Patent Application
20190365117
This disclosure pertains to mattress pads. More specifically, this disclosure pertains to reversible multi-layer mattress pads.
Under conventional approaches, mattress pads may be reversible. This may, for example, increase the longevity of the mattress pad. Additionally, mattress pads may use gel to assist the mattress pad in conforming to a user's body. However, the effectiveness of gel-based mattress pads may be reduced when temperatures cool (e.g., during winter, operation of air condition units, and/or the like). Additionally, reversing (or, “flipping”) a gel-based mattress pad is typically not possible (or at least not recommended), as it may be harmful to the mattress pad, and/or may remove the benefit of the mattress pad for the user.
Various embodiments of the present disclosure include reversible multi-layer mattress pads and methods of manufacturing reversible multi-layer mattress pads. In some embodiments, a reversible multi-layer mattress pad comprises a first layer comprising a first temperature-sensitive memory foam having a first density. The first layer being may be suitable for receiving a user on the first layer when the reversible multi-layer mattress is in a first position, and the first layer may be suitable for placement on a support structure when the reversible multi-layer mattress is in a second position. The first layer may provide a first level of firmness when an ambient temperature is within a first ambient temperature range, and the first layer may provide a second level of firmness when the ambient temperature is within a second ambient temperature range. The first level of firmness may be different from the second level of firmness, and the first ambient temperature range may be different from the second ambient temperature range. A second layer comprises a second temperature-sensitive memory foam having a second density different from the first density. The second layer may be suitable for placement on the support structure when the reversible multi-layer mattress is in the first position, and the second layer being may be suitable for receiving the user on the second layer when the reversible multi-layer mattress is in the second position. The second layer may provide the first level of firmness when the ambient temperature is within a third ambient temperature range, and the second layer may provide the second level of firmness when the ambient temperature is within a fourth ambient temperature range. At least one temperature value of the third ambient temperature range may be lower than the lowest temperature value of the first ambient temperature range, and the third ambient temperature range may be different from the fourth ambient temperature range. A third layer comprises a form-supporting foam. The third layer may be positioned (or, “disposed” or “placed”) in between the first layer and the third layer.
In some embodiments, the third layer is positioned below the first layer and above the second layer when the reversible multi-layer mattress is in the first position, and the third layer is positioned on top of the first layer and below the second layer when the reversible multi-layer mattress is in the second position.
In some embodiments, the first level of firmness is less firm than the second level of firmness, and the second ambient temperature range has at least one temperature value lower than the lowest temperature value of the first ambient temperature range.
In some embodiments, the first level of firmness is less firm than the second level of firmness, and the fourth ambient temperature range has at least one temperature value higher than the highest temperature value of the third ambient temperature range.
In some embodiments, the first ambient temperature range is the same as the fourth ambient temperature range, and the second ambient temperature range is the same as the third ambient temperature range.
In some embodiments, the first ambient temperature range is different from the fourth ambient temperature range, and the second ambient temperature range is different from the third ambient temperature range.
In some embodiments, the first temperature-sensitive memory foam and the second temperature-sensitive memory foam comprise a same type of temperature-sensitive memory foam.
In some embodiments, the first temperature-sensitive memory foam and the second temperature-sensitive memory foam comprise a different type of temperature-sensitive memory foam.
In some embodiments, the first temperature-sensitive memory foam comprises a gel-based temperature-sensitive memory foam.
In some embodiments, the second temperature-sensitive memory foam comprises an air-injected temperature-sensitive memory foam.
In some embodiments, each of the first layer, the second layer, and the third layer have any of a same height, width and depth.
In some embodiments, the first layer, the second layer, and the third layer are encased in an outer covering, and the first layer, the second layer, and the third layer are held in place at least partially by the outer covering.
In some embodiments, the reversible multi-layer mattress comprises a mattress pad. In some embodiments, the support structure comprise a mattress. In some embodiments, the support structure comprise a bedframe.
These and other features of the systems, methods, and non-transitory computer readable media disclosed herein, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for purposes of illustration and description only and are not intended as a definition of the limits of the invention.
Typical memory foam mattress may provide suitable levels of firmness in warm temperatures (e.g., in the summer), but may become too firm in colder temperatures (e.g., in the winter). Various embodiments described herein are directed to a reversible multi-layer mattress pad capable of providing suitable levels of firmness in both warm and cool temperatures. For example, a reversible multi-layer mattress pad may utilize a three-layer “stack” structure. The first layer may comprise a first temperature-sensitive memory foam (e.g., a gel-based foam) having a density suitable for warmer temperatures, and the second layer may comprise foam (e.g., an air-injected foam or “air foam”) having another density suitable for cooler temperatures. The second layer may comprise a second temperature-sensitive foam (e.g., temperature-sensitive memory foam) and/or a non-temperature-sensitive foam. A third layer disposed between the first and second layers may provide structural support for the reversible multi-layer mattress pad, and may comprise a structural foam (e.g., non-memory foam). Accordingly, during warm temperatures a user may position the mattress such the first layer is the “top” layer of the stack, and the second layer is the “bottom” layer of the stack. As the temperature cools, the first layer may become too firm (or, “harden”), and the user may flip the reversible multi-layer mattress so that the second layer, which is suitable for cooler temperatures, becomes the top layer, and the first layer becomes the bottom layer. This multi-layered structure may help ensure consistent, comfortable, and/or safe levels of firmness for the user, regardless of temperature.
In various embodiments, “top” and “bottom” layers of the reversible multi-layer mattress pad 102 are each configured to both receive a user (e.g., a person lying down on the reversible multi-layer mattress pad 102) and also be placed on another surface (e.g., a mattress or bedframe). For example, a user may sleep on the “top” layer during the summer, and flip the reversible multi-layer mattress pad 102 to sleep on the “bottom” layer during the winter. It will be appreciated that “top” and “bottom” are relative terms. For example, the “top” layer may become the “bottom” layer, and vice versa, when the reversible multi-layer mattress pad 102 is reversed (or, “flipped”).
In various embodiments, the reversible multi-layer mattress pad 102 is configured to provide a suitable level of firmness within “warmer” temperature ranges (e.g., above 75 degrees F.), and also provide a suitable level of firmness within “cooler” temperatures ranges (e.g., below 75 degrees). In some embodiments, the reversible multi-layer mattress pad 102 comprises three different layers. For example, the first layer may be suitable for receiving a user in warmer temperatures, a second layer may provide structural support for the reversible multi-layer mattress pad 102, and a third layer may provide a suitable level of firmness in cooler temperatures. As used herein, temperature may refer to ambient temperature in a proximity of the reversible multi-layer mattress pad 102 (e.g., the room temperature), a user's body temperature, and/or other temperature that may affect the reversible multi-layer mattress pad 102. For example, temperature may be determined based on an ambient temperature and a user's body temperature. Examples of the three-layer structure are described below. It will be appreciated that other embodiments may include fewer or greater number of such layers.
In some embodiments, the first layer 102a may function to provide a suitable level of firmness for a user during one or more warmer temperature ranges, and the second layer 102b may function to provide the same or different suitable level of firmness during one or more cooler temperature ranges. A suitable level of firmness may be based on one or more depths that the particular layer (e.g., first layer 102a, second layer 102b) is depressed when one or more weights are placed on one or more representative points of the particular layer. For example, each of the points may represent a particular resting feature of a user (e.g., head, body torso), and the weights may be estimated weights of those features of the user. In one example, a suitable level of firmness may depress the particular layer between 1-2″, and a non-suitable level of firmness may depress greater than 2″ and be considered too “soft,” or depress less than 1″ and be considered too firm (or, “hard”).
In the example of
In some embodiments, as used herein, warmer temperature ranges may include one or more of the following ranges:
Accordingly, the first layer 102a may be too firm in other temperature ranges, such as cooler temperature ranges. In some embodiments, as used herein, cooler temperature ranges may include one or more of the following ranges:
Although, it will be appreciated that while the layers of the reversible multi-layer mattress pad 102 may be may too firm or too soft (e.g., based on temperature) to provide a suitable level of firmness for a user, the reversible multi-layer mattress pad 102 may always provide proper firmness for placing on a bedframe, mattress, and/or the like. Accordingly, as used herein, the suitable level of firmness applies to a current “top” portion of the reversible multi-layer mattress pad 102.
In some embodiments, the first layer 102a has multiple densities that allow the first layer 102a to provide a suitable level of firmness during warmer temperature ranges. For example, the first layer 102a may have different densities particular to different points of the first layer 102a, such as the points (or, regions) estimated to be in contact with various body parts of the user.
In the example of
In some embodiments, the second layer 102b comprises a non-temperature sensitive foam (e.g., an air foam). Thus, for example, the second layer 102b may maintain a consistent, or substantially consistent, level of firmness (e.g., a suitable level of firmness) during warmer and cooler temperature ranges.
In some embodiments, the second layer 102c has multiple densities that allow the second layer 102c to provide a suitable level of firmness during cooler temperature ranges. For example, the second layer 102a may have different densities particular to different points (or, regions) of the first layer 102a, such as the points estimated to be in contact with various body parts of the user. Although the first layer 102a of the mattress or mattress pad may have multiple densities and the second layer 102b may have multiple densities, some embodiments may be designed so that the densities of the first layer 102a will be more dense than the respective densities of the second layer 102b. For example, if the first layer 102a has a first density for the upper body and a second density for the lower body, the second layer 102b may have a first density for the upper body that is less dense than the first density for the upper body of the first layer 102a, and may have a second density for the lower body that is less dense than the second density for the lower body of the second layer 102b.
In the example of
Although not shown, a mattress or mattress pad may include only two layers (a first layer and a second layer, without a structural third layer). A mattress or mattress pad may include more than three layers. For example, there could be two or more structural layers between the first and second layers.
In some embodiments, each of the ridges 302, 304 may have the same dimensions (e.g., height, depth, length) and/or density, while in other embodiments at least some of the ridges 302, 304 may have different dimensions and/or densities. For example, the dimensions and/or densities of the ridges 302, 304 may be based on their location on the respective layers 102a, 102. The locations may correspond to locations estimated to come into contact with various features of the user (e.g., head, torso). This may allow the reversible multi-layer mattress 102, and the corresponding layers 102a, 102b, to depress evenly, or substantially evenly, across the surface of the corresponding layers 102a, 102b. The different densities may also account for different temperatures at different parts of the user's body, allowing the corresponding layer to receive a consistent user body temperature across the surface of that layer.
In step 400, a first layer (e.g., first layer 102a) is formed. The first layer may comprise a first temperature-sensitive memory foam (e.g., a gel foam) having a first density. For example, the first density may be between 10-15 ILD. The first layer is suitable for receiving a user (e.g., a user lying down) on the first layer when the reversible multi-layer mattress is in a first position (e.g., the outer surface of the first layer is upward facing). The first layer is also suitable for disposing (or, “placing”) on a support structure (e.g., a bedframe, a mattress, and/or the like) when the reversible multi-layer mattress is in a second position (e.g., the outer surface of the first layer is downward facing). The first layer provides a first level of firmness (e.g., a suitable level of firmness) when an ambient temperature is within a first ambient temperature range (e.g., a warmer temperature range). Accordingly, the first layer provides a second level of firmness (e.g., a non-suitable level of firmness) when the ambient temperature is within a second ambient temperature range (e.g., a cooler temperature range). The first level of firmness is different from the second level of firmness, and the first ambient temperature range is different from the second ambient temperature range.
In some embodiments, the first level of firmness is less firm than the second level of firmness. For example, the first level of firmness may cause the first layer to depress between 1-2″ in response to a user lying down on the first layer, while the second level of firmness may cause the first layer to depress greater than 2″ in response to the user lying on the first layer. The second ambient temperature range may have at least one temperature value lower than the lowest temperature value of the first ambient temperature range. In other words, the second ambient temperature range may be considered “cooler” than the first ambient temperature range.
In step 402, a second layer (e.g., second layer 102b) is formed. The second layer may comprise temperature-sensitive memory foam having a second density different from the first density. For example, the second density may be suitable for cooler temperatures (e.g., 10-13 ILD). The second layer is suitable for placement on the support structure when the reversible multi-layer mattress is in the first position. The second layer being is also suitable for receiving the user on the second layer when the reversible multi-layer mattress is in the second position. The second layer provides a level of firmness (e.g., the first level of firmness) when the ambient temperature is within a third ambient temperature range (e.g., a cooler temperature range). Accordingly, the second layer may provide another level of firmness (e.g., the second level of firmness) when the ambient temperature is within a fourth ambient temperature range (e.g., a warmer temperature range). In some embodiments, at least one temperature value of the third ambient temperature range is lower than the lowest temperature value of the first ambient temperature range, and the third ambient temperature range is different from the fourth ambient temperature range.
In some embodiments, the first level of firmness is less firm than the second level of firmness. For example, the first level of firmness may cause the third layer to depress between 1-2″ in response to a user lying down on the third layer, while the second level of firmness may cause the third layer to depress greater than 2″ in response to the user lying on the third layer. The fourth ambient temperature range may have at least one temperature value higher than the highest temperature value of the third ambient temperature range. In other words, the fourth ambient temperature range may be considered “warmer” than the third ambient temperature range.
In various embodiments, the first ambient temperature range is the same as the fourth ambient temperature range, and the second ambient temperature range is the same as the third ambient temperature range. In other embodiments, the first ambient temperature range is different from the fourth ambient temperature range, and the second ambient temperature range is different from the third ambient temperature range.
In step 404, a third layer (e.g., third layer 102c) is formed. The third layer may comprise form-supporting foam. In some embodiments, the third layer is positioned below the first layer and above the second layer when the reversible multi-layer mattress is in the first position, and the third layer is positioned on top of the first layer and below the second layer when the reversible multi-layer mattress is in the second position.
In step 406, the third layer is disposed on top of the second layer. In step 408, the first layer is disposed on top of the third layer. In some embodiment, the first layer and the third layer may be adhered together using adherence material (e.g., glue). In some embodiments, the three layers may be encased in an outer covering, and the outer covering may hold the layers together instead of, or in addition to, adherence material.
Throughout this specification, plural instances may implement components, operations, or structures described as a single instance. Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as separate components in example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein.
The present invention(s) are described above with reference to example embodiments. It will be apparent to those skilled in the art that various modifications may be made and other embodiments may be used without departing from the broader scope of the present invention(s). Therefore, these and other variations upon the example embodiments are intended to be covered by the present invention(s).
