This application relates to mattresses. In particular, this application relates to modular mattress systems, methods, and devices.
Mattresses are commonly available in a range of sizes (such as twin, full, queen, king, California king, etc.), constructions or materials (such as innerspring; foam, such as latex foam, memory foam, high density foam; bladder, such as air or water), etc., and firmness levels (such as soft, medium, firm, extra firm, etc.).
As described herein, modular mattress systems can include modular components that can be selected, added, removed, and/or replaced individually of the other components of the modular mattress. This can provide one or more of the following advantages: improving customization and personalization of the modular mattress, permitting the function and feel of the modular mattress to change over time to adapt to changing user preferences or other conditions, facilitating replacement of old, worn, or damaged components of the modular mattress, permitting the modular mattress to be easily cleanable, decreasing waste to landfills, and increasing shipping efficiency, among others.
In a first aspect, a mattress may include, for example, a fabric cover configured to surround at least two foam layers, the fabric cover including an opening to allow access to an interior region of the fabric cover, a first foam layer positioned within the interior region of the fabric cover, and an encasement layer positioned below the first foam layer, the encasement layer comprising a recess configured to receive one or more modular support sections, and a plurality of modular support components received within the recess of the encasement.
In some embodiments, the mattress includes one or more of the following features, in any combination: wherein the recess comprises a keyed profile configured to engage with at least some of the one or more module support sections; wherein the keyed profiled comprises a honeycomb shape; wherein the one or more modular support sections comprise a head section, a torso section, and a foot section; wherein at least one of the head section, the torso section, and the foot section comprises at least two foam layers and is reversible; wherein at least one of the head section, the torso section, and the foot section comprises perforations such that subsections can be removed and replaced; wherein the one or more modular support comprise a plurality of individual modular support components; wherein at least one of the modular support components comprises a foam having a density different than a foam of another of the modular support components; wherein at least one of the modular support components comprises a hexagonal shape; wherein at least one of the modular support components comprises at least two foam layers and is reversible; wherein the plurality of individual modular support components are arranged within the recess in a honeycomb pattern; wherein the plurality of individual modular support components comprise at least 10, 20, 30, 40, 50, 60, 70, 80, or 100 modular support component; wherein the recess extends entirely through the encasement; wherein the recess extends partially through the encasement; and/or wherein the encasement comprises foam.
In another aspect, a mattress includes: a fabric cover configured to surround at least two foam layers, the fabric cover comprising an opening to allow access to an interior region of the fabric cover; a first foam layer positioned within the interior region of the fabric cover, the first foam layer comprising a first type of foam; and a second foam layer positioned within the interior region of the fabric cover and below the first foam layer, the second foam layer comprising two sublayers joined together, the two sublayers comprising a first sublayer comprising a second type of foam and a second sublayer comprising a third type of foam, wherein a support level of the mattress can be adjusted by flipping the second foam layer.
In some embodiments, the mattress includes one or more of the following features in any combination: wherein the opening is closeable with a zipper; wherein the second foam layer comprises a right part and a separate left part; and/or wherein the first foam layer covers both the right part and the left part.
In another aspect, a method for customizing a mattress includes, for example, selecting a plurality of modular support components, wherein at least some of the modular support components comprise different foam densities, arranging the plurality of modular support components within a recess in an encasement, and enclosing the encasement and the plurality of modular support components within a fabric cover.
In some embodiments, the method also includes one or more of the following features in any combination: positioning a foam layer within the fabric cover over the encasement and the plurality of modular support components; adjusting the mattress by removing at least one of the plurality of modular support components, and replacing it with another modular support components having a different foam density; wherein arranging the plurality of modular support components within a recess in an encasement comprises consulting with a chiropractor, doctor, or other healthcare professional; wherein the plurality of modular support components comprise a head section, a torso section, and a foot section; wherein at least one of the head section, the torso section, and the foot section comprises at least two foam layers and is reversible; wherein at least one of the modular support components comprises a hexagonal shape; wherein at least one of the modular support components comprises at least two foam layers and is reversible, and the method further comprises reversing the least one of the modular support component.
In another aspect, a modular and adjustable mattress can include an encasement comprising a recess formed therein, and a modular insert received in the recess, the modular insert comprising a first layer comprising a first level of support and a second layer comprising a second level of support, wherein the modular insert can be flipped to adjust a level of support for the modular insert depending on which of the first layer or the second layer is facing up.
In some embodiments, the first layer comprises a first foam having a first density and the second layer comprises a second foam having a second density different than the first layer. In some embodiments, the encasement comprises foam. In some embodiments, a bottom layer of the encasement is about four inches thick. In some embodiments, the modular insert is about eight inches thick and the recess is about eight inches deep. In some embodiments, the modular insert comprises a head section, a body section, and a foot section, each comprising a different texture. In some embodiments, the recess is configured to receive a left modular insert and a right modular insert, and each of the left modular insert and the right modular insert can be flipped independently. In some embodiments, the mattress includes a reversible topper positioned over the encasement and modular insert, wherein the reversible topper comprises a first layer comprising a first level of support and a second layer comprising a second level of support, wherein the reversible topper can be flipped to further adjust a level of support for the mattress depending on which of the first layer or the second layer of the reversible topper is facing up. In some embodiments, the recess of the encasement comprises straight-sided walls and the modular insert comprises straight-sided walls. In some embodiments, the recess comprises a recess with a geometric profile and the modular insert comprises a corresponding geometric profile.
In another aspect, a method for customizing a mattress can include placing one or more modular inserts into a recess of an encasement of a mattress, and placing a reversible topper comprising a first layer and a second layer over the one or more modular inserts in an orientation such that either the first layer or the second layer is oriented upwardly.
The method can include one or more of the following features in any combination: reversing the orientation of the reversible topper such that the other of the first layer or the second layer is oriented upwardly to adjust a level of support of the mattress; reversing the orientation of at least one of the one or more modular inserts to adjust a level of support of the mattress; wherein the first layer and second layer of the reversible topper comprise different materials; wherein the first layer and second layer of the reversible topper comprise different densities; wherein at least some of the one or more modular inserts comprise two layers, wherein each layer comprises a different material; wherein at least some of the one or more modular inserts comprise two layers, wherein each layer comprises a different density; wherein at least one of the modular inserts comprises a foot section, a torso section, and a head section, each having a different level of support.
These and other features and advantages will be described in greater detail below.
The features and advantages of the modular mattress system and methods described herein will become more fully apparent from the following description taken in conjunction with the accompanying drawings. These drawings depict only several embodiments in accordance with the disclosure and are not to be considered limiting of its scope. In the drawings, similar reference numbers or symbols typically identify similar components, unless context dictates otherwise. The drawings may not be drawn to scale.
Described herein are modular mattress systems, methods, and devices that permit a high degree of customization, while providing one or more additional benefits as described below.
Each human body has different pressure points and comfort levels. It can be hard for a mattress of generally uniform construction to accommodate the different pressure points and spinal alignment of a single individual. It is even more difficult for a mattress to accommodate two individuals that share a common mattress, as the comfort and spinal alignment needs of each person likely differ. People generally throw away their mattresses and fill up landfills when their mattresses do not accommodate their comfort needs.
Often, mattresses are bulky, and usually have innerspring coils made of hard gauge steel for support. Shipping costs for mattresses are usually high, and mattresses can take up three times as much space in warehouses than they need. Mattresses fill up landfills when disposed of and the steel springs will never decompose.
The modular mattresses described herein may alleviate or eliminate one or more of these problems. For example, in some embodiments, a modular mattress as described herein may comprise lightweight separate sections that can selected and interchanged as needed. Thus a user can select sections that work for their individual needs as desired. Further, the lightweight sections can provide that the components are easy to ship because they can shipped compressed in small boxes. Further, the interchangeable components are replaceable as needed, thereby reducing the amount of parts being thrown in landfills. In some embodiments, bedbugs, dead skin, food crumbs, pet stains and other debris can be vacuumed and washed from the modular mattresses for a fresh sleep. People generally sleep better when their mattress is aligned with their body, and some embodiments of the mattresses described herein facilitate a custom fit for each unique individual.
The following discussion presents detailed descriptions of the several embodiments of modular mattress systems shown in the figures. These embodiments are not intended to be limiting, and modifications, variations, combinations, etc., are possible and within the scope of this disclosure.
The modular mattress 100 can include, for example, a removable ticking or cover 102. Example covers are shown in
The comfort components (e.g., the comfort layer 104) can be made from any of a variety of materials that contribute to the comfort and/or feel of the mattress. For example, in some embodiments, the comfort layer 104 comprises a memory foam (viscoelastic foam) layer, a latex layer, a pillow top layer, etc. In some embodiments, the comfort layer 104 may be between about 1 and 4 inches thick, although other thicknesses are possible. In some embodiments, the comfort layer 104 is about 2 inches thick.
The support components (e.g., the support layer 106) can be made of any of a variety of materials that contribute to the support and/or feel of the mattress. For example, the support layer 106 can comprise a layer of supportive foam. The support layer 106 can be provided in a variety of different levels of firmness. For example, the support layer 106 can be provided in extra soft, soft, medium, firm, extra firm. Although five firmness levels are identified here, it will be appreciated that the support layers 106 can be provided with greater or fewer firmness levels in some embodiments. In some embodiments, the support layer 106 is between about 4 and 12 inches thick, although other thicknesses are also possible. In some embodiments, the support layer 106 is about 8 inches thick. Additional examples of support layers are shown in
The modular mattress 100 is referred to as herein as “modular” because a user can easily select and individually replace the individual components of the modular mattress 100 to customize the mattress 100 as desired. For example, a user can select a desired comfort layer 104 from among a plurality of options (e.g., memory foam (viscoelastic foam), layer, pillow top, etc.) and select desired support layer 106 from among a plurality of options (e.g., extra soft, soft, medium, firm, extra firm, etc.) to customize the modular mattress 100. The selected components can be placed inside the cover 102 to assemble the mattress. Further, at any time, the user may make changes to the modular mattress 100 by replacing one or more of the components. For example, the user can replace a viscoelastic comfort layer with a latex comfort layer. Similarly, the user can replace a medium support layer with an extra firm layer. Additionally, the user can, at any time, replace the cover 102 without replacing the internal components. Accordingly, the modular mattress system 100 can provide the user with a highly customizable mattress that can be adjusted and varied over time as desired.
Further, the modular mattress system 100 can reduce waste to landfills as the whole modular mattress 100 need not be discarded. For example, if a support layer 106 becomes worn and needs to be replaced, the support layer 106 can be removed (leaving the cover 102 and the comfort layer 104), discarded, and replaced with a new support layer 106. Thus, rather than discarding the entire mattress as necessitated by conventional mattresses, the modular mattress system 100 described herein reduces waste to landfills by providing that individual components can be removed and replaced as necessary.
The embodiments of
In some embodiments, the cover 102 is made from a fabric material. For example, the fabric material can be a stretch knit fabric. In some embodiments, the fabric is an aloe-vera stretch knit fabric. Other types of fabric can also be used. The fabric can be selected for indoor and/or outdoor use. In some embodiments, the cover 102 can be configured such that the mattress can be used outdoors, for example, as part of a piece of patio furniture. The fabric can be flame resistant or flame retardant. The fabric can provide a fire barrier. In some embodiments, the fabric comprises a non-skid fabric that helps to maintain the mattress in place.
In the illustrated embodiment of
In some embodiments, various dual-layer support layers 106 can be provided. For example, dual-layer support layers 106 can be provided that are extra soft, soft, medium, firm, and extra firm, and each can have two associated degrees of firmness (provided by the first layer 120 and the second layer 122). For example, the extra soft dual-layer support layers 106 can include a first layer 120 that is first degree of extra soft and a second layer 122 that is a second degree of extra soft. Thus, by providing five dual-support layers 106, ten different firmness levels can be achieved. Those of skill in the art will understand that the described five-dual support layers 106 are provided only by way of example and other numbers of dual-support layers 106 can be provided as desired.
In some embodiments, dual-layer support layers 106 can have first and second layers 120, 122 of disparate degrees of firmness. For example, a dual-layer support 106 can include a first layer 120 that is extra soft and a second layer 122 that is extra firm.
In some embodiments, two dual-layer supports 106 can be provided in a side-by-side arrangement as shown in
Additional support layers 106 will now be described with reference to
In some embodiments, the support layers can comprise an encasement that includes a recess formed therein. The recess can be configured to receive a plurality of modular support sections or components. The modular support components can be provided in a plurality of different support levels (e.g., extra soft, soft, medium, firm, extra firm, etc.) and can be arranged within the recess of the encasement in a wide variety of different configurations to achieve a high degree of modularity and customization. Further, the components (e.g., the encasement, the modular support sections, and the modular support components) can all be selected and replaced individually providing the benefits previously described.
In the illustrated embodiment, the encasement 126 comprises a frame 128. The frame 128 may be made from foam. The foam may be a high density foam, although other types of foam can be used. A recess 130 can be formed into the encasement 126. As will be discussed below, the recess 130 is configured to receive one or more of the modular support sections or components. The recess 130 can be surrounded by the frame 128. The recess 130 can be formed into an upper surface of the encasement 126 and extend towards a lower surface of the encasement 126. In some embodiments, the recess 130 is bounded on the bottom by a bottom layer 132. The bottom layer 132 may comprise foam that is similar to or different than the foam of the frame 128. In some embodiments, the recess 130 extends entirely through the encasement 126.
As noted above, in some embodiments, the support layer 106 is between about 4 and 12 inches thick, although other thicknesses are also possible. In some embodiments, the support layer 106 is about 8 inches thick. As such, the encasement 126 can be about 4 and 12 inches thick, although other thicknesses are also possible. In some embodiments, the encasement 126 is about 8 inches thick. The recess may extend about 50%, 75%, 80%, 85%, 90%, 95% or 100% of the way through the encasement 126 from the upper surface towards the lower surface. In some embodiments, the recess 130 extends to within about 1 inch, about 2 inches, about 3 inches, or about 4 inches of the bottom surface of the encasement 130. In some embodiments, the bottom layer 132 is about 1 inch, about 2 inches, about 3 inches, or about 4 inches thick. In some embodiments, the recess 130 is about 7 inches deep.
The recess 130 comprises an outline or profile 132. The profile 132 can comprise a wide variety of shapes. In the illustrated embodiment, the profile 132 provides a keyed profile. As used herein, a keyed profile comprises features that engage with corresponding features of an adjoining component. The keyed profile can be configured to engage with one or more of the modular support sections or components to help secure the modular support sections or components in place within the recess. In the illustrated embodiment, the keyed profile comprises a hexagonal or honeycomb outline configured to engage with the hexagonal or honeycomb shaped modular support sections or components shown in
Each modular support section 134 can be provided with the same options described above with reference to the support layer 106. That is, modular support sections 134 can comprise foam with different degrees of firmness (e.g., extra soft, soft, medium, firm, extra firm, etc.). Thus, by selecting different modular support sections 134, the user can customize different regions of the support layer 106. For example, a user could select a soft head section, a firm torso section, and an extra soft foot section. Further, a user can advantageously replace one or more of these sections individually from the other components of the mattress as desired.
As shown in the side view of
In some embodiments, various modular support sections 134 can be provided. For example, dual-layer modular support sections 134 can be provided that are extra soft, soft, medium, firm, and extra firm, and each can have two associated degrees of firmness (provided by the first layer 136 and the second layer 138). For example, the extra soft dual-layer modular support sections 134 can include a first layer 136 that is first degree of extra soft and a second layer 138 that is a second degree of extra soft. Thus, by providing five dual-support modular support sections 134, ten different firmness levels can be achieved. Those of skill in the art will understand that the described five-dual modular support sections 134 are provided only by way of example and other numbers of dual-layer modular support sections 134 can be provided as desired.
The thickness of modular support sections 134 can be configured to match the depth of the recess 130.
As shown in
As shown, the recess 130 of the encasement 126 can be filled with a plurality of modular support components 150 to provide a fully customizable support profile for the support layer 106. That is, each modular support component 150 can be selected so as to provide a different level support at the corresponding location into which the modular support component 150 is inserted. In the illustrated embodiment, the encasement 150 is configured to hold 60 different modular support components 150. This allows for 60 different locations of adjustable support. In some embodiments, other numbers of support components 150 can be used. For example, the encasement can be configured to hold 10, 20, 30, 40, 50, 60, 70, 80, 100, or more modular support components 150.
Each modular support component 150 can be provided with the same options described above with reference to the support layer 106. That is, modular support components 150 can comprise foam with different degrees of firmness (e.g., extra soft, soft, medium, firm, extra firm, etc.). Thus, by selecting different modular support components 150, the user can customize different regions of the support layer 106. For example, a user could select a soft head section, a firm torso section, and an extra soft foot section. Further, a user can advantageously replace one or more of these sections individually from the other components of the mattress as desired.
As shown in the side view of
In some embodiments, various modular support components 150 can be provided. For example, dual-layer modular support components 150 can be provided that are extra soft, soft, medium, firm, and extra firm, and each can have two associated degrees of firmness (provided by the first layer 152 and the second layer 154). For example, the extra soft dual-layer modular support components 150 can include a first layer 152 that is first degree of extra soft and a second layer 154 that is a second degree of extra soft. Thus, by providing five dual-support modular support components 150, ten different firmness levels can be achieved. Those of skill in the art will understand that the described five-dual modular support components 150 are provided only by way of example and other numbers of dual-layer modular support components 150 can be provided as desired.
The thickness of modular support components 150 can be configured to match the depth of the recess 130.
As shown in
In some embodiments, a modular mattress may utilize both modular support sections 134 and modular support components 150. For example, a user may select a head modular support section 134a and a foot modular support section 134c, and then fill the remaining section with a plurality of modular support components 150. Further, a user may remove a section of a modular support section 134 (e.g., using perforations 144) and replace the removed sections with one or more modular support components.
The use of modular support sections 134 and/or modular support components 150 can create a highly customizable and modular mattress 100.
In some embodiments, a doctor or chiropractor may provide information or otherwise help customize a modular mattress for a particular user.
The modular mattresses described herein can be adapted for use as pet beds. For example, a smaller encasement can be configured to receive a single modular support section and/or a plurality of modular support components for us with a dog or cat.
An example of a modular and adjustable mattress 200 is shown in
As shown in
As illustrated in
Each of the foam layers 212, 214 can be configured to provide a different stiffness of comfort level (for example, extra soft, soft, medium, firm, extra firm, etc.). The modular insert 204 can exhibit a different comfort level depending on which foam layer 212 is facing up. Thus, as shown, the mattress 200 may have a first comfort level on the left side of the mattress 200 and a second comfort level on the right side of the mattress 200. Further, users of the mattress 200 can flip the modular inserts 204 to change the comfort level. This allows the mattress 200 to be adjustable.
In some embodiments, the modular inserts 204 may also comprise additional foam layers, such as intermediary layers between the first and second layers 212, 214.
The textures of the head, body, and foot sections 206, 208, 210 of the modular inserts 204 can be formed in to each layer 212, 214 of the modular insert 204 such that the texture exists on both sides. This further allows the modular insert 204 to flappable or reversible as discussed above.
In some embodiments, the mattress 200 may be between 8 and 16 inches thick. For example, the mattress 200 can be 12 inches thick. In some embodiments, the modular inserts 204 are between 4 and 12 inches thick. For example, the modular inserts can be 8 inches thick. Other thicknesses are also possible. Thickness can be measured between tops of nodules opposite each other and extending from layers 212 and 214, respectively.
As described above, the mattress 200 includes modular inserts 204 that can be selected, added, removed, and/or replaced individually of the other components of the modular mattress 200. Further, the modular inserts 204 can be flipped to adjust their comfort level. This can provide one or more of the following advantages, such as, improving customization and personalization of the mattress 200, permitting the function and feel of the modular mattress 200 to change over time to adapt to changing user preferences or other conditions, facilitating replacement of old, worn, or damaged components of the mattress 200, permitting the modular mattress to be easily cleanable, decreasing waste to landfills, and increasing shipping efficiency, among others.
In the illustrated embodiment, the reversible topper 302 comprises a first layer 304 and a second layer 306. The first and second layers 304, 306, can each be made from a different material or comprise a different density such that the reversible topper can provide different feels depending on the orientation. For example, when the first layer 304 is oriented upwardly, the reversible topper can provide a different feel than when the second layer 306 is oriented upwardly. At any time, the user can reverse the orientation of the reversible topper to further customize the feel of the mattress 300.
In one example, the first layer 304 comprises latex and the second layer 306 comprises memory foam, such as a temperature and pressure neutral memory foam. Other materials can also be used for the layers 304, 306, such as any of the materials previously described.
As shown in
In the illustrated embodiment, of
The illustrated embodiment of
The mattress 300 can provide a high level of customization. For example, a user can select different modular components 312 and select an orientation of the reversible topper 302. Further, the modular components 312 can extend across an entire length of the recess 314 of the encasement, can comprise zoned components (such as head, torso, and feet) components, or can comprise smaller section components similar to the smaller components 150 described above. Additionally, the any or all of the modular components can be reversible providing even further customization. This can allow a user to dial in a very precise comfort level.
In the illustrated embodiment, the left side encasement 408 is populated with a plurality of small modular components 412. Each modular component can provide a different level of support at that area of the mattress 400 providing a high degree of customization. In some embodiment, each modular component 412 can also be revisable.
As illustrated, the right side encasement 408 includes a larger head and foot modular component 412 that covers an entire head and foot zone, respectively. These can also be customizable and reversible. The torso section is populated with a plurality of small modular components 412 providing a granular level of adjustment in that area.
The foregoing description details certain embodiments of the systems, devices, and methods disclosed herein. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the systems, devices, and methods can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the technology with which that terminology is associated.
It will be appreciated by those skilled in the art that various modifications and changes may be made without departing from the scope of the described technology. Such modifications and changes are intended to fall within the scope of the embodiments. It will also be appreciated by those of skill in the art that parts included in one embodiment are interchangeable with other embodiments; one or more parts from a depicted embodiment can be included with other depicted embodiments in any combination. For example, any of the various components described herein and/or depicted in the figures may be combined, interchanged or excluded from other embodiments.
The above description discloses several methods and materials of the present invention. This invention is susceptible to modifications in the methods and materials, as well as alterations in the fabrication methods and equipment. Such modifications will become apparent to those skilled in the art from a consideration of this disclosure or practice of the invention disclosed herein. Consequently, it is not intended that this invention be limited to the specific embodiments disclosed herein, but that it cover all modifications and alternatives coming within the true scope and spirit of the invention as embodied in the attached claims. Applicant reserves the right to submit claims directed to combinations and sub-combinations of the disclosed inventions that are believed to be novel and non-obvious.
This application is a continuation of International Patent Application No. PCT/US2019/053664, filed Sep. 27, 2019, which claims priority to U.S. Provisional Application No. 62/738,715, filed Sep. 28, 2018, each of which are incorporated herein by reference. Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
Number | Date | Country | |
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62738715 | Sep 2018 | US |
Number | Date | Country | |
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Parent | PCT/US2019/053664 | Sep 2019 | US |
Child | 17212703 | US |