This disclosure relates to mattress toppers, and in particular to air-filled mattress toppers.
This section provides background information related to the present disclosure which is not necessarily prior art.
A mattress topper is a relatively thick pad or cushion (between 2 and 5 inches) that is placed directly above a mattress in order to add an extra layer of comfort and protection. There are many different types of toppers, and they typically comprising some type of foam, such as memory form, or gel, or combination thereof. However, conventional toppers have suffered from a number of problems, including a lack of edge support, and “bottoming out” because while they are relatively thick, they are still significantly thinner than a mattress. In general, there is a lack of adjustable firmness with most toppers and with two people sleeping on the same mattress with a topper, they may be of different heights, weights and body styles that would indicate that they would desire different support structures to accommodate their specific needs.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
Generally, preferred embodiments of a mattress topper according to the principles of this invention have a length and width substantially corresponding to the length and width of a mattress so that the inflatable mattress topper can overlie the upper surface of the mattress, substantially within the perimeter of the mattress. The topper preferably comprises separate left and right inflatable chambers having common upper and lower walls, and each of the wall, a lower wall, and head, foot, left and right side walls. There are a plurality of generally elongate beams in each chamber, between the upper wall and the lower wall, to maintain a substantially uniform thickness across the length and width of the topper.
In some embodiments the left and right chambers can communicate with each other directly. In other embodiments the left and right chambers can communicate through an intermediary chamber. In still other embodiments the chambers may be isolated from each other, although one of the left and right chambers may communicate with a different chamber. In some embodiments the left and right chambers are adjacent to each other, and in some embodiments the left and right chambers are spaced apart.
In the preferred embodiment, the beams are parallel and extend substantially across the width of its respective chamber, from a point adjacent the left side of the chamber to a point adjacent the right side of the chamber. Alternatively the beams could extend substantially across the length of their respective chambers, from a point adjacent the head side to a point adjacent the foot side of the chamber. The beams are configured and spaced such that the each chamber has substantially uniform thickness of between one inch and six inches, and more preferably from two inches to four inches, from left edge to right edge, and from the top edge to the bottom edge. The seaming construction to connect the upper and lower layers may be a traditional coil construction, linear beam construction, oval beam construction or any other type of connecting methodology. In a preferred embodiment, the topper is made of a material having at least two layers: a fabric layer and a heat-sealable layer. The heat sealable layer in preferably fluid impervious, or the material includes a fluid impervious layer.
As described above, the topper preferably has substantially uniform thickness, and the width of the topper is between one and three inches narrower than the width of the bed on which the topper is designed to be used, and the length of the topper is between one and three inches shorter than the length of the bed on which the topper is designed to be used. The thickness of the topper is preferably less than about four inches or less.
The beams are preferably the same length, and extend between about 75% and about 95% of the distance across their respective chamber (whether extending from side to side or from head to foot. The distance between each beam and its adjacent beam is preferably greater than or equal to the height of the beams, and more preferably the distance between each beam and its adjacent beam is substantially equal to the height of the beam, to provide generally flat planar upper and lower surfaces.
The upper surfaces of the two chambers are preferably formed of the same ply of material, and similarly the lower surfaces of the two chambers are preferably formed of the same ply of material, so that the upper and lower surface of the topper are each formed of one continuous sheet. However, each chamber preferably has its own head, foot, left and right side walls.
In some embodiments the first and second chambers are spaced apart, with a gap between the left and right chambers. In some embodiments, an elongate foam member can be disposed in this gap between the left and right chambers. This prevents the formation of a low spot or crease in the middle of the topper. The topper can further comprise an elongate foam member adjacent the left side of the left chamber and the right side of the right chamber, each foam member extending substantially the length of its respective chamber. This helps prevent the topper from collapsing adjacent its edges.
In other embodiments an elongate inflatable element is disposed in the gap between the left and right chambers. This elongate inflatable element can be independent of the left and right chambers, but alternatively the elongate inflatable element can be in fluid communication with one of the left and right chambers to simplify manufacture and use.
A perimeter air chamber can extend around the left and right chambers. This perimeter air chamber, if present, is preferably in fluid communication with the elongate inflatable element disposed in the gap between the left and right chambers. Alternatively, or in addition, the perimeter air chamber can be in fluid communication with one of the left and right chambers. The width of the perimeter chamber is preferably substantially the same as the spacing between the beams.
In embodiments where there are separate left and right chambers, the right wall of the left chamber and the left wall of the right chamber are in opposed, facing relationship, and there are mating portions of hook and loop fastening material on the opposed, facing walls to secure the two chambers. Alternatively, or in addition, a band can surround the collective perimeters of the first and second chambers, and be secured for example with mating portions of hook and loop type fastening materials.
Valves can be provided to inflate the separate chambers. These valves can be configured to releasably connect to pumps to facilitate inflation, and or to manually or with a pump deflate the chambers. Some embodiments can include at least one pump in fluid communication with the left and right chambers, and more preferably there is a separate pump in communication with each of the left and right chambers to inflate and maintain pressure. A pump may also inserted into the topper and sealed to the outer wall for each separate chamber to easily inflate or deflate the chambers. At least one pressure sensor can be provided for sensing the pressure in the chambers, and a control can be provided that actuates the at least one pump in response to the pressure sensor to maintain a predetermined minimum pressure in each chamber. At least one pressure relief valve can be provided, and a control can also be provided to actuate the at least one pressure relieve valve in response to the pressure sensor to maintain the pressure below a predetermined maximum pressure in each chamber.
In some embodiments, the inflatable mattress topper can include an integral or removable pillow, for example comprising at least one inflatable wedge shaped envelope on one of the upper or lower walls of at least one of the chambers, and preferably on the upper wall of each chamber, adjacent the head wall.
In some embodiments the topper is inflated with a separate pump that can be permanently connected to the topper, or can be detachably connected to the topper. In other embodiments a pump is provided inside the topper, or is incorporated into one of the walls of the topper. The pump can have a switch control on the pump or it can be controllable by a wired or wireless remote control.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
Generally, a first preferred embodiment of a mattress topper according to the principles of this invention is indicated as 20 in
A Twin or Twin Extra Long version would consist of two chambers. The first chamber would be substantially the length and width of the mattress and a second chamber approximately 3″ to 4″ in height and width and would be a perimeter chamber that would be separately inflated for edge support. The topper can be adapted for a king, queen, or double size mattresses.
The preferred embodiments of the mattress topper are shown and described for a conventional queen mattress (which are 80 inches by 60 inches), and the topper has a length of 79 inches and a width of 59 inches. Topper sizes for king and double beds would be correspondingly smaller than their respective beds.
The topper would typically be placed over the mattress and underneath a fitted sheet. The fitted sheet would retain the topper in position and prevent it from slipping or shifting. Ideally, a fabric laminated to a dielectric heat seal-able substrate would also act to provide a non-slip surface on the upper and lower sides of the topper. The topper is preferably made from a heat sealable layer such as polyvinyl chloride (PVC) or thermoplastic polyurethane (TPU) which is laminated to a fabric layer such as a nylon (70 denier to 210 denier), polyester, or poly-cotton. The heat sealable material creates a reliable and manufacturing friendly material to create an air tight enclosure. Laminating improves the feel of the material and can help reduce stretching that can result reduction in internal pressure.
The topper 20 preferably comprises separate left and right inflatable chambers 22 and 24. Each of the chambers 22 and 24 has an upper wall 26 forming part of the upper surface of the topper, a lower wall 28 forming part of the lower surface of the topper, and head, foot, left and right side walls 30, 32, 34, and 36, that form part of edges of the topper at the head, foot and left and right sides of the bed. There are a plurality of generally elongate beams 38 between the upper wall 26 and the lower wall 28. In the preferred embodiment shown in
The beams 38 are preferably formed by a generally elongate rectangular tube 40 having two long walls 42, 44 and two short walls 46, 48 extending between the upper and lower walls 26, 28 of the chamber. Each of the long walls 42, 44 extend generally parallel to the top and bottom walls 30 and 32, and each of the short walls 46, 48 extend generally parallel to the left and right walls 34 and 36. As described above the beams 38 could be oriented differently, for example from the head to the foot of the topper, or on diagonal. Further, the beams 38 do not have to be parallel, and could be arranged in some other configuration.
The topper 20 preferably has substantially uniform thickness, and the width of the topper is between one and three inches narrower than the width of the mattress on which the topper is designed to be used, and the length of the topper is between one and three inches shorter than the length of the mattress on which the topper is designed to be used. The thickness of the topper is preferably less than about four inches.
The beams 38 are preferably the same length, and extend between about 75% and about 95% of the distance across their respective chambers (whether extending laterally across the width chamber, or longitudinally along the length of the chamber). The distance between each beam 38 and its adjacent beam is preferably greater than or equal to the height of the beams, and more preferably the distance between each beam and its adjacent beam is substantially equal to the height of the beam. This configuration helps provide smooth upper and lower surfaces for the topper.
Valves 39 can be provided in each of the chambers 22 and 24. The valves can be constructed according to the teachings of U.S. Pat. No. 6,709,246, entitled Inflation/Deflation Device Having Spring Biased Valve, the entire disclosure of which is incorporated herein by reference. The valves 39 allow the chambers to be quickly and easily connected and disconnected from a pump to facilitate filling or refilling the chambers. The valves 39 also have a manually operable button that allows a user to release pressure to adjust the topper to a desired level of firmness.
In some embodiments such as those shown in
In topper 20 shown in
In other embodiments such as show in
In some embodiments where there are separate left and right chambers, such as topper 20″ shown in
As noted above, the chambers 22 and 24 can be provided with a valve 39, so that they can be temporarily connected to a portable pump to fill or refill the chambers. Alternatively, at least one pump can be provided, in fluid communication with the left and right chambers 22 and 24, and more preferably there is a separate pump in communication with each of the left and right chambers. As shown in
The pumps can be a piston action/diaphragm pump, small enough to be mounted on the side surface of the topper, and quiet enough that it would not disturb/wake the sleeper if it turned on during the night. The pump can have a wired or wireless control for simple operation by the user.
In some embodiments, as shown in
In addition the topper can include a secondary comfort layer, for example polyurethane foam, memory foam, micro coils (metal or plastic springs) encapsulated with an air permeable fabric; or latex foam or other foams.
A sixth embodiment of a topper according to the principles of this invention is shown in
There are valves 39 communicating with the chambers 22 and 24, to permit a portable pump to be removably connected to the chambers to file or refile them. The valves 39 also allow the user to release pressure form the chambers to adjust the pressure.
As shown in
The embodiment shown in
The embodiment of
The embodiment of
The embodiment shown in
The embodiment shown in
Thus various embodiments of the invention provide an air topper that provides additional comfort, but are preferably 4 inches thick or less, so that they are thinner than a conventional mattress. Various embodiments provide side by side air (dual) chambers that can be separately inflated to desired firmness levels, providing features of larger, more complicated and expensive air mattresses, as an add-on to a conventional mattress. Embodiments of the toppers provide foam members, inflatable elements, or means for securing the independent chambers together to avoid an uncomfortable “crevasse” in the middle of the bed, between the chambers. Embodiments of the topper provide a thick edge (due to the thickness of the head, foot, left and right side walls 30, 32, 34, and 36), and further edge support is provided in some embodiments with foam edge members or inflatable edge members.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
Number | Date | Country | |
---|---|---|---|
62622238 | Jan 2018 | US |