each zone. Mattress


52


can also include sculptured foam core


94


or zone foam blocks


92


as described above. In addition, however, mattress


52


may be provided with combinations of the above as shown in FIGS.


1


(


b


) and


1


(


c


).




Mattress


52


can be provided with a combination of zone foam blocks


92


and air bladders


96


as shown in FIG.


1


(


b


) which illustratively shows air bladders


96


for supporting the scapula and sacrum of the user and zone foam blocks


92


for supporting the lumbar region and the thighs and legs of the user. Air bladders


96


can operate individually and separately, or air bladders


96


can be brought into fluid communication with one another in a manner similar to that described above with respect to FIG.


8


(


b


) so that they inflate and deflate generally at the same time and to generally the same extent.




Likewise, mattress


52


can illustratively include zone foam blocks


92


positioned to support the upper back, the seat, and the lower legs of the user and air bladders


96


to support the lumbar region and thighs of the user as shown in FIG.


1


(


c


). As mentioned above, air bladders


96


can operate individually and separately, or air bladders


96


can be brought into fluid communication with one another in a manner similar to that described above with respect to FIG.


8


(


b


) so that they inflate and deflate generally at the same time and to generally the same extent. As can be seen, any combination or positioning of zone foam blocks


92


and air bladders


96


can be provided in mattress


52


to meet the desired firmness and support characteristics of the user. Although preferred sculptured foam core


94


generally extends the full length of central opening


82


, shorter sculptured foam cores (not shown) can be provided for use in combination with air bladders


96


and zone foam blocks


92


if desired to provide the user with his or her preferred firmness and support characteristics without exceeding the scope of the invention as presently perceived.




Mattress


52


along with a “test mattress” (not shown) containing a multiple zone air bladder


96


can be used to determine the firmness, support, and interface pressure preferences of the user and to use the same to customize mattress


52


for each user. The preferred method for customizing mattress


52


is initiated when a potential user completes a questionnaire to aid in the analysis of that user's “sleep profile.” The sleep profile assesses such factors as the user's general health and sleep habits. A firmness recommendation is computed either in terms of a pressure for various zones of the test mattress or in terms of a foam type and density for each zone. In addition, a surface recommendation is established based on the user's responses to a surface recommendation questionnaire.




Once the surface and hardness recommendations are established, the user lies on the test mattress and air bladder


96


is pressurized to match the firmness recommendation. Zones of air bladder


96


are then adjusted to match the preferences of the user and the resulting preferred firmness readings are recorded.




An algorithm has been developed that correlates the air bladder pressure readings once the preferred firmness and support characteristics have been established by the user into a customized bed configuration. For example, the preferred firmness readings can be translated to establish the foam density that, if incorporated into a mattress will provide the firmness and support characteristics similar to those provided by the test sleeping surface having the preferred firmness readings.




This correlation can be developed by comparing the deformation of air bladder


96


having a selected air pressure when a known force is applied thereto by a probe of a known size, and then determining a foam ILD that provides the same deflection when the same force is applied to the foam by the same probe. A pressure deformation response curve can be developed that shows the foam ILD that provides generally the same deflection as air bladder


96


for various air pressures within bladder


96


.




Once the air pressure readings have been found that provide the user with his or her preferred firmness, support, and interface pressure characteristics, mattress


52


can be prepared using the pressure deformation response curve so that mattress


52


has mattress structure components or cores


88


including sculptured foam core


94


, zone foam blocks


92


, air bladder


96


, or a combination thereof that provide the user with the preferred characteristics. In addition, if desired, a computer can be used to map the pressure readings of the test mattress after finding the user's preferred firmness and support characteristics and a program can utilize the pressure map and the pressure deformation response curve to determine the arrangement of mattress structure components that will provide mattress


52


that meets the user's preferences.




Once the customized bed configuration is established, mattress


52


can be assembled from a kit at the point of sale containing the plurality of cores


88


for the user to test and verify that assembled mattress


52


meets his or her preferences. If mattress


52


is not satisfactory, cores


88


can be replaced at the point of sale. Once the user is satisfied with the arrangement of cores


88


, he or she can immediately take delivery of the completed customized mattress if desired. In the alternative, once the customized bed configuration is established, the data describing this configuration can be transmitted to a factory at which the mattress


52


can be assembled for delivery to the user.




In addition, if the user determines after assembly and delivery that the user prefers alternate firmness or support characteristics, cores


88


can again be readjusted or upgraded until the mattress


52


provides the desired firmness and support characteristics. If desired, a kit of cores


88


can be provided to the user so that the user can adjust the firmness and support characteristics.




The method for selecting mattress structure components or cores


88


to provide a customized foam mattress


52


to accommodate the musculoskeletal condition of the user includes providing a plurality of mattress structure components arranged for selective assembly of the components. The components comprise a plurality of foam cores


88


for filling longitudinally extending central opening


82


in mattress


52


above which the user rests. Foam cores


88


should have a variety of shapes and support and firmness characteristics from which to select a desired assembly.




The method also includes providing a test mattress having a similar longitudinally extending central opening filled with a plurality of longitudinally spaced apart air bladders extending transversely across the central opening and an air supply for selectively filling each air bladder to various pressures. A user is placed above the central opening of the test mattress and supported on the plurality of air bladders. The air pressure in each bladder is adjusted to a selected pressure to provide the support and firmness desired by the user. An equivalent foam core having the desired support and firmness characteristics corresponding to the selected air pressures is then selected and placed in the central opening to provide the customized mattress.




The mattress


52


in accordance with the present invention can be sized for a twin bed or a double bed as shown in FIGS.


1


(


a


)-


1


(


c


), or a queen-sized or a king-sized bed as shown in FIG.


2


. When mattress


52


is sized for the queen and king-sized beds, both sides of mattress


52


can be individually customized if desired to provide the firmness and support characteristics desired by individual sleep partners. Both cores


88


and toppers


86


can be selected for each side of mattress


52


to provide the desired firmness and support for each side of the bed. This flexibility results from the separate cores


88


that are provided for each side of mattress


52


.




In addition to this flexibility, use of distinct cores


88


for each half of mattress


52


operates to reduce the transmission of movement from one side of mattress


52


to the other. Thus, when one sleeping partner moves, the amount of movement experienced by the other sleeping partner as a result is minimized.




As mentioned above, mattress


52


can be provided with an air bladder having independent zones that are selectively adjustable by the user to provide varied firmness and support characteristics. If the same mattress


52


is used on a bed having articulating deck


138


, mattress


52


can be provided with hand held controller


256


for use by the user to control the adjustment of both the position of deck


138


and the support characteristics of each zone of air bladder


96


. In addition, hand held controller


256


can include a “memory set” feature which allows the user to establish preferred combination settings for deck


138


and mattress


52


.




In addition, the mattress can be provided with combinations of air bladders


96


, zone foam elements


92


, and sculptured foam core


94


to produce a “combination mattress.” Illustratively, mattress


52


can be provided having air bladder


96


supporting the scapula of the user, zone foam blocks


92


supporting the lumbar of the user, air bladder


96


in the seat portion supporting the sacrum of the user, and zone foam blocks


92


supporting the thighs and legs. If desired, air bladders


96


can be in fluid communication so that they inflate and deflate at the same times and to the same pressures or air bladders


96


can be independent of one another and independently controlled by the user so that the user can establish different characteristics of support and firmness for each of the scapula and the sacrum.




In an alternative embodiment of the present invention illustrated in

FIG. 24

, a mattress apparatus


452


is provided that includes at least four different combinations of firmness feels. Mattress apparatus


452


enables retailers to use a single testing apparatus to present a user with at least four different firmness feels prior to purchase. Thus, mattress apparatus


452


allows the retailer to conserve floor space by having fewer test mattresses in the store and the user to customize the feel of a mattress that they plan to purchase from retailer. The various firmness feels are accomplished by having mattress apparatus


452


provide users with vertical zoning (hereinafter “controlled compression”) and well as head-to-toe zoning. This generally two-dimensional zoning minimizes interface pressure between the user and mattress apparatus


452


by distributing the weight loading of the user on apparatus


452


.




Referring to

FIG. 24

, mattress apparatus


452


includes a top quilted panel


454


and an opposite bottom quilted panel


460


. Top quilted panel


454


has an upwardly facing top portion


459


, an opposite bottom portion (not shown), and a perimeter edge


456


. Illustratively, top portion


459


of top quilted panel


454


is stitched to include a quilt pattern. Top quilted panel


454


is made from a material that is somewhat elastic so that the user can “sink into” mattress apparatus


452


. Mattress apparatus


452


therefore conforms to the user's shape and relieves interface pressure.




Bottom quilted panel


460


of mattress apparatus


452


cooperates with top quilted panel


454


to define a mattress interior


472


as shown in

FIGS. 24 and 25

. Bottom quilted panel


460


includes an inwardly-facing top portion


462


, an opposite external bottom portion


464


, and an upwardly-extending side portion


466


. Side portion


466


includes a bottom edge


468


adjacent bottom portion


464


and a top edge


470


formed for attachment to perimeter edge


456


of top quilted panel


454


. As shown in FIG.


1


(


a


), a top quilted panel


454


could, however, be provided having a downwardly-extending side portion


67


defining a mattress side. Top edge


470


and perimeter edge


456


are attached by a sewn construction, such as a seam. It is understood, however, that a zipper and other attachment mechanisms such as hooks, buttons, tabs, and the like could be used to couple top and bottom quilted panels


454


,


460


together. Similar to top portion


459


, bottom portion


464


of bottom quilted panel


460


is stitched to include a shell quilt pattern and is manufactured from a material that is somewhat elastic. See FIG.


24


. While a shell quilt pattern is illustrated, it is understood that a wide variety of quilting patterns are contemplated in accordance with the present invention for top and bottom portions


459


,


464


. In addition, top and bottom portions


459


,


464


of top and bottom quilted panels


454


,


460


may be constructed from a wide variety of materials having a variety elasticities to provide apparatus


454


with different firmness feels.




Mattress apparatus


454


also includes a core


458


, a frame


474


that surrounds core


458


and has a head end section


476


, a foot end section


478


, and longitudinally extending side sections


480


joining head end and foot end sections


476


,


478


, an upper topper foam


479


, and a lower topper foam


481


. While the term “head end section” and “foot end section” will be used hereafter, it is understood that either section may be used to support a user's head and feet. Frame


474


is constructed of foam that is firmer than core


458


to provide additional support to the user when entering or exiting mattress apparatus


454


. It is understood, however, that a wide variety of materials having various firmnesses may be used to construct frame


474


. As shown in

FIG. 24

, frame


474


is received in mattress interior


472


. Head end and foot end sections


476


,


478


are coupled to side sections


480


at joints


483


. Head end section


476


, foot end section


478


, and side section


480


of frame


474


cooperate to define a central opening


482


above which the user will lie. Frame


474


is sandwiched between upper and lower topper foam


479


,


481


.




Referring to

FIG. 24

vertical upper topper foam


479


has a pre-selected first foam firmness and lower topper foam


481


has a pre-selected second foam firmness. In accordance with the present invention, the upper topper firmness is different than the lower topper firmness. The difference between the upper and lower topper firmness may vary. It is understood, however, that as the difference between the upper and lower topper firmness increases, so does the difference in mattress feel to the user due to the difference in the controlled compression.




Core


458


is received in central opening


482


of frame


474


and is positioned to lie between upper and lower topper foam


479


,


481


. Topper foam


479


,


481


provides vertical controlled compression and core


458


provides head-to-toe zoning in mattress apparatus


454


.




Core


458


includes a head-end block


490


, a foot-end block


492


, a seat block


494


positioned to lie between head-end and foot-end blocks


490


,


492


, and zoned blocks


410


,


412


. As shown in

FIG. 25

, each block


490


,


492


,


494


includes a top side


496


facing top quilted panel


454


, an opposite bottom side


498


facing bottom quilted panel


460


, and opposite side edges


500


extending between top and bottom sides


496


,


498


.




Each block


490


,


492


,


494


of core


488


has an individual pre-selected block firmness. Illustratively, each block


490


,


492


,


494


of core


488


is constructed of foam rubber, although it is understood that blocks


490


,


492


,


494


may be constructed of a wide variety of compressible materials and may be formed as inflatable bladders or the like. The firmness and support characteristics of the foam rubber may be pre-selected by the retailer to provide users with a test mattress apparatus that helps them customize a particular mattress feel. The firmness of blocks


490


,


492


,


494


range approximately between an ILD of about


15


to about


98


, although the firmness of blocks


490


,


492


,


494


may vary in accordance with the present invention. While each block


490


,


492


,


494


of core


488


has an individual pre-selected block firmness, it is understood that blocks


490


,


492


,


494


may have identical firmnesses if desired.




As shown in

FIG. 24

, zone blocks


410


,


412


of core


488


are positioned to lie in general alignment with the user's lumbar region and the thigh region. Blocks


410


,


412


are constructed of foam rubber, although it is understood that blocks


410


,


412


may be constructed of a wide variety of compressible materials or may be formed as air bladders. The firmness and support characteristics of the foam rubber may be pre-selected by the retailer to provide users with a test mattress apparatus that helps them customize a particular mattress feel. The firmness of blocks


410


,


412


range approximately between an ILD of about


15


to about


98


. It is understood, that the firmness of blocks


410


,


412


may vary in accordance with the present invention.




First block


410


is positioned to lie between and longitudinally abuts head-end block


490


and seat block


494


. Thus, first block


410


is generally aligned with the user's lumber region (not shown) when the user's head is positioned adjacent head-end block


490


on top quilted panel


454


. In addition, first block


410


has a pre-selected firmness. Preferably, the firmness of first block


410


is greater than the firmness of head-end and seat blocks


490


,


494


to provide additional support for the user's lumbar. Second block


412


is positioned to lie between and longitudinally abuts foot-end block


492


and seat block


494


. Thus, second block


412


is generally aligned with the user's upper thigh region (not shown) when the user's head (not shown) is positioned adjacent head-end block


490


on top quilted panel


454


. Second block


412


has a pre-selected firmness. Preferably, the firmness of second block


412


is different than the firmness of first block


410


and is greater than the firmness of foot-end and seat blocks


492


,


494


to provide additional support for the user's thighs. It is understood that the firmness of second block


412


can be greater than, less than, or equal to the firmness of first block


410


in accordance with the present invention.




As shown in

FIG. 25



a,


block


410


and seat block


494


are provided with an anti-shear coating


430


. Illustratively anti-shear coating


430


is applied to each block


490


,


410


,


412


,


494


, and


496


so that blocks


410


,


412


can move in a vertical direction independently of adjacent blocks


490


,


492


,


494


enabling head-to-toe zoning. Anti-shear coating can be a coating formed on or applied to blocks


410


,


412


,


490


,


494


,


496


, as shown in FIGS.


1


(


a


) and


2


. Anti-shear coating may also be a sleeve


98


having an interior


100


receiving block


410


,


412


. Sleeve


98


is made from a material having a low coefficient of friction such as such as a polypropylene anti-shear material or nylon. Moreover, slip cover


598


or sleeve


638


as will be described hereafter may be used as an anti-shear coating in accordance with the present invention.




If mattress apparatus


452


is sized to accommodate one user, each block


410


,


412


extends the entire width of central opening


482


to engage opposing side sections


480


. If, however, as shown in

FIG. 25

, mattress apparatus


452


is sized to accommodate two users, central opening


482


is a pre-determined width


432


and first and second blocks


410


,


412


extend only one-half of width


432


. In such an instance, central opening


482


can receive side-by-side left and right sets


416


,


418


of first and second blocks


410


,


412


, providing the retailer with eight different testing mattress feels. Thus, each first block


410


of left and right sets


416


,


418


engages head-end block


490


and seat block


494


. Second block


412


of left and right sets


416


,


418


engages foot-end block


492


and seat block


494


. In addition, blocks


410


,


412


of left set


416


about blocks


410


,


412


of right set


418


longitudinally.




It is understood that mattress apparatus


452


can be used to provide the user with multiple firmness configurations on a foundation, such as box springs, a stationary deck of a bed, an articulating deck of a bed, or the like. Mattress apparatus


452


may also rest upon a floor, a table, or any generally planer, upwardly facing surface without exceeding the scope of the invention as presently claimed.




Mattress apparatus


452


of the present invention is capable of providing each user with at least four different firmness configurations, depending upon the orientation of the mattress apparatus


452


relative to the user. Each of these four firmness configurations will have a unique vertical and head-to-toe controlled compression feel. For example, the user may experience two firmness configurations when resting upon top quilted panel


454


. Once upon top quilted panel


454


, the user's head may be positioned above either head-end block


490


or foot-end block


492


, each having a pre-selected firmness. When the user's head is positioned over head-end block


490


, the user's lumbar region will be aligned with first block


410


having the first block firmness. When the user's head is positioned over foot-end block


492


, the user's lumbar region will be aligned with second block


412


having the second block firmness.




In order for the user to experience two additional firmness configurations, mattress apparatus


452


must simply be tuned over so that the user will lie upon bottom quilted panel


460


. Since lower topper foam


481


adjacent panel


460


has a different firmness than upper topper foam


479


adjacent panel


454


, the user will experience a different overall vertical controlled compression feel. The head-to-toe zoning will also vary depending upon whether the user's head is positioned over head-end block


490


, or over foot-end block


492


as previously described. While mattress apparatus


452


has been described with reference to a retail test apparatus, it is understood that mattress apparatus


452


may be purchased by the user for personal use in the home or other care facility. In addition, mattress


452


is configured to provide the user with a favorite combination of firmness, depending upon the user's head position, and the orientation of mattress


452


relative to the user.




In another embodiment of the present invention, shown in

FIG. 26

, a mattress


552


is provided that permits a user upgrade from two-dimensional zoning to three-dimensional zoning at a low cost. Mattress


552


achieves the three-dimensional zoning at a low cost by providing a one-piece bladder


590


and a plurality of zone blocks


592


mounted upon bladder


590


. The combination of one-piece bladder


590


and zone blocks


592


above bladder


590


can provide the “feel” of a costlier system including a multi-chambered air mattress. Mattress


552


is upgradable, meaning that the user may upgrade to bladder


590


from a less costly foam, conventional springs, water tubes, or the like. Zone blocks


592


will cooperate with the foam to provide vertical controlled compression as well as head-to-to controlled compression.




Upgraded mattress


552


is shown in

FIG. 26

has three-dimensional zoning and includes an upper quilted panel


554


having a perimeter edge


556


and a lower quilted panel


560


. Upper and lower quilted panels


554


,


560


cooperate to define a mattress interior


572


which houses bladder


590


. Lower quilted panel


560


includes an upwardly-facing panel portion


562


constructed of a foam/fiber blend and an upwardly-extending side portion


566


. Side portion


566


includes a top edge


568


that is coupled to perimeter edge


556


with a zipper. It is understood that upper and lower quilted panels


554


,


560


can be coupled together by hooks, snaps, and the like in accordance with the present invention. It is also understood, that a seam may be used to couple panels


554


,


556


together without exceeding the scope of the present invention.




Mattress


552


includes a frame


574


that is received in mattress interior


572


. Frame includes a head-end foam section


576


, a foot-end foam section


578


, and longitudinally extending side foam sections


580


joining head-end and foot-end sections


576


,


578


to define a central opening


582


. Hook and loop type fasteners


579


are mounted on sections


576


,


578


,


580


of frame


574


as will be discussed below. It is understood that fasteners may be hooks, snaps, and the like in accordance with the present invention. Referring to

FIG. 27

, frame


574


rests upon panel portion


562


of lower quilted panel


560


and blocks


592


are positioned to lie between bladder


590


and upper quilted panel


554


. Upper quilted panel


554


is constructed of material similar to lower quilted panel


560


and is configured to minimize the ability of the user to perceive the interface between blocks


592


and frame


574


.




Bladder


590


is positioned to lie within central opening


582


of frame


574


and rests upon panel portion


562


. Bladder


590


is a one-piece air bladder, although it is understood that bladder


590


may be a water bladder, or a bladder that is suitable for containing other fluids. Bladder is filled with air to a capacity that permits bladder


590


to compress depending upon the weight of the load. It is understood that the amount of allowable compression will vary depending upon the volume of air within air bladder


590


.




As shown in

FIG. 26

, blocks


592


cooperate with the air bladder


590


to provide three-dimensional zoning. Zone blocks cooperate to provide vertical controlled compression and head-to-toe zoned controlled compression, and bladder


590


acts to provide side-to-side zoning based upon the volume of air within bladder


590


. Each block


592


extends the full width of central opening


582


to rest upon opposing side sections


580


. In addition, a first one of blocks


592


engages head-end section


576


, a last one of blocks


592


engages foot-end section


578


, and blocks


592


therebetween engage one another. Blocks are generally rectangular in shape and include an upper side


553


engaging panel


554


, and opposite lower side


555


, and opposite sides


557


that longitudinally abut one another. Upper side


553


of blocks


592


may be affixed to upper quilted panel


554


to prevent migration on bladder


590


. In addition, lower side


555


of blocks


592


include hook and loop fasteners


581


that cooperate with fasteners


579


on frame


574


to hold blocks


592


in position within mattress interior


572


. While two blocks


592


as shown with fasteners


581


it is understood that greater or fewer than two blocks may include fasteners in accordance with the present invention. In addition, it is understood that a variety of releasable fasteners such as snaps, zippers, etc. may be used in accordance with the present invention.




Each block


592


can be provided with an anti-shear coating


430


as shown in

FIG. 25



a


so that each block


592


can compress in a vertical direction independently of adjacent blocks


592


and provide head-to-toe controlled compression. Anti-shear coating


430


is constructed as previously discussed in the specification. Alternatively, as shown in

FIG. 28

, a slip cover


598


may be provided to serve as an anti-shear coating in accordance with the present invention. Slip cover


598


includes a top member


630


and a bottom member


632


coupled to top member


630


in order to form a plurality of pockets


634


therebetween. Pockets


634


are spaced apart by seams


636


. Referring now to

FIG. 29

, pockets


634


receive blocks


592


. In addition, pockets


634


permit individual compression of blocks


592


as shown by arrows


595


relative to one another. Moreover, pockets


634


beneficially inhibit migration of blocks


592


within mattress


552


. When slip cover


598


is used, hook and loop fasteners can be sewn to slip cover


598


or slipcover


598


may permitted to simply rest upon frame. Slip cover


598


like coating


430


allows independent action of blocks


592


and thus head-to-toe controlled compression.




Frame


574


and blocks


592


may be made from a foam rubber such as urethane foam. Frame


574


is firmer than blocks


592


to provide additional support to the user when entering or exiting mattress. The firmness and support characteristics of the foam rubber can be customized in accordance with the desires of the user of mattress


552


. The firmness and support characteristics of the foam rubber is customized by techniques previously described in the specification. Although urethane foam is the preferred material for these components, any material providing support and firmness characteristics similar to those provided by foam rubber, for example polyester fiber and latex foam, can be used without exceeding the scope of the invention as presently perceived.




If mattress


552


is for use in a queen-sized or king-sized bed, central opening


582


is a second width and each block


592


extends only one-half of the second width. In such instance, central opening


582


can receive side-by-side left and right sets (not shown) of blocks


592


.




An alternative embodiment of mattress apparatus


610


is illustrated in FIG.


30


. Apparatus


610


has three-dimensional zoning and includes upper quilted panel


554


and lower quilted panel


560


as previously discussed. Frame


574


cooperate to surround blocks


651


. Sleeves


638


are provided to act as an anti-shear coating for blocks


651


. Each sleeve


638


includes an upper panel


640


, a lower panel


642


, and side panels


644


coupling upper and lower panels


640


,


642


together. In addition, sleeve


638


includes a plurality of spaced-apart pockets


646


therein that are defined by seams


648


. Each upper panel


640


includes slots


650


therethrough. Slots


650


define an opening into pockets


646


and are sized to receive zoned blocks


651


therethrough. Blocks


651


are similar to blocks


592


except are formed to have a reduced dimension. Similar to slip cover


598


, sleeve


638


permits individual compression of blocks


651


and thus a third-dimension of zoning.




Sleeve


638


enables three-dimensional zoning by enabling vertical zoning (“controlled compression”); head-to-toe zoning; and side-to side zoning. Blocks


651


within sleeve


638


provide vertical zoning (“controlled compression”) and positioning of blocks


651


extending between head end


576


and foot end


578


of frame


574


provides the second dimension of support. As shown in

FIG. 30

the positioning of sleeves


638


give support variation in a third side-to-side direction. Placing blocks


651


in sleeves


638


secures blocks


651


in position and provides a neat appearance, durability, and ease of assembly. In addition, sleeves


638


are of a uniform size and shape and are used in a twin, double, queen, or king sized mattress. The uniform dimensions of sleeves


638


enable a manufacturer to reduce inventory. It is understood, that blocks


651


are also uniform in size and shape so as to extend through pockets


646


. It is also understood that side panels


644


of sleeves


638


may be coupled together to form a matrix to prevent individual sleeves


638


from turning and to hold sleeves


638


in position relative to one another. Mattress apparatus


610


also rests on a foundation


596


such as box springs, a stationary deck of a bed, an articulating deck of a bed, or the like. Mattress apparatus


610


can also rest on a floor or any other generally planar, upwardly facing surface without exceeding the scope of the invention as presently perceived.




In another embodiment of the present invention, an economy mattress


652


that enables two-dimensional zoning is provided. As shown in

FIG. 31

, mattress


652


enables a user to create a customized firmness configuration with vertical controlled compression and head-to-toe controlled compression. To the extent that mattress


652


resembles mattress apparatus


452


illustrated in

FIG. 24

, like reference numerals will be used to denote like components. Core


662


of mattress


652


includes a set of transversely extending blocks


664


made from materials similar to blocks


592


as previously discussed.




Referring to

FIG. 31

, core


662


is received in central opening


482


of frame


474


and is positioned to lie between lower quilted panel


460


and upper quilted panel


454


. Blocks


664


of core


662


longitudinally abut one another in central opening


482


. Blocks


664


include opposite ends


669


, a top side


670


, an opposite bottom side


672


, and side edges


673


,


675


extending therebetween when mattress


652


is for use in a single bed, each block


664


extends the full width of central opening


482


and opposite ends


669


are coupled to opposing side sections


480


of frame


474


. As shown, for example in

FIG. 32

, top side


670


of block


664


is coupled to topper


674


. The ability of blocks


664


to migrate throughout central opening


482


is minimized by coupling topper


674


to both frame


474


and to core


662


. In preferred embodiments, blocks


664


are coupled to side sections


480


and topper


674


by an adhesive


676


. It is understood that a wide variety of commercially available adhesives


676


can be used in accordance with the present invention so long as the adhesive chosen is compatible with the materials being adhered. Moreover, blocks


664


may be coupled to side sections


480


and topper


674


by releasable connectors such as hook-and-loop type connectors, buttons, snaps, and the like. It is understood that zone blocks


664


may be coupled to only topper


674


or only to side sections


480


without exceeding the scope of the present invention.




Referring now to

FIG. 33

, anti-shear coating


430


having a low coefficient of friction may be positioned to lie between each block


664


to encourage movement therebetween. The relative movement enables head-to-toe zoning. For example, since blocks


664


move relative to one another and will have various firmness levels, a user resting upon top quilted panel


454


will experience various firmness levels from head-to-toe. It is understood that slip cover


598


or sleeve


638


may also be used in accordance with the present invention. When, however, greater than one sleeve


638


is used, three-dimensional zoning as previously discussed with reference to

FIG. 30

will result.




In an additional embodiment of the present invention, a movable support component


710


is provided as shown in FIG.


34


. While support component


710


is shown with mattress


754


, component


710


is suitable for use with a variety of mattress apparatuses


452


,


552


,


652


, etc. Support component


710


includes an individual inflatable air bladder


716


that may be positioned in a variety of locations within or upon mattress


710


. By moving component


710


, air bladder


716


provides the user with selective localized controlled compression.




Bladder


716


is shown in

FIG. 34

being positioned between block


715


and foam bottom


717


of frame


474


. Bladder


716


may also be positioned to lie between block


715


and upper quilted panel


454


, or between quilted panel


454


and the user. Support component


710


can be aligned with the lumbar region of a user or with any other region such as under the user's thigh, feet, head or any other region if desired. In addition, bladder


716


is preferably an air bladder and may be inflated and deflated by the user to adjust the firmness of support component


710


. Bladder


716


is manipulated by a control system such as that previously described in the specification with reference to hand controller


256


. Although a wide variety of commercially available controllers may be used in accordance with the present invention. Thus, the user of mattress


754


is permitted to alter selectively the firmness of a particular section of mattress


754


.





FIG. 35

illustrates still another embodiment of the present invention wherein a super pillow top


4090


and an attachment mechanism


850


are provided. Attachment mechanism


850


cooperates with an anti-slip material


1036


, as will be discussed hereafter, to secure super top


4190


on a mattress


4052


. Super top


4090


in accordance with the present invention provides the user with two-dimensional zoning upon a wide variety of surfaces. For example, super top


4090


will provide zoning to a variety of commercially available spring-coil mattresses, single chamber air mattresses, water beds, and the like. Super top


4090


includes a shell


4016


and a set of transversely extending blocks


4664


, made from materials similar to blocks


592


as previously discussed, positioned to lie within shell


4016


. While blocks


4664


are illustrated and described, it is understood that a foam block with a pre-determined generally single firmness or a convoluted block having a variety of firmnesses may be used in accordance with the present invention. In any event, super top


4090


is thicker than pillow tops


724


,


1010


,


1210


as will be discussed hereafter.




Shell


4016


includes a top quilted panel


4018


and a bottom quilted panel


4020


coupled to top panel


4018


by a seam. It is understood, however, that a zipper and other attachment mechanisms such as hooks, buttons, tabs, and the like could be used to couple top and bottom quilted panels


4018


,


4012


together. In fact, when a seam is not used to couple top and bottom panels


4018


,


4012


together, blocks


4664


are held in an adjacent relationship relative to one another by a sleeve


4050


(

FIG. 35



c


). Bottom panel


4020


includes side walls


4022


extending upwardly toward top panel


4018


to define an interior region


4024


in which to receive blocks


4664


. In addition, super top


4090


may be formed with a “summer top” and a “winter top” as will be discussed hereafter with reference to pillow top assembly


1010


. If super top


4090


is for use in a queen-sized bed (not shown) or a king-sized bed (not shown), each block


4664


extends only one-half of the interior region


4024


. In such instance, super top


4090


can alternatively include side-by-side combinations including a set of zone foam blocks


4664


, sculptured foam core (not shown), and air bladder (not shown). Handles


103


are coupled to side walls


4022


of super top


4090


. As shown in

FIG. 35



a,


each handle


103


includes opposite ends


119


and a handle portion


121


. Handle portion


121


cooperates with super top


4190


to define a griping aperture


123


.




Super top


4090


in accordance with the present invention is configured to lie on a mattress


4052


having an outer shell


4102


, frame


574


, and a one-piece air bladder


4106


. Shell


4102


includes a top panel


4108


and a bottom panel


4120


. Bottom panel


4120


includes side walls


4122


extending upwardly toward top panel


4108


to define an interior region


4124


in which to receive frame


574


and bladder


4106


. Handles


101


are coupled to side walls


4122


. As shown in

FIG. 35



a,


each handle


101


includes spaced-apart ends


113


and a handle portion


11




5


therebetween. Handle portion


115


cooperates with side portion


4066


of mattress


4052


to define a gripping aperture


117


. Handles


10


are positioned to lie vertically adjacent handles


103


once super top


4190


is positioned upon mattress


4052


. While mattress


4052


is illustrated and described, it is understood that interior region


4124


of mattress may include foam, conventional springs, water tubes, or the like in accordance with the present invention.




Mattress


4052


is configured to lie upon mattress foundation


120


, as shown in

FIG. 35



b.


Foundation


120


has hook and loop type fasteners


4121


coupled thereto. Foundation


120


may be any number of a wide variety of platforms, such as box springs, a stationary deck of a bed, an articulating deck of a bed, or the like. Mattress


4052


can also rest on a floor or any other generally planar, upwardly facing surface without exceeding the scope of the invention as presently perceived.




Attachment mechanism


850


includes at least one strap


105


that is sized for extension through gripping apertures


117


,


123


of respective handles


101


,


103


. Referring now to

FIG. 36

, strap


105


includes a first end


107


with hook and loop type fasteners


109


,


129


and a second end


111


having hook and loop type fasteners


139


. Although hook and loop type fasteners


109


,


129


,


139


are illustrated and described, it is understood that various releasable or permanent fastening mechanisms such as snaps, buttons, adhesives, zippers, rivets and the like are not outside the scope of the present invention.




To couple super top


4190


to mattress


4052


, second end


111


of strap


105


is extended through gripping apertures


117


,


123


of handles


101


,


103


as shown in

FIG. 35



b


and fasteners


139


are coupled to hook and loop type fasteners


4121


on foundation


120


. First end


107


of strap


105


is then folded over handle


103


so that hook and loop type fasteners


109


,


129


engage one another. Although only two handles


101


,


103


are illustrated on super top


4190


and mattress


4052


, it is understood that any number of handles, such as four handles or greater than or fewer than four handles, could be provided as desired on each. In addition, while mattress


4052


is illustrated, it is understood that attachment mechanism


850


is suitable for use with a wide variety of mattresses.




In accordance with yet another embodiment of the present invention, a mattress


752


is provided and illustrated in FIG.


37


. Mattress


752


includes a fabric shell


720


, a frame


774


positioned to lie within shell


720


, zoned blocks


810


providing two-dimensional zoning, seat section blocks


812


, a lumbar section block


814


, a topper


722


, and a pillow top


724


including flexible straps


726


extending about fabric shell


720


to couple pillow top


724


to shell


720


. Frame


774


includes a head-end foam section


776


, a foot-end foam section


778


, and longitudinally extending side foam sections


780


joining head-end and foot-end sections


776


,


778


to define a central opening


782


. Releasable connectors


730


such as hook-and-loop type connectors are coupled to sections


776


,


778


and topper


772


to hold topper upon frame


774


. It is understood that releasable connectors such as buttons, snaps, and the like may be used without exceeding the scope of the present invention.




As shown in

FIG. 37

, zone blocks


810


, seat section blocks


812


, and lumbar section block


814


are sized for positioning within central opening


782


of frame


774


. Blocks


810


,


812


, and


814


, are constructed of foam rubber, although it is understood that blocks


810


,


812


, and


814


may be constructed of a wide variety of compressible materials or may be formed as air bladders. The firmness and support characteristics of the foam rubber may be pre-selected by the retailer or customer. It is also understood that mattress


752


may include any number of blocks


810


in any number of sections, mattress


752


may include only blocks of the type in seat section


812


shown in

FIGS. 37 and 38

, mattress


752


may include only blocks if the type in lumbar section


814


shown in

FIGS. 37 and 39

, or mattress


752


may include both blocks of the types in seat and lumbar sections


812


,


814


in accordance with the present invention.




Referring now to

FIG. 38

, each seat section block


812


is a composite block


818


, which provides the user with targeted controlled compression. Composite block


818


includes a softer upper section


820


, a firm core section


822


and a soft lower section


824


. Composite block


818


is illustratively about four inches (10.2 cm) thick with about a two inch (5.1 cm) thick core


822


. Upper and lower sections


820


,


824


are about one inch (2.5 cm) thick and cover core section


822


. It is understood that the dimensions of composite block


818


may vary without exceeding the scope of the present invention. As shown in

FIG. 38



a,


when the user is lying down on block


812


, the load is distributed generally uniformly across soft layer


820


causing soft layer


820


to compress slightly to absorb the load. As shown in

FIG. 38



b,


when the user raises to a sitting position, significant compression occurs in layers


820


,


824


while center core remains relatively in position to provide support. Thus, when in a sitting position, the user's weight is directed down against core


822


rather than being distributed across the entire surface of composite block


818


. So, composite block


818


provides a softer feel (see FIG.


38


(


a


) when the user's weight is distributed across the whole surface of composite block


818


(and compressed only into upper section


820


) plus necessary firmness when (FIG.


38


(


b


) most of the user's weight is directed toward core


822


.




Upper and lower sections


820


,


824


may be coupled to the core


822


by releasable or permanent fastening mechanisms such as adhesives, hook and loop type fasteners, straps, sleeves, and the like. Although the thickness and number of layers of composite block


818


are illustrated and described, it is understood that a variety of thickness and layers may be used so long as a firm core is surrounded by softer upper and lower sections.




In accordance with still another embodiment of the present invention, lumbar block


814


is provided for use with mattress


752


to provide greater resolution in head-to-toe zoning. As shown in

FIG. 39

, lumbar block


814


includes a composite block


830


having three sections


832


,


834


,


836


positioned to lie in a side-by-side relationship. Sections


832


,


834


,


836


have predetermined firmness levels to provide a desired firmness to a user's pre-determined “sweet spot”. Illustratively, composite block


830


includes a firm center section


832


and softer side sections


834


,


836


positioned to lie on either side of the center section


832


. Thus, lumbar block


814


provides firmness to a user's predetermined “sweet spot”, while providing softer support on either side of that predetermined sweet spot. It is understood, that center section


832


is not necessarily firmer than side sections


834


,


836


as the firmness of sections


832


,


834


,


836


may vary without exceeding the scope of the present invention.




As shown in

FIG. 39

, side sections


834


,


836


of lumbar block


814


are positioned to lie adjacent different blocks


810


in a series of blocks


810


to provide the targeted head-to-toe zoning. Composite block


830


illustratively extends nine inches (22.9 cm) between blocks


810


and is four inches (10.2 cm) deep. Center section


832


is three inches (7.6 cm) wide and each of the two side sections is three inches (7.6 cm) wide to form the nine inch (22.9 cm) width of composite block


814


. Side sections


834


,


836


may be coupled to the center section


832


by releasable or permanent fastening mechanisms such as adhesives, hook and loop type fasteners, sleeves, straps, and the like.




Mattress structure


900


in accordance with another embodiment of the present invention is shown in

FIGS. 40 and 41

and provides the user with threedimensions of zoning. Mattress structure


900


includes a fabric shell


720


, zoned blocks


910


, foam side rails


974


, foam end rails


975


, a slip cover


976


, a topper


912


, an air chamber


914


positioned to lie between the blocks


910


and the topper


912


, and pillow top


724


. Topper


912


provides vertical controlled compression and includes flexible straps


978


configured to extend about air chamber


914


and blocks


910


to hold topper


912


upon chamber


914


. Straps


978


are coupled to topper


912


using an adhesive, although it is understood that a wide variety of releasable and non-releasable fastening mechanisms such as hook-and-loop type fasteners, snaps, buttons, and seams may be used in accordance with the present invention.




Individual blocks


910


have a variety of sizes and firmness levels that can vary to create zones within mattress structure


900


of various firmness. Thus blocks


910


produce a “customized” mattress structure


900


that is proportioned to fit the needs of a particular size and shaped person (not shown) air bladder mattress structure


900


to provide the user with three-dimensional zoning, as previously discussed. Blocks


910


and topper


912


are preferably constructed of a foam material similar to blocks


592


and topper


586


. As shown in

FIG. 40

, air chamber


914


is positioned to lie over blocks


910


. Chamber


914


is selectively inflatable and provides the user with side-to-side zoning. Air chamber


914


is capable of approximately 2.5 inches (6.4 cm) of thickness. Thus, the thin air chamber


914


positioned over the blocks


910


is configured to permit the user lying on bed


900


to adjust the amount of air in air chamber


914


and thus the side-to-side firmness feel of bed


900


as well as magnifying or minimizing the head-to-toe zoning by varying the pressure in the air chamber. It is understood that the thickness of air chamber


914


may be varied in accordance with the present invention.




Referring now to

FIG. 41

, air chamber


914


includes a plurality of inner supports


920


therein. Inner supports


920


cooperate to define air channels


922


in air chamber


914


. Air channels


922


maybe in fluid communication with one another or be individual channels. Controller


990


permits user to inflate or deflate channels


922


to provide desired mattress feel. Controller


990


may be a hand-held or headboard/sideboard mountable controller in accordance with the present invention. It is understood that controller may be any one of a wide variety of controllers as previously described herein or any one of a variety of commercially available inflation/deflation controllers.




As shown in

FIG. 42

, a pillow top assembly


1010


in accordance with the present invention provides separate sleeping surfaces for warm summer months cooler winter months. Pillow top assembly


1010


includes a shell


1016


and a foam pad


1014


positioned to lie within shell


1016


. Shell


1016


includes a top quilted panel


1018


having thermal properties designed for sleeping comfort during cooler months and a bottom quilted panel


1020


having thermal properties designed for sleeping comfort during warmer months.




Pillow top assembly


1010


in accordance with the present invention is configured to lie on a mattress, a mattress overlay, or a mattress replacement system


1022


(hereinafter “mattress”). As shown in

FIG. 42

, mattress


1022


has a head end


1024


, foot end


1026


longitudinally spaced-apart from head end


1024


, a longitudinally-extending first edge


1028


therebetween, and a longitudinally-extending second edge


1030


spaced apart from first edge


1028


. In addition, mattress


1022


includes an upper panel


1032


.




As used throughout the description and claims, the phrase “head end” will be used to denote the end of any referred-to object that is positioned to lie nearest head end


1024


of mattress


1022


and the phrase “foot end” will be used to denote the end of


10


any referred-to object that is positioned to lie nearest to foot end


1026


of mattress


1022


. The phrase “first edge” will be used to denote the edge of any referred-to object that is positioned to lie nearest first edge


1028


of mattress


1022


and the phrase “second edge” will be used to denote the edge of any referred-to object that is positioned to lie nearest second edge


1030


of mattress


1022


. Also, unless otherwise noted, identical element numbering of pillow top assembly


1010


elements will be used on alternative embodiments. As described above, mattress


1022


can be any mattress for use in a home, a mattress for use in a hospital or other care facility, or any other type of mattress having an upwardsfacing surface


44


above which a person rests. Illustrative mattress


1022


supports pillow top assembly


1010


of the present invention.




Pillow top assembly


1010


rests on upper panel


1032


so that pillow top assembly


1010


lies outside of the mattress interior (not shown). According to the present invention, pillow top assembly


1010


includes a series of four straps


1034


, one strap


1034


situated adjacent each corner. Pillow top assembly


1010


is secured to mattress


1022


by looping each strap


1034


over a respective comer of mattress


1022


. Pillow top straps


1034


are used in conjunction with anti-slip material


1036


which keeps pillow top


1010


constrained. Pillow top assembly


1010


can also lay freely on mattress


1022


or can be coupled to mattress


1022


by use of hook and loop type fasteners or other suitable coupling means. Although four straps


1034


are illustrated on assembly


1010


, is understood that greater than or fewer than four straps, could be provided in accordance with the present invention.




Shell


1016


of pillow top assembly


1010


that houses pad


1014


includes top quilted panel


1018


that cooperates with bottom quilted panel


1020


to define an interior region


1046


therebetween. As shown in

FIG. 43

, top quilted panel


1018


is preferably constructed of an adhesive sheet


1048


, a foam layer


1050


constructed of polyurethane foam and positioned to lie adjacent adhesive sheet


1048


, a winter layer


1052


constructed of a wool/polyester blend or pure wool or anti-microbial polyester fiber positioned to lie adjacent foam layer


1050


and having a first thermal resistance, and a cloth


1054


constructed of rayon, cotton, or cotton blend Damask cloth covering winter layer


1052


. It is understood, however, that cloth


1054


may be constructed of a wide variety of natural or synthetic fibers that are used in the manufacture of cloth including non-air and nonliquid permeable cloth. Furthermore, a non-air and non-liquid permeable top quilted panel


1018


and bottom quilted panel


1020


may be used without exceeding the scope of the present invention. Foam layer


1050


provides a pre-determined vertical controlled compression to the user. Foam layer


1050


is relatively soft to allow the user to sink into winter layer


1052


. Thus greater percentage of the user's surface area engages winter layer


1052


providing a warm feel to the user.




Bottom quilted panel


1020


is constructed of adhesive sheet


1048


, a foam layer


1056


constructed of polyurethane foam and positioned to lie adjacent adhesive sheet


1048


, a summer layer


1058


constructed of an anti-microbial polyester fiber or wool/polyester blend or pure wool positioned to lie adjacent foam layer


1056


and having a second thermal resistance, and cloth


1054


covering summer layer


1058


as shown, for example, in FIG.


43


. In the preferred embodiment of the present invention, foam layer


1056


of bottom quilted panel


1020


, situated next to summer layer


1058


, is made of foam having a second firmness that is greater than foam layer


1050


of top quilted panel


1018


, positioned next to winter layer


1052


. Thus a smaller percentage of the user's surface area engages summer layer


1058


providing a cooler feel to the user and made of foam having a second firmness that is greater than that of foam layer


1050


.




As described above, the preferred embodiment of the present invention includes top and bottom quilted panels


1018


,


1020


that have a different thermal resistance. For example, when winter layer


1052


of top quilted panel


1018


is constructed of a wool/polyester blend, it effectively creates a “winter top” due to its high thermal resistance. Likewise, when summer layer


1058


of bottom quilted panel


1020


is constructed of a polyester fiber with anti-microbial, it effectively creates a “summer top” due to its low thermal resistance to the growth of unwanted organisms. Thus, the “summer top” provides the user with a cooler skin feel and the “winter top” provides the user with greater thermal resistance and therefore a warmer skin feel. Therefore, during the cooler winter months, the winter top can be placed nearest the user. When the weather becomes warmer, pillow top assembly


1010


may be flipped over so that the summer top is nearest the sleeper. Thus, pillow top assembly


1010


provides two sides with different thermal properties for different environmental conditions that occur with the change of seasons. In addition, winter layer


1052


can be plusher than summer layer


1058


. So, more of the user's surface area engages the surface of winter layer


1052


and winter layer feels warmer to the user. Summer layer


1058


can be firmer than winter layer


2063


. So, the user sinks into summer layer


1058


less than winter layer


1052


, less of the user's surface area engages summer layer


1058


, and therefore more of the user is exposed to air and is cooler. Further, turning the pillow top assembly


1010


for different seasons will increase the longevity of assembly


1010


and even wear.




As shown in

FIG. 43

, top quilted panel


1018


includes a first perimeter edge


1060


and bottom quilted panel


1020


includes a second perimeter edge


1062


that is coupled to first perimeter edge


1060


at a seam


1064


. While seam


1064


is illustrated and described, it is understood that a releasable fastener such as zippers and he like may be used in accordance with the present invention. As shown in

FIGS. 42 and 43

, top and bottom quilted panels


1018


,


1020


are quilted. Quilting


1066


, according to the present invention, runs through each layer


1018


,


1020


individually, but quilting could run all the way through pillow top assembly


1010


without exceeding the scope of the present invention. Thus, quilting


1066


can provide both aesthetic appeal as well as structural support to pillow top assembly


1010


.




Pad


1014


lies within interior region


1046


of shell


1016


. Pad


1014


cooperates to form an easy-to-assemble, one-piece, pillow top assembly


1010


with a predetermined vertical controlled compression. As shown in

FIG. 42

, pad


1014


is shaped as a relatively flat rectangular block and has a uniform predetermined firmness. As shown in

FIGS. 42 and 43

, pad


1014


is positioned to lie between top and bottom quilted panels


1018


,


1020


in interior region


1046


of shell


1016


and extends from head end


1024


to foot end


1026


of mattress


1022


. Adhesive sheets


1048


provide further structural support for pillow top assembly


1010


by serving as an adhesive connection between top and bottom quilted panels


1018


,


1020


and pad


1014


. Pad


1014


can also be sculpted to a desired shape or formed from a piece of foam having firmness that varies along its length or across its width without exceeding the scope of the invention as presently perceived.




According to the present invention, an anti-skid material


1036


is provided to inhibit sliding movement of pillow top assembly


1010


on upper panel


1032


adjacent anti-skid material


1036


. Anti-skid material


1036


is particularly useful on articulating beds (not shown) where movement can occur between mattress


1022


and pillow top assembly


1010


during articulation of mattress


1022


. In addition, non-slip material


1036


inhibits sliding movement of pillow top assembly


1010


when the user is entering or exiting mattress


1022


. Pillow top assembly


1010


includes a head region


1038


, a seat region


1040


, and a foot region


1042


. Non-slip material


1036


is positioned to lie between seat region


1040


and mattress


1022


. Because non-slip material


1036


is not placed between head and foot regions


1038


,


1042


and mattress


1022


, motion or slipping is permitted in articulating beds between mattress


1022


and head and foot regions


1038


,


1042


. This movement allows head and foot regions


1038


,


1042


to adjust to the underlying motion of mattress


1022


due to articulation of the articulating bed while the seat region


1040


of pillow top assembly


1010


remains generally stationary relative to seat region


1040


of mattress


1022


. This relative motion between the pillow top and mattress minimizes the “shear” between the surface and the patient. Anti-skid material


1036


is made of Sleep Tights (polyvinyl chloride (PVC) on a polyester scrim), rubber foam, or any suitable material that will restrict the movement of pillow top assembly


1010


relative to mattress


1022


adjacent to non-slip material


1036


.




As shown in

FIG. 44

, a pillow top assembly


2110


provides a user with two-dimensional zoning. Specifically, assembly includes a series


2112


of standardized zoned blocks


2114


that cooperate to provide vertical controlled compression and head-to-toe zoning. Pillow top assembly


2110


allows a user to have head-to-toe zoning on a conventional inner spring mattress, conventional water mattress, or a conventional single chamber air bladder to achieve both zoning and adjustable firmness for a lower cost than adjustable air bladders. Each block


2114


in series


2112


is constructed of a foam material similar to blocks


592


and has an individual firmness level. Thus, blocks


2114


of different firmness levels create zones within pillow top assembly


2110


of various firmness. Thus, series


2112


produces a “customized” pillow top or assembly


2110


or super top, as previously discussed, proportioned to fit the needs of a particular size and shape person (not shown) or to provide the user with the desired firmness characteristics. Assembly of modular blocks


2114


is completed by using shell


1016


that surrounds blocks


2114


and holds them securely in their pre-determined positions. As with pillow top assembly


1010


, pillow top assembly


2110


and other embodiments of pillow top assemblies disclosed herein may be reversible, meaning that pillow top assembly


2110


and other embodiments of pillow top assemblies mentioned below include a summer top and an opposing winter top as described in detail above with respect to pillow top assembly


1010


.




As shown in

FIG. 44

, blocks


2114


are generally rectangular in shape. Blocks


2114


are formed to include a top surface


2168


facing top quilted panel


1018


, a bottom surface


2170


facing bottom quilted panel


1020


, opposite side edges


2172


extending between top and bottom surfaces


2168


,


2170


, and first and second ends


2174


,


2176


extending between top surface


2168


and bottom surface


2170


. Second end


2176


of a first block


2178


in series


2112


abuts and is affixed to first end


2174


of a second block


2180


in series


2112


to form a contact joint


2182


therebetween. Likewise, second end


2176


of second block


2180


abuts and is affixed to first end


2174


of a third block


2184


to form a contact joint


2182


therebetween. Third block abuts a fourth block


2188


and fourth block abuts a fifth block


2190


in a similar manner. Blocks


2114


, however, need not be coupled together in accordance with the present invention. First, third, and fifth blocks


2178


,


2184


,


2190


are preferably made of foam of substantially the same degree of firmness. Second and fourth blocks


2180


,


2188


are preferably made of a foam that has a higher degree of firmness than first third, and fifth blocks


2178


,


2184


,


2190


. This arrangement provides symmetry to pillow top assembly


2110


. It is understood, that blocks


2114


may be formed as trapezoids, rectangles, honeycombs, or any number of shapes that are capable of fitting together at a contact joint to form series


2112


of blocks


2114


that extend between head end


1024


and foot end


1026


of mattress


1022


without exceeding the scope of the present invention. It is also understood that the firmness of assembly


2110


may be varied by including a single block


2114


with convolutions to provide head-to-toe zoning.




Illustrative blocks


2114


in series


2112


are constructed in the same manner and have similar firmness ranges as previously discussed blocks


92


. The actual degree of firmness of blocks


1114


can be pre-selected to offer a range of choices for the end user. For example, three firmness arrangements can be pre-selected to offer users a “soft” pillow top assembly, a “medium” pillow top assembly having zoned blocks with a higher degree of firmness than the soft pillow top assembly, or a “hard” pillow top assembly having zoned blocks with a higher degree of firmness than the medium pillow top assembly. Thus, customers can select their degree of firmness from the pre-selected choices. Many degrees of firmness in addition to the three just mentioned may also be designed into pillow top assembly


2110


according to the present invention.




In still another embodiment of the present invention, a heat-dispersement apparatus


1140


is provided that is suitable for positioning between pillow top assembly


1010


and mattress


1022


as shown, for example, in FIG.


45


. Dispersement apparatus


1140


provides the user with a heat sensation similar to a waterbed without the weight or risk of tear and cools the user when the mass of apparatus


1140


is at an ambient temperature that is lower than the body temperature of the user. It is understood that apparatus


1140


may also be positioned to lie between a wide variety of pillow top assemblies and mattresses so long as pillow top assembly is not so thick as to act as an insulator preventing heat from reaching the user.




Heat-dispersement apparatus


1140


includes an impermeable liner


1142


defining an interior cavity


1144


, gel


1146


positioned to lie in cavity


1144


, and at least one heating element


1148


. Heating element


1148


may be any number of commercially available wired-heating pads configured to lie spaced apart from gel


1146


, or may integral with apparatus


1140


(not shown) such that element


1148


is submersed in gel


1146


. Gel


1146


suitable for use with the present invention is thermally conductive, provides a heat sink, and masks the feel of the wires of heating element


1148


from the user. It is understood, however, that while a gel is illustrated and described, a wide variety of dense thermally conductive materials, such as dense foam, may be used in accordance with the present invention. The desired heating characteristics of apparatus


1140


may vary in accordance with the present invention depending upon the thermal conductivity and density of gel


1146


, the number of heating elements


1148


, and size of apparatus


1140


. Apparatus


1140


holds heat generated by heating elements


1148


and evenly dissipates heat through gel


1146


and thus across mattress


1022


.




Heat-dispersement apparatus


1140


provides the user with the ability to pre-heat pillow top assembly


1010


before use or to provide a heating source during sleep. In one embodiment, apparatus


1140


creates a heat region


149


that enables the user to customize pillow top assembly


1010


to the user's pre-determined heating specifications. For example, a person with back ailments may wish to heat their lumbar region separately from the rest of their body. Further, a person might desire to heat their lower legs and feet separately from the rest of their body during the winter. Many other combinations of independent heat regions


149


are also available for medical, comfort, and other reasons as well. Heat region


149


is created by placing a localized heating element


1148


adjacent desired heat region


149


. While apparatus


1140


is illustrated and described, other heat sources and heating elements


1148


may be used in accordance with pillow top assembly


1010


of the present invention.




As shown in

FIGS. 46

,


47


, and


49


yet another pillow top assembly


1210


or super top, in accordance with the present invention is provided. Pillow top assembly


1210


provides two-dimensional zoning to users. Specifically, pillow top assembly


1210


includes two series


1212


,


1213


of standardized zoned blocks


1214


for mattresses


1022


sleeping more than one person. Individual blocks


1214


in each series


1212


,


1213


cooperate to provide both vertical controlled compression and head-to-toe zoning. Blocks


1214


are constructed from foam materials similar to blocks


592


, have a variety of sizes and firmness levels, and create zones within pillow top assembly


1210


of various firmness. Thus, series


1212


,


1213


produce a “customized” assembly


1210


to fit the needs of particular sized and shaped people or to provide each user with their desired firmness characteristics. Shell


1016


surrounds blocks


1214


and holds them securely in their pre-determined position. Assembly


1210


may also be formed with one series


1212


of blocks


1214


in accordance with the present invention.




Blocks


1214


lie within interior region


1046


of shell


1016


. As shown in

FIG. 46

, zone blocks


1214


are generally uniformly shaped and are positioned in a side-by-side relationship within interior region


1046


between top and bottom quilted panels


1018


,


1020


. In addition, blocks


1214


extend from head end


1022


to foot end


1026


of shell


1016


that extends from head end


1022


to foot end


1026


of mattress


1022


. Adhesive sheets (not shown) may be used to provide further structural support for pillow top assembly


1210


by serving as an adhesive connection between top and bottom quilted panels


1018


,


1020


and blocks


1214


.




Referring now to

FIG. 47

, blocks


1214


are sculptured to a rectangular shape and provide both vertical controlled compression and head-to-toe zoning. It is understood that blocks


1214


may be formed as trapezoids, honeycombs, or any number of shapes that are capable of fitting together at a contact joint without exceeding the scope of the present invention. Blocks


1214


need not, however, necessarily be coupled together in accordance with the present invention. Blocks


1214


are formed to include a top surface


1254


facing top quilted panel


1018


, a bottom surface


1056


facing bottom quilted panel


1020


, opposite side edges


1058


extending between top and bottom surfaces


1254


,


1256


, and first and second ends


1260


,


1262


extending between top surface


1254


and bottom surface


1256


. Second end


1262


of a first block


1272


in series


1212


abuts first end


1260


of an adjacent block


1274


in series


1212


to form a contact joint


1264


therebetween. Heat-dispersement apparatus


1140


enables a user to have two-dimensions of zoning as well as the heat-sensation similar to a waterbed.




Anti-skid material


1036


is positioned to lie between seat section


1273


of pillow top assembly


1212


and mattress


1022


to prevent movement between mattress


1022


and pillow top assembly


1212


during articulation of mattress


1022


. In addition, anti-skid material


1036


inhibits sliding movement of pillow top assembly


1212


when the user is entering or exiting mattress


1022


. Anti-skid material


1036


rests upon mattress


1022


, although it is understood that anti-skid material


1036


may be coupled to shell


1016


. Referring now to

FIG. 49

, heat dispersement apparatus


1140


may be positioned between pillow top assembly


1210


and mattress


1022


.




As shown in

FIG. 48

, yet another pillow top assembly


1310


in accordance with the present invention is provided. Pillow top assembly


1310


includes an upper zone series


1312


that has a different firmness than a lower zone series


1314


. Thus, pillow top assembly


1310


provides the user with at least two different firmness feels depending upon whether the user is adjacent the top quilted panel


1018


or bottom quilted panel


1020


. Specifically, the user will experience different vertical controlled compression depending upon what quilted panel


1018


,


1020


to user engages.




Upper zone series


1312


is positioned to lie adjacent top quilted panel


1018


and bottom zone series


1314


is positioned to lie adjacent bottom quilted panel


1020


. Panels


1018


,


1020


may be formed as summer and winter tops as previously described in addition, individual blocks


1316


in series


1312


,


1314


have a variety of sizes and firmness levels and create head-to-toe firmness zones within pillow top assembly


1310


. Such differences in firmness between upper and lower zone series can be created by using blocks


1316


with different foam density, or by the use of ribs or other techniques known to those of ordinary skill in the art. Illustratively, anti-skid material


1036


is positioned to lie between seat section


1373


of pillow top assembly


1310


and mattress


1022


to prevent movement between mattress


1022


and pillow top assembly


1310


during articulation of mattress


1022


as discussed above. In addition, anti-skid material


1036


inhibits sliding movement of pillow top assembly


1310


when the user is entering or exiting mattress


1022


.




Referring now to

FIG. 50

, another pillow top assembly


2310


in accordance with the present invention is provided. Pillow top assembly includes a series


2312


of generally trapezoidal-shaped blocks


2314


to provide the user with two-dimensional zoning. Individual blocks


2314


in series


2312


are constructed of a foam material similar to blocks


592


. Blocks


2314


may have a variety of firmness levels to create zones of various firmness within pillow top assembly


2310


. Assembly of modular blocks


2314


is made easy by using shell


1016


that surrounds blocks


2314


and holds them securely in their pre-determined position. Blocks


2314


are formed to include a top surface


2354


facing top quilted panel


1018


, a bottom surface


2356


facing bottom quilted panel


1020


and angled first and second ends


2360


,


2362


diverging from top surface


2354


toward bottom surface


2356


. As shown in

FIG. 50

, second end


2362


of a first block


2372


in series


2312


abuts first end


2360


of an adjacent block


2374


in series


2312


to form a contact joint


2364


therebetween. Anti-shear coating


430


is positioned to lie at joint


2364


between first and second ends


2360


,


2362


of adjacent blocks


2314


in series


2312


so that each block


2314


can move independently of adjacent blocks


2314


and provide head-to-toe zoning.




It is understood that blocks


2314


may be formed as cubes, rectangles, honeycombs, or any number of shapes that are capable of fitting together to form a series


2312


of blocks


2314


. In the illustrative trapezoidal blocks


2314


, second end


2362


of first block


2372


in series


2312


is overlapped by first end


2360


of adjacent block


2374


in series


2312


. Alternatively, it is understood that second end


2362


of first block


2372


in series


2312


may overlap first end


2360


of adjacent block


2374


in series


2312


. It is believed that this overlapping configuration provides gradual shifting of the firmness from one zone block


2314


to the next block


2314


in series


2312


. Illustrative blocks


2314


in series


2312


are constructed of the same material as blocks


94


and the firmness of blocks


2314


can be varied as previously described for blocks


94


. Blocks


2314


can also be sculpted to a desired shape or formed from a piece of foam having firmness that varies along its length or across its width without exceeding the scope of the invention as presently perceived.




The firmness of each block


2314


can be selected at the point of sale to allow the user to have a custom designed pillow top assembly


2310


without having to wait for a remote factory to construct and deliver pillow top assembly


2310


. Furthermore, if the user desires to change the firmness configuration of pillow top assembly


2310


, the user can return pillow top assembly


2310


to the point of sale for adjustment. At the point of sale, blocks


2314


can be removed and replaced to match the user's preference.




Referring now to

FIG. 51

, a reversible pillow top assembly


2210


in accordance with the present invention is provided. Pillow top assembly


2210


includes a lower set


2212


of generally trapezoidal-shaped blocks


2214


that have a different firmness feel than an upper set


2218


of generally trapezoidal-shaped blocks


2214


positioned to lie upon lower set


2212


. Thus, pillow top assembly


2210


provides the user with at least two different firmness feels depending upon whether the user is adjacent upper set


2218


or lower set


2212


. The stacked configuration of first and second sets


2212


,


2218


allows the user to further customize the vertical controlled compression of pillow top assembly


2210


as well as to alter the feel of the head-to-toe zoning.




As shown in

FIG. 51

, upper set


2212


includes transversely extending blocks


2214


. Lower set


2218


of blocks


2214


extends transversely across first set


2212


of blocks


2214


. It is understood, however, that to achieve certain desirable customization, blocks


2214


within first and second sets


2212


,


2218


may have a variety of firmness, and be positioned to lie in a variety of configurations. Pillow top assembly includes a summer top and an opposing winter top as previously discussed with reference to assembly


1010


. So, preferably firmer foam blocks are positioned to lie adjacent the summer top so that the user is prevented from sinking into foam and a plusher foam blocks adjacent the winter top.




Zoned pillow top assemblies


2310


and


2210


of

FIGS. 50 and 51

are positioned to lie upon anti-skid material


1036


as previously discussed. Anti-skid material prevents slipping of pillow top assemblies


2310


,


2210


when the user enters or exits mattress and prevents slipping of assemblies


2310


,


2210


adjacent seat sections during articulation of mattress


1022


. Pillow top assemblies


2310


,


2210


may also be customized for mattresses sleeping more than one person (not shown). Pillow top assemblies


2310


,


2210


can be customized so that one portion of mattress


1022


provides the firmness characteristics desired by one person and another portion provides the firmness characteristics of that person's sleeping partner. Therefore, multiple personal preferences can be accommodated by one pillow top assembly


2310


,


2210


.




As previously discussed, anti-shear coating


140


may be positioned to lie between adjacent blocks


1214


,


2114


,


2214


,


2314


so that blocks


1214


,


2114


,


2214


,


2314


can move independently of one another to provide head-to-toe zoning. While only blocks


2314


will be discussed hereafter, it is understood that the discussion of blocks


2314


applies to blocks


1214


,


2114


, and


2214


as well. As shown in

FIG. 52

, a slip cover


1598


may be provided to serve as an anti-shear coating and to join blocks


2314


together in a single unit in accordance with the present invention. Slip cover


1598


includes a top member


1630


and a bottom member


1632


coupled to top member


1630


to form a plurality of pockets


1634


therebetween. Pockets


1634


are spaced apart by seams


1636


. Referring now to

FIG. 53

, pockets


1634


receive blocks


2314


and snaps


1635


are provided to close an opening


1637


to pockets


1634


to retain blocks


2314


therein. Pockets


1634


beneficially inhibit migration of blocks


2314


within pillow top assembly


2310


and permit independent action of blocks


2314


. The independent action of blocks is shown by arrows


1595


in

FIG. 53

to provide head-to-toe zoning. Slip cover


1598


is made from a material having a low coefficient of friction such as “parachute material” or nylon.




If desired, an alternative sleeve


1638


, shown for example in

FIG. 54

, may be provided to act as an anti-shear coating. Sleeve


1638


enables two-dimensional zoning by permitting vertical controlled compression and head-to-toe zoning. Sleeve


1638


includes an upper panel


1640


, a lower panel


1642


, and sides


1644


coupling upper and lower panels


1640


,


1642


together. In addition, sleeve


1638


includes a plurality of spaced-apart pockets


1646


therein that are defined by seams


1648


. Each upper panel


1640


includes at least one slot


1650


therethrough that defines an opening into pocket


1646


and is sized to receive a foam block


2314


therethrough. Reduced-sized blocks


1214


,


2114


, and


2214


may also be used with sleeve


1638


in accordance with the present invention. Similar to slip cover


1598


, sleeve


1638


enables the individual compression of blocks


1651


. It is understood that pockets


1646


may be configured in a variety of shapes and sizes to receive blocks of various sizes and shapes in accordance with the present invention.




As shown in

FIG. 55

, a mattress structure


3010


is provided that permits a user upgrade from two-dimensional zoning to three-dimensional zoning. Mattress structure


3010


achieves the two-dimensional zoning by providing a plurality of zone blocks


3016


. Mattress structure


3010


is upgradable, meaning that the user may upgrade to bladder


3032


as shown in

FIG. 56

, from a less expensive foam topper


3024


. Zone blocks


3016


will cooperate with foam topper


3024


or with bladder


3032


to provide vertical controlled compression as well as head-to-to controlled compression. Bladder


3032


provides the side-to-side controlled compression to permit the three-dimensional zoning.




Referring now to

FIG. 62

a mattress structure


8010


is provided that is easy to ship to a user and that is symmetrical, which enables generally error-proof installation. Mattress structure includes fabric shell


3014


, zoned blocks


8016


, foam side rails


8018


, foam end rails


8020


, and slip cover


3022


. Blocks


8016


have a variety of sizes and firmness levels that can vary to create zones within mattress structure


8010


of various firmness to provide a “customized” mattress structure


8010


proportioned to fit the needs of a particular size and shaped person or to provide a mattress having the desired firmness characteristics. Blocks


8016


are preferably constructed of a foam material similar to blocks


592


.




As shown in

FIG. 62

, blocks


8016


are positioned to lie within slip cover


3022


in fabric shell


3014


. Blocks cooperate with slip cover


3022


to forma a core portion of mattress structure


8010


. Blocks


8016


are formed Blocks


3016


are formed in a rectangular shape (See

FIGS. 62 and 63

) and include a top surface


8050


facing top panel


3040


of shell


3014


, a bottom surface


8052


facing bottom panel


3042


of shell


3014


, opposite ends


8054


,


8056


and side edges


8058


,


8060


extending between top and bottom surfaces


8050


,


8052


. As shown in

FIG. 62

, mattress structure


8010


includes eight blocks


8016


. Two blocks


8016


form opposite ends


8062


,


8064


while six blocks


8016


form a middle segment


8066


. It is understood that greater or fewer than eight blocks


8016


may be used without exceeding the scope of the invention as presently perceived.




Referring now to

FIG. 63

, a portion of side rail


8018


is positioned to lie adjacent and is affixed to end


8054


of each block


8016


and a portion of side rail


8018


is positioned to lie adjacent and is affixed to opposing end


8056


of each block


8016


. A portion of topper


8057


is positioned to lie adjacent and is affixed to top surface


8050


of each block


8016


and a portion of topper


8057


is positioned to lie adjacent and is affixed to bottom surface


3052


. As shown in

FIG. 63

, end rail


8020


is positioned to lie between spaced apart rails


8018


. The purpose of end rails


8020


and side rails


8018


is to build a firm perimeter amount the mattress. This firm perimeter serves to keep the user from rolling out and improves comfort when sitting on the edge of the bed. As shown in

FIG. 62

, end rail


8020


is positioned to lie between spaced-apart side rails


8018


at opposite ends


8062


,


8064


.




Side and end rails


3018


,


3020


and topper


8057


are affixed to blocks


3016


by an adhesive. It is understood that a wide variety of commercially available adhesives can be used in accordance with the present invention so long as the adhesive is suitable for use with the material used to form side and end rails


8018


,


8020


, toppers


8057


, and blocks


8016


. Alternatively, side and end rails


8018


,


8020


and topper


8057


can be coupled to blocks


8016


by hook-and-loop type connectors, buttons, snaps, and the like without exceeding the scope of the invention as presently perceived. Side and end rails


8018


,


8020


and topper


3057


are constructed of materials similar to frame


574


and blocks


592


as previously discussed. As was discussed in connection with

FIG. 59

, it should be understood that fewer than all of blocks


8016


may be affixed to side rails


8018


in accordance with the present invention.




As described above, side rails


8018


, end rails


8020


, and topper


8057


of mattress structure


8010


are integrally coupled to blocks


8016


minimizing the number of components for assembly by the seller or the user. To further simplify the assembly of mattress structure


8010


, the firmness characteristics of side rails


8018


, end rails


8020


, topper


8057


, and blocks


8016


may be selected to be symmetrical about a point in the middle of mattress structure


8010


so that it is impossible to improperly place blocks


8016


in interior region


3044


. Mattress structure


8010


will provide the expected firmness characteristics regardless of the orientation of blocks


8016


in interior region


3044


provided that blocks


8016


are arranged in the proper order relative to one another.




Mattress structure


3010


includes a fabric shell


3014


, zoned blocks


3016


, a slip cover


3022


, and pillow topper


3024


. Individual blocks


3016


have a variety of sizes and firmness levels that can vary to create zones within mattress structure


3010


of various firmness to produce a “customized” mattress structure


3010


proportioned to fit the needs of a particular size and shaped person (not shown) or to provide a mattress having the desired firmness characteristics. Blocks


3016


are preferably constructed of a foam material similar to blocks


592


.




Fabric shell


3014


includes a top panel


3040


, a bottom panel


3042


, and a side wall


3043


, that cooperate to define an interior region


3044


therebetween. Top and bottom panels


3040


,


3042


and side wall


3043


are constructed of a permeable rayon material. It is understood, however that top and bottom panels


3040


,


3042


and side wall


3043


may be constructed of a wide variety of natural and synthetic fibers that are used in the construction of cloth, such as cotton, wool, polyester, and blends thereof. Non-air and non-liquid permeable top and bottom panels may also be used without exceeding the scope of the present invention.




Top panel


3040


of fabric shell


3014


includes a first perimeter edge


3046


and bottom panel


3042


includes a second perimeter edge


3048


. Top panel


3040


is constructed of a material having a low coefficient of friction to allow a pillow top to move relative to mattress structure


3010


minimizing shear to the user. In addition, top panel


3040


may also include a portion having an anti-skid material


1036


affixed thereto, preferably in a central location such as adjacent to seat section


3099


, as shown, for example in FIG.


55


. Anti-skid material


1036


inhibits sliding movement of a pillow top


3130


relative to top panel


3040


adjacent to anti-skid material


1036


while the top panel material permits movement of pillow top


3130


relative to top panel


3040


adjacent to other surfaces of top panel


3040


during mattress articulation.




Perimeter edge


3046


of top panel


3040


defines a first area dimension and perimeter edge


3048


of bottom panel


3042


defines a second area dimension that is substantially equivalent to first area dimension. The first and second area dimensions will vary depending upon whether mattress structure is a twin sized mattress, full sized mattress, queen sized mattress, or king sized mattress. Side wall


3043


extends between the first and second perimeter edges


3046


,


3048


. As shown in

FIG. 55

, side wall


3043


is coupled to bottom panel


3042


by a seam and top panel


3040


by a zipper


3041


. It is understood, however, that hook and loop type fasteners, zippers, buttons, snaps, and a wide variety of permanent or releasable coupling mechanisms may be used to couple top panel


3040


and bottom panel


3042


to side wall


3043


without exceeding the scope of the invention as presently perceived.




As shown in

FIG. 57

, blocks


3016


are positioned to lie within slip cover


3022


adjacent bottom panel


3042


of fabric shell


3014


. Blocks


3016


cooperate with slip cover


3022


to form a core portion of mattress structure


3010


. Blocks


3016


are formed in a rectangular shape (See

FIGS. 56 and 58

) and include a top surface


3050


facing top panel


3040


of shell


3014


, a bottom surface


3052


facing bottom panel


3042


of shell


3014


, opposite ends


3054


,


3056


and side edges


3058


,


3060


extending between top and bottom surfaces


3050


,


3052


. As shown in

FIGS. 57 and 58

, mattress structure


3010


includes eight blocks


3016


. Two blocks


3016


form opposite ends


3062


,


3064


while six blocks


3016


form a middle segment


3066


. It is understood that greater or fewer than eight blocks


3016


may be used without exceeding the scope of the invention as presently perceived.




Referring now to

FIG. 55

, a portion of side rail


3018


is positioned to lie adjacent and is affixed to end


3054


of each block


3016


and a portion of side rail


3018


is positioned to lie adjacent and is affixed to opposing end


3056


of each block


3016


. The purpose of end rails


3020


and side rails


3018


is to build a firm perimeter amount the mattress. This firm perimeter serves to keep the user from rolling out and improves comfort when sitting on the edge of the bed. As shown in

FIG. 56

, end rail


3020


is positioned to lie between spaced-apart side rails


3018


at opposite ends


3062


,


3064


.




Side and end rails


3018


,


3020


are affixed to blocks


3016


by an adhesive. It is understood that a wide variety of commercially available adhesives can be used in accordance with the present invention so long as the adhesive is suitable for use with the material used to form side and end rails


3018


,


3020


, and blocks


3016


. Alternatively, side and end rails


3018


,


3020


can be coupled to blocks


3016


by hook-and-loop type connectors, buttons, snaps, and the like without exceeding the scope of the invention as presently perceived. Side and end rails


3018


,


3020


are constructed of materials similar to frame


574


and blocks


592


as previously discussed. As will be discussed further in connection with

FIG. 59

, it should be understood that fewer than all of blocks


3016


may be affixed to side rails


3018


in accordance with the present invention.




As described above, side rails


3018


and end rails


3020


of mattress structure


3010


are integrally coupled to blocks


3016


minimizing the number of components for assembly by the seller or the user. To further simplify the assembly of mattress structure


3010


, the firmness characteristics of side rails


3018


, end rails


3020


, and blocks


3016


may be selected to be symmetrical about a point in the middle of mattress structure


3010


so that it is impossible to improperly place blocks


3016


in interior region


3044


. For example, if each block is of uniform firmness from side rail


3018


to side rail


3018


; if each portion of side rail


3018


is made from material of the same firmness; if each end rail


3020


is made from material of the same firmness; and if the firmness characteristics of blocks


3016


vary so that the firmness characteristics of blocks


3016


(


a


) are equivalent, the firmness characteristics of blocks


3016


(


b


) are equivalent, the firmness characteristics of blocks


3016


(


c


) are equivalent, and the firmness characteristics of blocks


3016


(


d


) are equivalent; then even when the firmness characteristics of blocks


3016


(


a


) vary from those of blocks


3016


(


b


),


3016


(


d


), or when the firmness characteristics of any of blocks


3016


(


b


),


3016


(


c


),


3016


(


d


) vary from the others, mattress structure


3010


will provide the expected firmness characteristics regardless of the orientation of blocks


3016


in interior region


3044


provided that blocks


3016


are arranged in the proper order relative to one another.




As shown in

FIGS. 55 and 56

, slip cover


3022


is provided to house blocks


3016


and rails


3018


,


3020


to permit independent action of blocks


3016


. Slip cover


3022


therefore permits both vertical controlled compression and head-to-toe zoning. Slip cover


3022


is positioned to lie adjacent bottom panel


3042


of fabric shell


3014


. Slip cover


3022


includes a top panel


3070


facing away from bottom panel


3042


of fabric shell


3014


and an opposite bottom panel


3072


adjacent bottom panel


3042


. In addition, a plurality of transversely extending seams


3078


(See

FIG. 57

) extend between opposite top and bottom panels


3070


,


3072


to form a plurality of pockets


3080


therebetween that receive blocks


3016


therein. Slip cover


3022


is made material having a low coefficient of friction as were sleeves


98


,


598


so that friction acting between blocks


3016


is minimized enabling the individual compression of blocks


3016


. Moreover, pockets


3080


inhibit migration of blocks


3016


within interior region


3044


of shell


3014


and, when blocks


3016


are shipped within pockets


3080


, blocks


3016


are retained in their proper order adding to the ease of assembly of mattress structure


3010


as described above. Finally, slip cover


3022


permits blocks


3016


to be folded together to enable efficient storage or shipping of mattress structure


3010


. Thus, mattress structure


3010


is easy to unfold as it is symmetric along a center line. This folding feature enables structure to be shipped easily. Moreover, sleeve


3022


covers blocks


3016


for an aesthetically pleasing appearance.




As shown in

FIG. 55

, bottom panel


3072


of slip cover


3022


is formed to include slots


3084


therethrough. Slots


3084


permit the insertion of blocks


3016


and rails


3018


,


3020


into pockets


3080


as shown by arrows


3081


. Slots


3084


expose blocks


3016


to bottom panel


3042


. So, friction between blocks


3016


and panel


3042


inhibit sliding movement of slip cover


3022


relative to shell


3014


. Illustratively, one slot


3084


extends into each pocket


3080


although, if desired, multiple slots could be provided to further ease assembly of mattress structure


3010


. Slot


3084


is approximately 2 inches (5.1 cm) in width so that block


3016


engages bottom panel


3042


of shell


3014


to inhibit slip cover


3022


from sliding thereon. It is understood that the size as well as the positioning of slot


3084


may vary in accordance with the present invention.




As shown in

FIG. 55

, a foam topper


3024


is positioned to lie upon slip cover


3022


within interior region


3044


of shell


3014


to form first configuration


3028


. Topper


3024


extends across slip cover


3022


and engages side wall


3043


of fabric shell


3014


to lie over zone blocks


3016


and side and end rails


3018


,


3020


. Topper


3024


is constructed of materials similar to blocks


3016


. The firmness of topper


3024


is less than the firmness of blocks


3016


. It is understood, however that the firmness of topper


3024


can be greater than that of blocks


3016


without exceeding the scope of the present invention.




Topper


3024


includes an upper side


3092


and an opposite bottom side


3094


facing slip cover


3022


. Bottom side


3094


is formed to include interruptions


3096


therein. Illustratively, bottom side


3094


includes convolutions. It is understood, that topper


3024


can be formed without interruptions


3096


or that upper side


3092


may be formed with interruptions in accordance with the present invention. Topper


3024


also includes opposite ends


3098


having a pre-determined height, and side edges


3100


engaging opposite ends


3098


at spaced-apart corners


3102


.




As shown in

FIG. 55

, straps


3104


extend from topper


3024


to minimize movement of topper


3024


within interior region


3044


of fabric shell


3014


. Straps


3


l


04


include opposite ends


3106


coupled to upper side


3092


of topper


3024


adjacent each comer


3102


and a middle portion


3108


extending between opposite ends


3106


. Middle portion


3108


serves as a loop and is sized to extend under zoned core slip cover


3022


to couple topper


3024


thereto. Straps


3104


are coupled to topper


3024


using hook and loop type fasteners. It is understood, however, that straps


3104


may be coupled to core


3024


using a wide variety of adhesives, snaps, buckles, ties, buttons, seams or the like in accordance with present invention.




As shown in

FIG. 56

, mattress structure


3010


may be upgraded to replace topper


3024


of first configuration


3028


with static air bladder


3032


and a thin topper


3034


to form an upgraded second configuration


3030


. Upgraded configuration


3030


provides three-dimensional zoning which includes the advantages of head-to-toe zoning along with the advantage of adjustable firmness. Bladder


3032


is positioned to lie upon the zoned core


3022


within interior region


3044


. Bladder


3032


extends across zoned core


3022


and engages side walls


3043


of fabric shell


3014


. Thus, bladder


3032


lies over eight composite zones. Bladder


3032


is preferably inflated and deflated using air, however any acceptable fluid such as other gasses or liquids such as water and water having additives to adjust the viscosity of the resultant liquid can be used to inflate bladder


3032


without exceeding the scope of the invention as presently perceived. Thus, throughout the specification and claims such fluid will be referred to as air, although it is understood that other fluids may be used.




Bladder


3032


is a “one-zone” bladder having one continuous air pocket extending through bladder


3032


so that the entire bladder


3032


is uniformly inflated and deflated each time air is added to or removed from bladder


3032


. Illustratively, bladder


3032


is inflated to a maximum height of about 2.5 inches (6.4 cm). It is understood, however, that the height of bladder


3032


may vary without exceeding the scope of the present invention. Bladder


3032


may also be a multiple-zoned air bladder having independently inflatable zones (not shown) without exceeding the scope of the present invention. Bladder


3032


is positioned over blocks


3016


. Therefore, should bladder


3032


deflate, blocks


3016


will provide support to the user.




Bladder


3032


is constructed from an upper sheet


3086


of an air impermeable material that is bonded to a lower sheet


3088


of an air impermeable material about a perimeter. It is understood that upper and lower sheets


3086


,


3088


may be bonded together by heat. Specifically, upper and lower sheets


3086


,


3088


are constructed of a nylon outer portion and a urethane inner portion. To couple upper and lower sheets


3086


,


3088


together the urethane inner portions are placed together and heated until the inner portions are bonded together. It is understood that bladder may be formed using a wide variety of techniques, such as a perimetral bead of adhesive to form an air-tight perimetral seal. Upper and lower sheets


3086


,


3088


cooperate to define an internal region


3090


of bladder


3032


that is air impermeable, as shown in FIG.


60


. In addition, I-beams


3091


are positioned within internal region


3090


and are affixed to both upper sheet


3086


and lower sheet


3088


in order to establish the height of fully-inflated bladder


3032


and to provide uniform height across bladder


3032


when inflated. I-beams extend generally transversely across bladder


3032


and are formed to include holes (not shown) therethrough. Holes permit air to travel through bladder


3032


upon compression of bladder


3032


due to a user moving upon bladder


3032


or to articulation of the frame upon which bladder


3032


is situated.




As shown in

FIG. 58

, thin topper


3034


is positioned to lie upon upper sheet


3086


of bladder


3032


. Thin topper


3034


has a top side


3110


, an opposite bottom side


3112


facing bladder


3032


, opposite ends


3114


having a pre-determined height, and side edges


3116


(See

FIG. 59

) engaging opposite ends


3114


at spaced-apart corners


3118


. Bottom side


3112


of topper


3034


is formed to include interruptions


3120


therein. Illustratively, bottom side


3112


includes convolutions therein. It is understood that thin topper


3034


can be formed without interruptions


3120


or that top side


3110


may be formed with interruptions in accordance with the present invention.




As shown in

FIG. 56

, straps


3122


extend from topper


3034


to minimize movement of topper


3034


and bladder


3032


within interior region


3044


of fabric shell


3014


. Straps


3122


include opposite ends


3124


coupled to top side


3110


of topper


3034


adjacent each comer


3118


and a middle portion


3126


that serves as a loop and extends between opposite ends


3124


. Middle portion


3126


is sized to extend under zoned core


3022


to couple topper


3034


thereto. Straps


30122


are coupled to thin topper


3034


using hook and loop-type fasteners (not shown). It is understood, however, that straps


3122


may be coupled to topper


3034


using a wide variety of adhesives, snaps, buckles, ties, buttons, seams, or the like without exceeding the scope of the invention as presently perceived. Thus, mattress structure


3010


may be interchanged with core


3024


and bladder


3032


/topper


3034


.




A reversible mattress structure


3210


, shown, for example in

FIG. 59

can be provided in accordance with the present invention. Mattress structure


3210


is easy to ship and assembly and provides the user with two-dimensions of zoning. Mattress structure


3210


includes a fabric shell


3214


, end foam blocks


3215


, a center block


3216


, and a cover


3224


formed to receive blocks


3215


and center block


3216


. Cover


3224


permits mattress structure to be easy to unfold as it is symmetric along a center line. This folding feature enables efficient storage or shipping of mattress structure


3210


. Cover


3224


in mattress structure


3210


also allows the blocks


3215


,


3216


to be easily positioned inside the zippered fabric shell


3214


. Cover


3224


also helps to “self-locate” blocks


3215


,


3216


within shell


3214


since corner seams on cover


3224


align with block comers.




Center block


3216


and end blocks


3215


cooperate to define firmness characteristics for mattress structure


3210


. For example, blocks


3215


,


3216


may provide the user with various degrees of vertical controlled compression and head-to-toe zoning. It is understood that the firmness level of blocks


3215


,


3216


may be selected such that structure


3210


has a “soft” or “plush” characteristics, “firm” characteristics, and various firmness characteristics therebetween, as well as various combinations thereof While one center block


3216


and two end blocks


3215


are illustrated, it is understood that greater or fewer blocks


3215


,


3216


may be used in accordance with the present invention.




Fabric shell


3214


includes a top panel


3240


, a bottom panel


3242


, and a side wall


3243


, that cooperate to define an interior region


3244


therebetween. Top and bottom panels


3240


,


3242


and side wall


3243


are constructed in a manner similar to shell


3014


as previously discussed. An anti-skid material


1036


may be affixed to top panel


3240


of fabric shell


3214


adjacent center block


3116


. Top panel


3240


above blocks


3215


, however, is constructed to permit relative movement of a pillow top thereon. Thus, portions of pillow top (not shown) away from anti-skid material


1036


, for example, opposite head and foot ends of the pillow top that are positioned to lie directly upon top panel


3240


of fabric shell


3214


, are free to slide relative to top panel


3240


during articulating movement of frame


3012


. A center section of pillow top (not shown) remains generally stationary relative to top panel


3240


upon anti-skid material


1036


.




Top panel


3240


of fabric shell


3214


includes a first perimeter edge


3246


and bottom panel


3242


includes a second perimeter edge


3248


. Perimeter edge


3246


of top panel


3240


defines a first area dimension and perimeter edge


3248


of bottom panel


3242


defines a second area dimension that is substantially equivalent to first area dimension. The first and second area dimension will vary depending upon whether mattress structure is a twin sized mattress, a full sized mattress, a queen sized mattress, or a king sized mattress. Side wall


3243


extends between the first and second perimeter edges


3246


,


3248


. Illustratively, side wall


3243


is coupled to top and bottom panels


3240


,


3242


by seams. It is understood, however, that hook and loop type fasteners, a zipper, buttons, snaps, and a wide variety of coupling mechanisms may be used in accordance with the present invention to couple top panel


3240


and bottom panel


3242


.




As shown in

FIG. 59

, blocks


3215


,


3216


are sized for extension into cover


3224


. Blocks


3215


,


3216


cooperate with cover


3224


to form a core


3225


of mattress structure


3210


, as shown in FIG.


60


. Blocks


3215


,


3216


are symmetrical in shape and have generally the same pre-determined width w and length L. It is understood that when mattress structure


3210


is a full sized mattress, king sized mattress, or queen sized mattress, greater than one set of end and center blocks


3215


,


3216


may be used in a side-by-side relationship in accordance with the present invention.




Blocks


3215


include a top surface


3250


facing top panel


3240


of shell


3214


, a bottom surface


3252


facing bottom panel


3242


, opposite ends


3254


,


3256


and side edges


3258


,


3260


extending between top and bottom surfaces


3250


,


3252


. Blocks


3215


are constructed of a resilient foam material such as urethane foam. Blocks


3215


have a generally equal size and firmness level. It is understood, however, that blocks


3215


may have a variety of sizes and firmness levels and create zones of various firmness in accordance with the present invention. The firmness and support characteristics of the foam rubber can be varied in accordance with the desires of the user of mattress structure as previously discussed with reference to blocks


3016


. It is also understood that various materials may be used to construct blocks


3215


as was previously discussed with reference to blocks


3016


.




As shown in

FIG. 61

, center block


3216


includes outer zoned blocks


3340


, and center zoned block


3341


. Blocks


3340


and


3341


are symmetric, meaning that blocks


3340


,


3341


have a similar size, shape, firmness, and are aligned along a common axis. Blocks


3340


and


3341


are formed as previously discussed with reference to blocks


3016


. Blocks


3340


, however, are firmer than block


3341


to provide additional support for the user's thighs and lumbar. Center zoned block


3341


is less firm to compress adjacent the user's seat. As shown in

FIG. 61

, a polyethylene film


3342


having a low coefficient of friction extends about each block


3340


to permit blocks


3340


to move independently relative to one another. It is understood that a wide variety of materials having a low coefficient of friction may be adhered to blocks


3340


or may extend around blocks


3340


to permit relative movement therebetween in accordance with the present invention.




As shown in

FIG. 61

, a foam side rail


3318


is positioned to lie adjacent each opposite end


3054


,


3056


of foam blocks


3340


. Side rails


3318


are affixed to blocks


3340


by an adhesive. It is understood that a wide variety of commercially available adhesives can be used in accordance with the present invention so long as the adhesive selected is suitable for use with the material from which blocks


3340


are made. Moreover, side rails


3318


can be coupled to blocks


3340


by hook-and-loop type connectors, buttons, snaps, and the like. Side rails


3318


are constructed similar to frame


574


as previously discussed and are constructed of a firmer foam than blocks


3215


,


3216


. Side rails


3318


provide support to the user when entering or leaving mattress structure


3210


. Side rails


3318


are only on center block


3216


because center block


3216


is where users climb on and off of mattress structure


3210


. It is understood, however, that side rails


3318


may be positioned adjacent one or more of blocks


3215


.




As shown in

FIGS. 59 and 61

, topper portions


3322


engage top and bottom surfaces


3250


,


3252


of blocks


3215


and top and bottom surfaces


3050


,


3052


of blocks


3340


. Topper portions


3322


provides vertical “controlled compression to minimize interface pressure with user and to maximize comfort. Blocks


3215


,


3216


underneath topper surfaces


3322


compress and varying degrees to provide support to various parts of the user. Topper portions


3322


also minimize the ability of the user to perceive the interface between blocks


3340


and rails


3318


. Top and bottom surfaces


3250


,


3252


and


3050


,


3052


of blocks


3215


and


3340


are heat bonded to opposing toppers


3322


. It is understood that blocks


3215


,


3340


may be coupled to toppers


3322


by hook-and-loop type connectors, buttons, snaps and the like or by a wide variety of commercially available adhesives so long as the adhesive selected is compatible with the materials being adhered.




Cover


3224


is provided to house blocks


3215


and


3216


and toppers


3332


. Cover


3224


is positioned to lie adjacent bottom panel


3242


of fabric shell


3014


. Cover


3224


includes a top panel


3270


facing away from bottom panel


3242


and an opposite bottom panel


3272


. A side wall


3271


extends between top and bottom panels


3270


,


3272


. Top and bottom panels


3270


,


3272


are coupled to side wall


3271


by a seam and form a cavity (not shown) between top and bottom panels


3270


,


3272


. In addition, three pockets


3280


are formed therebetween that receive blocks


3215


,


3216


along line


3281


therein as shown in FIG.


59


. Pockets


3280


are spaced apart by seams


3282


that permit individual compression of blocks


3215


,


3216


relative to one another. Moreover, pockets


3280


inhibit migration of blocks


3215


,


3216


within interior region


3244


of shell


3214


. Cover


3224


is made from a material having a low coefficient of friction such as a polyester non-woven material or nylon to serve as an anti-shear coating.




Further, cover


3224


permits blocks


3215


,


3216


to be folded together, as shown in

FIG. 60

, to enable efficient storage or shipping of mattress structure


3210


. Thus, mattress structure


3210


is easy to unfold as it is symmetric along a center line. Moreover, cover


3224


covers blocks


3215


,


3216


for an aesthetically pleasing appearance. Since cover


3224


is symmetric, mattress structure


3210


is essential “fool proof” in that users receiving structure


3210


in their home cannot install cover


3224


into shell


3214


improperly.




Referring now to

FIG. 64

, a mattress retention bracket


7010


is provided in accordance with the present invention for use with a mattress structure


3010


to prevent mattress structure


3010


from sliding off of foot-end


7055


of foundation


120


. Foundation


120


is formed to include a foam covering (not shown) to give foundation


120


the appearance of a conventional set of box springs. While mattress structure


3010


is illustrated and described, it is understood that retention bracket


7010


may be used with any number of mattresses in accordance with the present invention. Bracket


7010


includes a cantilevered support bar


7014


and a retainer


7016


.




Retention bracket


7010


includes a support frame


7012


having base legs


7036


,


7038


and a cantilevered retainer-support leg


7018


elevated above base legs


7036


,


7038


. Retainer


7016


is coupled to retainer-support leg


7018


above base legs


7036


,


7038


by screws


7020


. It is understood, however, that any number of fasteners such as pins, rivets, staples, etc. may be used in accordance with the present invention. Support frame


7012


is formed for secure stationary positioning upon foundation


120


. Retainer-support leg


7018


interconnects opposite legs


7036


,


7038


.




Retainer-support leg


7018


as shown in

FIG. 64

has a curved shaft


7040


portion with a concave side


7052


arranged to face respective base legs


7036


,


7038


and an opposite convex side


7054


. The retainer-support leg


7018


includes opposite end portions


7056


,


7058


and the curved shaft


7040


portion extends between the opposite end portions


7056


,


7058


. Curved shaft portion


7040


also includes apertures (not shown) therethrough. The end portions


7056


,


7058


are positioned in a spaced-apart relation to one another. It is understood that retainer-support leg


7018


may be formed in a variety of shapes so long as it interconnects base legs


7036


,


7038


.




Each base leg


7036


,


7038


is configured to wrap about foundation


120


and includes a coupling end


7058


in generally a first plane and an upstanding end


7066


extending vertically above the first plane. Preferably, each base leg


7036


,


7038


extends vertically upward from the first plane toward retainer-support leg


7016


. Coupling ends


7058


each include an aperture


7022


sized to receive a screw


7024


therethrough. It is understood that any number of fasteners such as pins, rivets, staples, etc. may be used in accordance with the present invention.




Retainer


7016


includes a base portion


7070


and a tab


7072


that extends vertically away from base portion


7070


. Base portion


7070


is configured to lie generally adjacent retainer-support leg


7018


and includes apertures (not shown) that are sized to receive screws


7020


therethrough.




To couple mattress retention bracket


7010


to foundation


120


and mattress structure


3010


, base legs


7036


,


7038


are wrapped about foundation


120


and ends


7058


are coupled to foundation by screws


7024


. Thus, support frame


7012


is held securely onto foundation


120


. Tab


7072


of retainer


7016


is inserted into a pre-formed slit


7074


formed within block


3016


. Base portion


7070


of retainer


7016


is aligned with retainer-support leg


7018


and screws


720


are extended through base portion


7070


, fabric shell


3014


, and apertures in curved shaft portion


7040


to couple retainer


7016


to support frame


7012


. Thus, stationary tab


7072


prevents blocks


3016


from sliding off of foot-end


7055


of foundation


120


.




In an alternative embodiment of the present invention, a mattress retention apparatus


9100


is shown in FIG.


65


. Retention apparatus


9100


prevents an associated mattress structure


3014


from sliding laterally upon a foundation


9120


having a solid deck


9122


. Retention apparatus


9100


includes an L-shaped bracket


9102


that is coupled to deck


9122


by screws


9130


. It is understood that any number of fasteners such as pins, rivets, staples, etc. may be used in accordance with the present invention. Bracket


9102


includes an upper portion


9104


that comes along side of mattress structure


3104


to prevent mattress structure


3104


from sliding off of foundation


9120


while foundation


9120


is being articulated.




Still another embodiment of the present invention is illustrated in FIG.


65


. Retainer


7016


, as previously discussed with reference to

FIG. 64

, is coupled solid support


9122


of foundation


9120


by screws


9020


. It is understood, however, that any number of fasteners such as pins, rivets, staples, etc. may be used in accordance with the present invention. Retainer


7016


may be used to couple any number of a wide variety of mattress structures directly to foundation


9120


, so long as foundation


9120


has a solid deck


9122


.




Although the invention has been described in detail with reference to a preferred embodiment, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.



Claims
  • 1. A mattress apparatus for providing a user with three-dimensional firmness zoning, the mattress apparatus comprising:a mattress shell having a top cover, a bottom cover, a head end, a foot end, and side panels extending from the bottom cover toward the top cover between the head and foot ends, a plurality of longitudinally spaced, transversely extending resilient blocks having a top side, a bottom side configured to face the bottom portion of the shell, and opposite ends extending between the top and bottom sides, the resilient blocks being independently movable relative to one another, an inflatable bladder positioned to lie upon the top side of at least one of the blocks, and a topper positioned to lie upon the inflatable bladder, the topper including opposite ends configured for attachment to the head and foot ends of the shell and sides configured for attachment to the side panels.
  • 2. The mattress apparatus of claim 1, further comprising a sleeve defining spaced-apart pockets holding the blocks therein, the sleeve positions the blocks adjacent one another and permits individual compression of the blocks so that each resilient block moves in a vertical direction independently of adjacent blocks.
  • 3. The mattress apparatus of claim 2, wherein the sleeve is formed to include slots that define openings into the pockets and the slots are sized to receive the blocks therethrough.
  • 4. The mattress apparatus of claim 3, further comprising a plurality of sleeves positioned to lie adjacent one another.
  • 5. The mattress apparatus of claim 4, wherein the sleeves are coupled together.
  • 6. The mattress apparatus of claim 2, wherein the sleeve includes a top member and an opposite bottom member coupled to the top member and the top and bottom members cooperate to define openings into pockets that are sized to receive the blocks therethrough.
  • 7. The mattress apparatus of claim 2, wherein the sleeve is adapted to extend between the head end and foot end of the mattress shell.
  • 8. The mattress apparatus of claim 1 wherein the topper is made of foam material.
  • 9. The mattress apparatus of claim 1, wherein the topper includes straps configured to extend about the inflatable bladder and at least one of the resilient blocks to hold the topper upon the inflatable bladder.
  • 10. The mattress apparatus of claim 1 wherein the resilient blocks, the inflatable bladder and the topper are positioned to lie between the top cover and the bottom cover of the mattress shell.
  • 11. The mattress apparatus of claim 1 wherein the topper is configured to compress when a force is applied to the topper by a user positioned to lie on the mattress apparatus.
  • 12. A mattress apparatus for providing a user with three-dimensional firmness zoning, the mattress apparatus comprising:a plurality of longitudinally spaced, transversely extending resilient blocks having a top side, a bottom side, and opposite ends extending between the top and bottom sides, the resilient blocks being independently movable relative to one another, an inflatable bladder positioned to lie upon the top side of at least one of the blocks, and a topper positioned to lie upon the inflatable bladder, the topper being made of foam material configured to compress when a force is applied to the topper by a user positioned to lie on the mattress apparatus.
  • 13. The mattress apparatus of claim 12 further comprising a mattress shell having a top cover, a bottom cover, a head end, a foot end, and side panels extending from the bottom cover toward the top cover between the head and foot ends, and the topper, the adjustable bladder, and the resilient blocks are positioned to lie between the top cover and the bottom cover.
  • 14. The mattress apparatus of claim 13 further comprising a pillow top overlying the resilient blocks, the inflatable bladder, the topper, and the top cover of the mattress shell.
  • 15. The mattress apparatus of claim 12 further comprising a sleeve defining spaced-apart pockets holding the blocks therein, the sleeve positions the blocks adjacent one another and permits individual compression of the blocks so that each resilient block moves in a vertical direction independently of adjacent blocks.
  • 16. A mattress including a first layer containing first and second regions having first and second different compressibilities, respectively, the first and second regions being oriented in the mattress with respect to each other so that the first region supports a first region of the body of a person reclining on the mattress and the second region supports a second region of the body of the person, the mattress further including a second layer oriented over the first layer and including a bladder for containing a fluid and a port through which the fluid can be introduced into the bladder to alter the firmness of the second layer.
  • 17. The mattress of claim 16 wherein the fluid includes a compressed gas or mixture of gases.
  • 18. The mattress of claim 17 wherein the fluid includes compressed air.
  • 19. The mattress of claim 16 wherein the first layer is divided into at least three regions, a head/torso region having a first compressibility, a seat region having a second and different compressibility, and a leg region having a compressibility different from at least one of the first and second compressibilities.
  • 20. The mattress of claim 19 wherein the first layer is divided into at least four regions, a head/torso region having a first compressibility, a lumbar region having a second and different compressibility, a seat region having a compressibility different from at least one of the first and second compressibilities, and a leg region having a compressibility different from at least one of the first and second compressibilities.
  • 21. The mattress of claim 20 wherein the first layer is divided into at least five regions, a head/torso region having a first compressibility, a lumbar region having a second and different compressibility, a seat region having a compressibility different from at least one of the first and second compressibilities, a thigh region having a compressibility different from at least one of the first and second compressibilities, and a lower leg region having a compressibility different from at least one of the first and second compressibilities.
  • 22. The mattress of claim 19 wherein at least one of the regions includes vertically adjacent materials having two different compressibilities presenting a first compressibility to a person reclining on the at least one of the regions during a first interval of compression and a second compressibility to the person on the at least one of the regions during a second interval of compression.
  • 23. The mattress of claim 16 further including a region of compressible material surrounding the first layer, the surrounding region having a lower compressibility and greater firmness than at least one of the first and second compressibilities.
  • 24. The mattress of claim 23 wherein the surrounding region has a lower compressibility and greater firmness than both of the first and second compressibilities.
  • 25. The mattress of claim 16 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 26. The mattress of claim 25 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 27. The mattress of claim 26 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 28. The apparatus of claim 20 wherein at least one of the regions includes vertically adjacent materials having two different compressibilities presenting a first compressibility to a person reclining on the at least one of the regions during a first interval of compression and a second compressibility to the person on the at least one of the regions during a second interval of compression.
  • 29. The apparatus of claim 28 further including anit-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 30. The apparatus of claim 29 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 31. The apparatus of claim 30 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 32. The apparatus of claim 21 wherein at least one of the regions includes vertically adjacent materials having two different compressibilities presenting a first compressibility to a person reclining on the at least one of the regions during a first interval of compression and a second compressibility to the person on the at least one of the regions during a second interval of compression.
  • 33. The apparatus of claim 32 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 34. The apparatus of claim 33 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 35. The apparatus of claim 34 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 36. The apparatus of claim 17 further including a region of compressible material surrounding the first layer, the surrounding region having a lower compressible and greater firmness than at least one of the first and second compressibilites.
  • 37. The apparatus of claim 36 wherein the surrounding region has a lower compressibility and greater firmness than both of the first and second compressibilities.
  • 38. The apparatus of claim 36 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 39. The apparatus of claim 38 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 40. The apparatus of claim 39 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 41. The apparatus of claim 18 further including a region of compressible material surrounding the first layer, the surrounding region having a lower compressibility and greater firmness than at least one of the first and second compressibilities.
  • 42. The apparatus of claim 41 wherein the surrounding region has a lower compressibility and greater firmness than both of the first and second compressibilities.
  • 43. The apparatus of claim 41 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 44. The apparatus of claim 43 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 45. The apparatus of claim 44 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 46. The apparatus of claim 19 further including a region of commpressible material surrounding the first layer, the surrounding region having a lower compressibility and greater firmness than at least one of the first and second compressibilities.
  • 47. The apparatus of claim 46 wherein the surrounding region has a lower compressibility and greater firmness than both of the first and second compressibilities.
  • 48. The apparatus of claim 46 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 49. The apparatus of claim 48 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 50. The apparatus of claim 49 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 51. The apparatus of claim 20 further including a region of compressible material surrounding the first layer, the surrounding region having a lower compressiblity and greater firmness than at least one of the first and second compressibilities.
  • 52. The apparatus of claim 51 wherein the surrounding region has a lower compressibility and greater firmness than both of the first and second compressibilities.
  • 53. The apparatus of claim 51 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 54. The apparatus of claim 53 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 55. The apparatus of claim 54 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 56. The apparatus of claim 21 further including a region of compressible material surrounding the first layer, the surrounding region having a lower compressibility and greater firmness than at least one of the first and second compressibilities.
  • 57. The apparatus of claim 56 wherein the surrounding region has a lower compressibility and greater firmness than both of the first and second compressibilities.
  • 58. The apparatus of claim 56 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 59. The apparatus of claim 58 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 60. The apparatus of claim 59 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 61. The apparatus of claim 22 further including a region of compressible material surrounding the first layer, the surrounding region having a lower compressibility and greater firmness than at least one of the first and second compressilities.
  • 62. The apparatus of claim 61 wherein the surrounding region has a lower compressibility and greater firmness than both of the first and second compressibilities.
  • 63. The apparatus of claim 61 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 64. The apparatus of claim 63 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 65. The apparatus of claim 64 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 66. The apparatus of claim 19 further including anti-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 67. The apparatus of claim 66 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 68. The apparatus of claim 67 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 69. The apparatus of claim 20 further including anit-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 70. The apparatus of claim 69 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 71. The apparatus of claim 70 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 72. The apparatus of claim 21 further including anit-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 73. The apparatus of claim 72 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 74. The apparatus of claim 73 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
  • 75. The apparatus of claim 22 further including anit-shear material between the first and second regions permitting relative movement up and down of the first and second regions with respect to each other as a person reclines on the mattress.
  • 76. The apparatus of claim 75 wherein the anti-shear material includes a sleeve for receiving one of the first and second regions.
  • 77. The apparatus of claim 76 wherein the anti-shear material includes sleeves for receiving both of the first and second regions.
Parent Case Info

This is a divisional U.S. patent application Ser. No. 09/064,297, filed Apr. 22, 1998, now U.S. Pat. No. 6,115,861 claiming benefit of priority of U.S. provisional applications No. 60/061,492, filed Oct. 9, 1997; No. 60/061,494, filed Oct. 9, 1997; and No. 60/066,627, filed Nov. 26, 1997; and which is a continuation-in-part of U.S. patent application Ser. No. 09/033,116, filed Mar. 2, 1998, which is a divisional U.S. patent application Ser. No. 08/565,409, filed Nov. 30, 1995, which issued as U.S. Pat. No. 5,815,865 on Oct. 6, 1998.

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Provisional Applications (3)
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60/066627 Nov 1997 US
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Continuation in Parts (1)
Number Date Country
Parent 09/033116 Mar 1998 US
Child 09/064297 US