VENTILATING SLEEP SYSTEM

DISPOSITIF DE VENTILATION DE COUCHAGE

English Abstract

Embodiments of a ventilated sleep system are disclosed, and typically may be
configured
to provide ventilation to a mattress, for example through an upper surface of
a foundation allowing
airflow therethrough. Typically, sleep system embodiments may include
mattresses with foam
layers with pinholes and a bottom cover allowing airflow therethrough, and
some embodiments
also include foam pillars. Such sleep system embodiments typically may have
such a ventilation
mattress atop such a ventilation foundation, with airflow therebetween.

Claims

CLAIMS
What is claimed is:
1. A sleep system comprising:
a mattress, which comprises:
a mattress cover; and
one or more foam layers within the mattress cover;
wherein the mattress cover comprises a bottom surface;
wherein the bottom surface of the mattress cover comprises a mattress air
permeable
element;
wherein the mattress is spring-free;
wherein the one or more foam layers each comprise a plurality of substantially
vertical
air passageways which pass through the entire thickness of the corresponding
foam
layer;
wherein the one or more foam layers comprise:
a base layer of foam comprising a sculpted upper surface with a plurality of
foam
pillars projecting upward;
a transition layer of foam with uniform thickness located atop and in contact
with
the upper surface of the base foam layer;
a middle sculpted layer of foam having a sculpted lower surface with a
plurality of
foam pillars projecting downward, wherein the middle sculpted layer of foam is
located
atop and in contact with the transition layer of foam; and
a top layer of foam with uniform thickness, which is located above the middle
sculpted layer; and
a mattress foundation, which comprises:
43

a support structure;
an air flow unit; and
a foundation cover comprising an upper surface;
wherein the upper surface of the foundation cover comprises a foundation air
permeable element; and
wherein the mattress is located atop the foundation, and wherein the mattress
and
foundation are in fluid communication with each other.
2. The sleep system of claim I wherein the middle sculpted layer of foam
further
comprises a sculpted upper surface with a plurality of foam pillars projecting
upward.
44

3. A sleep system comprising a mattress, which comprises:
a cover;
wherein the cover comprises a bottom surface, and wherein the bottom surface
comprises an air permeable element.
4. The sleep system of claim 3 wherein the entire bottom surface of the
mattress cover is
formed of high airflow mesh fabric.
5. The sleep system of claim 3 wherein the mattress cover further comprises an
upper
surface, and wherein the upper surface comprises a second air permeable
element.
6. The sleep system of claim 3 wherein the mattress further comprises one or
more foam
layers within the mattress cover.
7. The sleep system of claim 6 wherein the mattress is spring-free.
8. The sleep system of claim 6 wherein the one or more foam layers each
comprise a
plurality of substantially vertical air passageways.
9. The sleep system of claim 8 wherein the one or more foam layers comprise:
a base layer of foam comprising a sculpted upper surface with a plurality of
foam
pillars projecting upward;
a transition layer of foam with uniform thickness located atop and in contact
with the
upper surface of the base foam layer;

a middle sculpted layer of foam having a sculpted lower surface with a
plurality of
foam pillars projecting downward, wherein the middle sculpted layer of foam is
located
atop and in contact with the transition layer of foam; and
a top layer of foam with uniform thickness, which is located above the middle
sculpted
layer.
10. The sleep system of claim 9 wherein the middle sculpted layer of foam
further
comprises a sculpted upper surface with a plurality of foam pillars projecting
upward.
11. The sleep system of claim 10 wherein the sculpted upper surface of the
middle sculpted
layer of foam comprises pillars of a different size than the sculpted lower
surface of the
middle sculpted layer of foam.
12. The sleep system of claim 9 wherein the one or more foam layers further
comprises a
penultimate foam layer with uniform thickness located atop and in contact with
the
middle sculpted layer and beneath and in contact with the top layer of foam.
13. The sleep system of claim 9 wherein at least some of the substantially
vertical air
passageways in the foam layers align to provide continuous airflow paths from
the
bottom surface of the mattress to an upper surface of the mattress.
14. The sleep system of claim 3 further comprising a mattress foundation,
which
comprises:
a support structure;
46

an air flow unit; and
a cover comprising an upper surface, and wherein the upper surface of the
foundation
cover comprises a foundation air permeable element;
wherein the mattress is located atop the foundation and wherein the mattress
and
foundation are in fluid communication with each other.
15. The sleep system of claim 14 wherein the foundation cover further
comprises a port for
fluid communication of the foundation with the outside environment; and
wherein the
remainder of the cover other than the upper surface and the port is
substantially air
impermeable.
16. The sleep system of claim 15 wherein the air flow unit is located within
the support
structure and cover of the foundation.
17. The sleep system of claim 14 wherein the air flow unit comprises
filtration.
18. The sleep system of claim 14 wherein the air flow unit comprises a climate
control unit
operable to cool or heat air.
19. The sleep system of claim 8 wherein the one or more foam layers comprise
two
sculpted foam layers, each comprising a sculpted surface with a plurality of
foam
pillars.
20. The sleep system of claim 19 wherein the two sculpted foam layers comprise

a lower sculpted foam layer with sculpted surface facing upward; and
47

an upper sculpted foam layer with sculpted surface facing downward.
48

Description

CA 02956830 2017-01-31
Ventilating Sleep System
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional of and claims priority to
related U.S. provisional
patent application serial no. 62/289,773 filed February 1, 2016 and entitled
"Mattress Ventilating
Foundation and Sleep System". This application also claims priority to U.S.
Patent Serial No.
15/183,348 (entitled "Mattress Ventilating Foundation and Sleep System" and
filed June 15, 2016)
and to related U.S. provisional patent application serial no. 62/175,767
(filed June 15, 2015 and
entitled "Mattress Ventilating Foundation and Sleep System"); and to U.S.
Patent Application
Serial No. 14/681,278 (entitled "Independent Foam Spring Mattress" and filed
April 8, 2015), and
to related provisional patent application serial no. 61/977,989 (entitled
"Independent Foam Spring
Mattress" and filed April 10, 2014). Thus, this application claims priority to
all five applications
set forth above. All of the above-cited priority documents are hereby
incorporated by reference
for all purposes as if reproduced in their entirety to the extent that they
are compatible (e.g. not
inconsistent) with and/or do not directly contradict disclosure herein (e.g.
the explicit disclosure
herein would always govern/trump in instances of contradiction, inconsistency,
or
incompatibility).
STATEMENT REGARDING FEDERALLY SPONSORED
RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more complete understanding of the present disclosure,
reference is now made to
the following brief description, taken in connection with the accompanying
drawings and detailed
description, wherein like reference numerals represent like parts.
1

CA 02956830 2017-01-31
[0005] Fig. 1A is a schematic diagram illustrating an exemplary
sleep/bedding system, in
which a mattress may be used atop one of two possible ventilating foundation
exemplary variants;
[0006] Fig. 1B is a schematic diagram illustrating an alternate exemplary
sleep/bedding
system, in which a mattress may be used atop one of two possible ventilating
foundation
exemplary variants;
[0007] Fig. 1C illustrates a detailed embodiment of a sleep/bedding system
similar to that of
Fig. 1B and having an internal air input unit with optional HEPA filter and an
access panel, with
Fig. 1Ca showing a side view, Fig. 1Cb showing an end view (from the foot of
the bed), and Fig.
1Cc showing a top view;
[0008] Fig. 1D illustrates a detailed embodiment of a sleep/bedding system
similar to that of
Fig. 1B and having an external air input unit with optional HEPA filter and an
access panel, with
Fig. 1Da showing a side view, Fig. 1Db showing an end view (from the foot of
the bed), and Fig.
1Dc showing a top view;
[0009] Fig. 1E illustrates a perspective view of an exemplary sleep/bedding
system similar to
Fig. 1C;
[0010] Figs. 2A1 and 2A2 illustrate an exemplary mattress embodiment
(without the cover
being shown, to allow viewing of internal components) which is an all-foam
(e.g. spring-free)
mattress configured for ventilation, with Fig. 2A1 showing an exploded
perspective view of an
exemplary mattress and Fig. 2A2 showing a cut-away (e.g. cross-section)
elevation view of the
exemplary mattress of Fig. 2A1;
[0011] Figs. 2B1 and 2B2 illustrate an exemplary mattress embodiment
(similar to that of Fig.
2A1 in configuration, but comprising different foam materials for at least
some of the layers)
configured for ventilation, with Fig. 2B1 showing an exploded perspective view
of an exemplary
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CA 02956830 2017-01-31
mattress and Fig. 2B2 showing a cut-away (e.g. cross-section) elevation view
of the exemplary
mattress of Fig. 2B1;
[0012] Fig. 3 illustrates a top/plan view of an exemplary base (sculpted)
layer of foam (of the
sort that might be used in Fig. 2A1, for example);
[0013] Fig. 4 illustrates a bottom/plan view of an exemplary middle
sculpted foam layer (of
the sort that might be used in Fig. 2A1, for example);
[0014] Figs. 5A and 5B illustrate exemplary mattress embodiments configured
for ventilation;
[0015] Figs. 6A and 6B illustrate detailed views of the middle sculpted
foam layers;
[0016] Figs. 7A and 7B illustrate alternative detailed views of the middle
sculpted foam
layers; and
[0017] Figure 8 illustrates an exemplary base foam layer similar to that
shown and described
in Fig. 3.
3

CA 02956830 2017-01-31
'
,
, DETAILED DESCRIPTION
[0018] It should be understood at the outset that although illustrative
implementations of one
or more embodiments are illustrated below, the disclosed systems and methods
may be
implemented using any number of techniques, whether currently known or not yet
in existence.
The disclosure should in no way be limited to the illustrative
implementations, drawings, and
techniques illustrated below, but may be modified within the scope of the
appended claims along
with their full scope of equivalents.
[0019] The following brief definition of terms shall apply throughout
the application:
[0020] The term "comprising" means including but not limited to, and
should be interpreted in
the manner it is typically used in the patent context.
[0021] The term "foam" means a material in a lightweight cellular form,
for example resulting
from introduction of gas bubbles during manufacture to produce a consistent
cell structure, and/or
any of various light, porous, semirigid or spongy materials or cellular
solids, usually the solidified
form of a liquid full of gas bubbles, which may be used as a building material
or for shock
absorption, and includes open cell foams such as polyurethane foam, latex,
memory foam, specialty
memory foam, gel memory foam, gel latex foam or other gel foams, etc.;
[0022] The term "IFD" means indentation force deflection, and describes
a well-known
measurement system for foam firmness;
[0023] Directions, such as up (e.g. upward) and/or down (e.g. downward),
typically are intended
to be based on the mattress (or sleep system or foundation) in its normal
sleeping position as
understood by persons of skill; for example, the upper surface of the mattress
might face the ceiling
and/or serve as the sleep surface upon which the user might lie, while the
bottom surface of the
mattress might face the floor or ground and/or be placed atop a foundation;
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CA 02956830 2017-01-31
[0024] The phrases "in one embodiment," "according to one embodiment," and
the like
generally mean that the particular feature, structure or characteristic
following the phrase may be
included in at least one embodiment of the present invention, and may be
included in more than
one embodiment of the present invention (importantly, such phrases do not
necessarily refer to the
same embodiment);
[0025] If the specification describes something as "exemplary" or as an
"example," it should
be understood that refers to a non-exclusive example:
[0026] The terms "about" or "approximately" or the like, when used with a
number may mean
that specific number, or alternatively, a range in proximity to the specific
number, as understood
by persons of skill in the art field (for example, +/- 10%); and
[0027] If the specification states a component or feature "may," "can,"
"could," "should,"
"would," "preferably," "possibly," "typically," "optionally," "for example,"
"often," or "might"
(or other such language) be included or have a characteristic, that particular
component or feature
is not required to be included or have the characteristic. Such component or
feature may be
optionally included in some embodiments, or it may be excluded.
[0028] Typical sleep or bedding systems may have a conventional (typically
inner-spring)
mattress located atop a conventional box spring foundation unit. In such
conventional sleep
systems, there is typically no interaction between the mattress and the box
spring foundation, other
than the fact that the box spring foundation supports (e.g. underlies) the
mattress. While
conventional sleep systems may be sufficient for some sleepers/users, many
users might desire
and are looking for an improved sleep experience.
[0029] For example, many users might find conventional sleep systems rather
hot (especially
when the mattress includes foam, and most especially when the mattress
includes memory foam),
resulting in a rather sweaty, uncomfortable night's sleep of the sort that may
result in restlessness

CA 02956830 2017-01-31
and lack of deep slumber. Other users may have allergy problems, and a
conventional mattress
may, over time, collect dust and other allergens that might trouble the user
during sleep.
Additionally, conventional inner-spring mattresses may not support the user's
body as effectively
as desired, perhaps resulting in discomfort.
[0030]
The presently disclosed embodiments may address one or more of these issues.
For
example, disclosed embodiments may provide ventilation (e.g. airflow), such
that the mattress
may better breathe and/or disperse heat (e.g. improving sleep comfort while a
user is atop the
mattress); disclosed embodiments may refresh the mattress, for example sucking
out stale air with
potential allergens (which could happen either when the user is atop the
mattress or, alternatively,
when the user is not on the mattress (for example, based on a timer)); and/or
disclosed
embodiments may provide superior comfort/support. Typically, disclosed
embodiment sleep
systems might have the mattress and foundation interact with each other (for
example, being in
fluid communication), to provide one or more such sleep benefits, as persons
of skill will
understand based on the disclosure below. Typical foundation embodiments might
comprise an
upper surface (of a cover) allowing airflow therethrough (and typically having
an air flow unit
(such as a fan or air pump) operable to direct air through the upper surface),
while typical mattress
embodiments might comprise a bottom surface (of a cover) (and in some
embodiments a top
surface of the cover) allowing airflow therethrough (and often also including
air pathways (such as
pinholes) vertically throughout the mattress). So, most disclosed sleep system
embodiments
typically might have a ventilation mattress atop a ventilation foundation,
with airflow
therebetween.
[0031]
Disclosed embodiments relate generally to mattress ventilation sleep systems
(and/or
related foundations and/or mattresses), which typically would include a
mattress ventilation
foundation in conjunction with a mattress (for example, typically located atop
the foundation).
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CA 02956830 2017-01-31
Typically, the mattress ventilation foundation might comprise a support
structure (such as support
struts and structural frame, for example, which might be similar to a
conventional box spring
foundation), operable to support a mattress in a manner similar to a
conventional mattress
foundation (and which typically might be hollow); an air flow unit (such as a
forced air supply
unit (e.g. fan) operable to either blow air into the supported mattress atop
the foundation or suck
air from the supported mattress); and a cover (including an upper, support
surface upon which the
mattress would lay), which would typically include a means for airflow between
the foundation
(e.g. the air flow unit) and the supported mattress (e.g. an air permeable
element/panel, such as
one or more panels of high air flow mesh fabric located in the upper surface
of the foundation
cover, for example). In some embodiments, the air flow unit might include
filtration (such as a
HEPA filter), which might for example be located at the intake and/or outtake
for the air flow unit.
The air flow unit might be housed within the support structure of the
foundation in some
embodiments, while in other embodiments the air flow unit might be external to
(for example,
mounted onto) the support structure (for example, mounted onto the bottom
surface of the
cover/support structure and in fluid communication with the hollow cavity
within the
cover/support structure by an opening).
100321
Typically, the foundation cover would surround/enclose/encompass the support
structure on all sides, and the foundation cover would be airtight/air
impermeable (e.g. formed of
an airtight material such as fabric overtop a polyvinyl substrate, for
example) except for the
attachment/fluid communication port (e.g. inlet/outlet/opening) for the air
flow unit (which allows
fluid communication between the external environment and the hollow cavity
within the
foundation, for example) and the means for airflow between the foundation and
the supported
mattress (e.g. air permeable element/panel, such as high airflow mesh
panel(s)). For example, the
bottom and side surfaces of the foundation cover would typically be airtight
(except for the
7

CA 02956830 2017-01-31
. irilet/outlet/opening for the air flow unit), while the upper surface of
the foundation cover (which
would typically support and/or contact the bottom surface of the mattress)
would include the
means for airflow between the foundation (e.g. the air flow unit) and the
supported mattress (e.g.
at least one air permeable element/panel, such as one or more panels of high
air flow mesh fabric
located in the upper surface of the foundation cover, for example). In some
embodiments, the
entire upper surface of the foundation cover might be formed of high airflow
mesh fabric, while in
other embodiments, the upper surface might include a plurality of panels of
such high airflow
mesh fabric and/or other means for allowing airflow between the foundation and
the supported
mattress (such as air passageways).
[0033] Typically, air might flow through the hollow cavity of the
foundation to the upper
surface of the foundation cover (as directed by the air flow unit, for
example), but alternatively,
there could be tubing or ducts leading from the air flow unit to the upper
surface of the foundation
cover (e.g. to specific locations on the upper surface of the foundation cover
corresponding to the
pinholes in the supported mattress thereupon). In such embodiments, it might
not be necessary for
the bottom and sides of the foundation cover to be airtight.
[0034] Additionally, some embodiments of the air flow unit might
optionally comprise a
climate control unit, which might cool and/or heat air flowing through the air
flow unit (for
example, before the air flows into the supported mattress atop the
foundation). In some
embodiments, the climate control unit would be located within the housing for
the air flow unit,
while in other embodiments, the climate control unit might be located external
to such housing
(e.g. it may be either separate or combined with the blower portion of the air
flow unit). Similarly,
embodiments of the air flow unit might optionally comprise an air ionizer (for
electric sterilization
of air prior to entering the foundation) and/or an ultraviolet germicidal
irradiation light (for
irradiating light sufficiently to substantially destroy harmful microbes, such
as bacteria, prior to
8

CA 02956830 2017-01-31
entering the foundation). As with the optional climate control unit, the air
ionizer and/or UV
germicidal irradiation light units could be located within the housing for the
air flow unit or (in
other embodiments) located external to such housing (e.g. each may be either
separate or
combined with the blower portion of the air flow unit). Typically, the air
flow unit might be
controlled/operated by a controller, which might be a separate device and
which might allow for
remote control of the air flow device (e.g. the blower and/or climate control
unit). In some
embodiments, the controller and/or air flow unit may include a timer, for
example allowing the
user to set the air flow unit for a regular (for example daily or weekly)
refresh cycle. And
typically, the air flow unit would be electrically powered (for example with a
plug allowing power
to be drawn from a standard electrical wall socket).
[0035]
So typically in operation, air might be drawn into the foundation (for example
by the
air flow unit, through the intake opening/fluid communication port), and then
forced out the upper
surface (for example through a high airflow mesh fabric upper surface or
panel(s)) and into the
supported mattress. This may allow for a supported mattress to be refreshed
with clean air and/or
may enhance sleep comfort for a user lying atop the mattress. Alternatively,
air might be sucked
out of the supported mattress (for example by operating the air flow unit in
reverse to create
suction), into the foundation (for example through the upper surface of the
cover of the
foundation, perhaps through one or more high air flow mesh panels), and out
the air flow unit's
outtake opening/fluid communication port (which might be the same intake
opening if the air flow
device is operated for blowing instead of suction in some embodiments). In
some embodiments,
the air flow unit might be operable to run in forward (e.g. blowing mode)
and/or reverse (e.g.
suction mode). So in some embodiments, the air flow unit might be run in
reverse (for example,
suction mode to suck air from the supported mattress) to refresh the mattress
(e.g. a refresh cycle,
which in some embodiments might be periodically run), while the air flow unit
might be run in
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CA 02956830 2017-01-31
forward (for example, blowing mode to blow fresh (e.g. filtered) and/or
climate controlled (e.g.
cooled or heated) and/or ionized and/or UV sanitized air into the supported
mattress) to enhance
sleep comfort atop the supported mattress (for example, improving allergy
conditions and/or
temperature and/or airflow for the user atop the supported mattress, perhaps
while the user is
actually lying atop/sleeping on the mattress).
[0036]
While it is possible that any sort of mattress might be used to some advantage
atop
such a ventilation foundation, more typically specialized air flow (e.g.
ventilation) mattress
embodiments might be used in conjunction with the disclosed foundation
embodiments. For
example, the mattress might comprise a mattress cover having a bottom surface
which includes a
means for airflow between the foundation and the supported mattress (e.g. into
and/or out of the
mattress, for example at least one air permeable element/panel). For example,
in some
embodiments the bottom surface of the mattress cover might be formed of or
include one or more
panels of high airflow mesh fabric (or alternatively, the bottom surface of
the mattress cover might
include air passageways, which might correspond to those of the upper surface
of the foundation
cover). In some embodiments, the top surface of the mattress cover might also
comprise air
permeable element/panel or other means of airflow into/out of the mattress
(e.g. high airflow mesh
or loosely woven fabric panel(s)). And in some embodiments, the remainder of
the mattress cover
might be (substantially) air impermeable. Furthermore, the mattress might
comprise one or more
(and typically a plurality of) primarily vertical air pathways (e.g. pin
holes), operable to allow air
flow vertically throughout the mattress (for example from the bottom of the
mattress to the top of
the mattress). In some embodiments, the mattress might be an all-foam and/or
spring-free
mattress. For example, the mattress might be formed entirely of layers of
foam, and each layer of
foam might include vertical pin holes, at least some of which align to provide
continuous airflow
passages/pathways/pinholes vertically throughout the mattress.

CA 02956830 2017-01-31
[00371
Some such mattress embodiments might include one or more foam layers having a
sculpted surface with a plurality of foam pillars. For example, some
embodiments might have a
base layer of foam (e.g. the bottom layer of foam) with an upward facing
sculpted surface (e.g. the
pillars of foam facing/projecting upward), and another layer of foam
(typically a middle foam
layer, located somewhere between the base foam layer and the uppermost (sleep
surface) layer of
foam) with a downward facing sculpted surface (e.g. the pillars of foam
facing/projecting
downward). Typically, the sculpted foam layers would each have scoring (e.g. a
series of
grooves/gaps) forming a grid on one surface (termed the sculpted surface),
with the grid pattern
resulting in a plurality of foam pillars projecting outward from a common,
unified slab/base of
foam (e.g. the surface opposite the sculpted surface typically would be flat,
such that the foam
pillars would all be joined together into an integral whole layer at their
bases/bottoms). The
sculpted foam layer(s) might effectively replace the support functionality of
the springs while also
often providing added benefits. For example, a sculpted foam surface (e.g.
foam pillars) may
provide more flexibility in adjusting to various body contours than metal
springs, and therefore
may be more effective in reducing pressure points against the human body than
traditional metal
springs in conventional mattresses. More specifically, the layer(s) of foam
with a sculpted surface
would typically include a plurality of foam pillars (or blocks), each of which
is freestanding (e.g.
independent) with respect to the other pillars, but all of which are joined
together into a single
integral base (which typically has a flat exterior surface). So, the base
portion of the pillars are all
joined together (e.g. a common base), while the remaining freestanding portion
of the layer of
foam comprises a plurality of independent pillars separated from one another
by a gap or groove
on all sides. Stated another way, the sculpted layer(s) of foam may comprise
each a base portion
(which typically is a uniform flat sheet of foam) and a pillar portion (which
typically comprises a
plurality of independent pillars or blocks of foam, each of which is
completely separate from the
11

CA 02956830 2017-01-31
other pillars), with the pillar portion being securely attached to a surface
of the base portion (so in
effect the pillars project out from the flat base portion). Thus, the sculpted
surface of the sculpted
layer of foam would typically be the distal surface of the pillars (or pillar
portion). Typically, the
sculpted layer of foam may be formed by cutting a pattern of grooves in one
surface (which would
then become the sculpted surface) of an initially uniform (e.g. flat sheet
with constant thickness)
sheet of foam, thereby forming a plurality of foam pillars which extend out
from the base portion
(with the pillar portion and the base portion integrally forming a single
layer of foam having
different shapes/characteristics on opposing sides). Thus, the sculpted layer
of foam might also be
termed a contour cut layer of foam in some embodiments (since in many
embodiments the layer of
foam is sculpted via cutting, for example contour cutting). In other
embodiments, it may be
possible to form the sculpted layer of foam by molding (with the mold forming
the pillar portion
projecting outward from the base portion). Typically, the substantially one
entire surface of the
sculpted foam layer (e.g. the entire sculpted surface) would be entirely
comprised of such pillars
(e.g. substantially the entire sculpted surface of the sculpted foam layer
would be formed of
pillars), although in other embodiments the sculpted surface might have
pillars only on a portion
of the sculpted surface.
[0038]
Typical mattress embodiments might have vertical pin holes passing through (at
least)
the base portion of the sculpted foam layers, and such pin holes might
typically be positioned to
align with the grooves/gaps between the foam pillars (so that air could flow
continuously through
the vertical pin holes and the grooves to pass from one surface of the
sculpted foam layer all the
way through to the other surface of the sculpted foam layer). In some
embodiments, the base layer
of foam would comprise a foam component having a sculpted surface (typically
with pillars facing
upward) surrounded by foam edge support perimeter rails (which typically would
be solid blocks
of foam encompassing the sides of the base foam component with sculpted
surface, and typically
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CA 02956830 2017-01-31
having an uncompressed height approximately equal to the uncompressed height
of the base foam
component (e.g. the upper surface of the edge support perimeter rails would
typically be
approximately the same as the uncompressed height of (e.g. flush with) the
upper surface of the
foam pillars of the base foam component with sculpted surface).
[0039]
Typically, mattress embodiments would have at least one (foam) layer located
between
the base sculpted foam layer (which typically would have the sculpted surface
(e.g. foam pillars)
facing upward) and the middle sculpted foam layer (which typically would have
the sculpted
surface (e.g. foam pillars) facing downward), and would have at least one
(foam) layer located
above the middle sculpted foam layer (e.g. a sleep surface layer (typically of
foam) would be
located atop the middle sculpted foam layer). In some embodiments, the foam
pillars of the base
sculpted foam layer would be larger (e.g. the cross-section/footprint/outer
surface of the pillars
would be larger) than the foam pillars of the middle sculpted foam layer. And
as mentioned
above, typically the various (foam) layers of the mattress would each have
vertical pin holes, at
least some of which would align to provide continuous airflow from the bottom
to the top of the
mattress. For example, in some embodiments all (foam) layers located above the
base layer of
foam might have vertical pinholes which entirely align, even though the base
foam layer might
have less vertical pinholes spaced further apart such that only some of the
pinholes in the
remaining layers align with pinholes in the base layer. Although the base
layer in some
embodiments may have fewer pinholes spaced further apart than the other layers
of foam, air may
be operable in some such embodiments to move through the grooves in the base
portion (e.g. since
the pinholes in the base portion may be in fluid communication with the
grooves in the base
portion) to the pinholes in the upper layers of foam which are not aligned
with the pinholes in the
base layer of foam.
13

CA 02956830 2017-01-31
[00401
Typically, the sculpted layer of foam would have a plurality of foam pillars
forming the
sculpted surface, and the pillars would be configured within the sculpted foam
layer and the
mattress as a whole to essentially be limited to movement only (or in some
embodiments,
primarily) in the vertical direction (e.g. without any horizontal/sideways
movement of the pillars
during use of the mattress). In other words, the configuration of the foam
layers of the mattress
(for example, with the layers placed in contact in such a way as to minimize
shear or torsion in the
pillars during construction (e.g. essentially placing the pillars only in
compression) and with the
layers perhaps laminated together) would typically ensure that compression on
the top (e.g. sleep
surface) of the mattress would be transmitted to the foam pillars entirely as
a vertical (e.g.
compression) force (without, for example, introducing any (e.g. substantial)
horizontal, shear, or
torsion forces to the foam pillars) for each affected foam pillar.
Additionally, each pillar of foam
in the sculpted layer would typically be configured for essentially
independent movement (e.g.
each pillar moves independent of the other surrounding/proximate pillars).
This independence
might arise due to the contour cuts (e.g. grooves/gaps) separating the foam
pillars and/or the fact
that the base of the foam pillars would be linked by conformable foam (e.g. in
the form of an
integrated base of foam linking all pillars together). So, embodiments might
have pillars of the
sculpted foam layer configured for essentially independent movement and/or
essentially only
vertical movement during usage of the mattress (e.g. by a user lying atop the
mattress). Typical
embodiments might have the pillars configured for independent movement
essentially only in the
vertical direction. For example, each foam pillar might be operable to move
vertically without
substantially imparting any vertical movement to surrounding/proximate foam
pillars in the
sculpted foam layer. Thus, movement by one foam pillar typically might not
impart any
movement to other foam pillars in proximity within the sculpted foam layer
(such that each pillar
movement would independently relate to its own loading from the sleep surface
above). So, each
14

CA 02956830 2017-01-31
foam pillar of an exemplary sculpted foam layer in a disclosed mattress
embodiment may be
operable to only (or in some embodiments primarily) carry/support compression
forces from
directly above the foam pillar. Of course, Applicant does not intend to be
bound by theory, but
rather simply notes that the presently disclosed embodiments may
perform/operate differently
and/or better. Such configuration of the sculpted foam layer (with regard to
movement) may be
quite different from the typical movement allowed/provided by conventional
metal springs (e.g.
coil springs in a mattress). Conventional coil spring mattresses have a series
of springs which
typically are linked by wire across their top surfaces. Thus, the coil springs
do not move
independently (e.g. movement by one coil spring necessarily affects the
surrounding coil springs
due to the rigid nature of the linking wire frame) and the linking wire frame
at the top of the coil
springs may typically introduce non-vertical (e.g. non-compression) forces
into the springs (such
that the coil springs may flex and move horizontally and/or torsionally, for
example, in response to
a user atop the mattress sleep surface). Thus, the disclosed embodiments (with
foam pillars in a
spring-less mattress) may perform quite differently in operation than a
conventional spring
mattress. Applicant notes that disclosed mattress embodiments typically do not
include traditional
springs, but for example might be termed all-foam mattresses (e.g. all the
cushion/support
elements are foam) and/or (metal/coil) spring-free mattresses (e.g. no
springs, even if the mattress
embodiment may include some other cushion/support element(s) in addition to or
instead of one or
more foam elements).
[0041]
While typical sleep system embodiments would comprise a mattress embodiment
atop
a foundation embodiment, other embodiments might be focused on only the
mattress or only the
foundation. In other words, disclosed mattress embodiments could alternatively
be used with
conventional foundation elements (or even separately/alone), and disclosed
foundation
embodiments could alternatively be used with conventional mattress elements
(although doing so

CA 02956830 2017-01-31
Might reduce potential benefits available through the joint use of disclosed
mattress
embodiment(s) with disclosed foundation embodiment(s), since the joint use of
ventilation
mattress atop ventilation foundation may provide for improved fluid
communication
therebetween). A preferred embodiment, however, would typically place a
mattress configured to
allow airflow/air transfer (e.g. airflow) through its bottom surface (and
perhaps also typically
having some means of air distribution throughout the mattress (e.g. pinholes)
for air passing
through the bottom surface of the mattress) atop a foundation configured to
provide airflow/air
transfer (for example, forced airflow, which might be suction and/or blowing)
through its upper
surface.
[0042] Turning now to the figures for specific exemplary embodiments, Fig.
1A illustrates
exemplary embodiment(s) of a ventilated sleep system 100 (typically comprising
a mattress and a
foundation), with a ventilated mattress 140 used in conjunction with
(typically directly atop) a
ventilation foundation (such as either 120a or 120b, which basically differ
regarding the location
of the air flow unit 130a). The mattress 140 has a bottom surface 142 which
allows airflow into
and/or out of the mattress 140. For example, the bottom surface 142 of the
mattress 140 cover
might be formed of or comprise high airflow mesh fabric (for example 150gsm
100% polyester
spacer mesh fabric restricting airflow CFM less than about 35% at 3 PSI). In
some embodiments,
the upper surface of the mattress 140 might also allow airflow into/out of the
mattress 140 (for
example, with the upper surface of the mattress 140 cover being formed of or
comprising high
airflow mesh fabric, similar to that used for the bottom surface 142 of the
mattress cover as
described above).
[0043] Either foundation 120a (with an air flow unit 130a external to the
support structure of
the foundation and/or cover of the foundation, for example externally mounted
on the foundation,
perhaps underneath the foundation at or near the foot end of the bed, for
example centered from
16

CA 02956830 2017-01-31
side to side, and in fluid communication with the foundation hollow cavity via

inlet/intake/opening 132a) or 120b (with air flow unit 130b located within the
foundation support
structure and/or cover, for example mounted internally on the bottom/base
panel of the foundation,
perhaps within the foundation at or near the foot end of the bed, for example
on the left side when
looking at the foundation from the foot, and in fluid communication with the
external environment
via inlet/intake/opening 132b) might optionally be used with the mattress 140,
with the mattress
140 being located atop either foundation 120a or 120b to form the ventilated
sleep system 100. In
both foundation embodiments 120a and 120b, the upper surface 122a or 122b,
respectively, of the
foundation 120a/b would be configured to allow airflow out of the foundation
(for example, into a
mattress 140 directly atop (and in contact with) the foundation. So for
example, the upper surface
122a or 122b of the foundation cover might be formed of or comprise high
airflow mesh fabric
(similar to that described above with respect to the bottom surface 142 of the
mattress cover, for
example, to allow airflow communication between the foundation and the
mattress 140, for
example). And typically, the foundation might be held above the floor by a
frame or legs 111a,b
(which might be similar to conventional bed frames used for conventional box
springs, for
example, and which might provide sufficient clearance from the floor to allow
the required airflow
for operation of the ventilation mattress system). Typically, the frame would
not interfere with or
block the inlet/intake/opening 132a/b for the air flow unit 130a,b.
[0044]
So in Fig. 1A, air might pass into the foundation 120a,b, for example through
a filter
such as a HEPA filter and/or through a climate control unit (which might, for
example, be
operable to cool and/or heat the air) via an air flow unit 130a,b, passing
through the
foundation120a/b (e.g. hollow cavity) to exit through the upper surface 122a,b
of the
foundation120a/b and enter the bottom surface 142 of the mattress 140 in order
to pass (vertically)
through at least a portion of the mattress 140. In such a system, the air flow
unit 130a,b might
17

CA 02956830 2017-01-31
piimp air into the mattress 140 through the foundation 120a/b. Alternatively,
air might flow
through the system in reverse, with the air flow unit 130a,b sucking air out
of the mattress 140 and
into the foundation 120a/b (and then out to the external environment). The air
flow unit 130a,b
typically might displace about 100 ¨ 300 CFM, and typically might operate at
less than about 6
dB. In some embodiments, the upper surface of the mattress 140 might also
allow for airflow (for
example, being formed of or comprising high airflow mesh or loosely woven
fabric panels, similar
to those previously described). In some embodiments, the high airflow fabric
panels throughout
the sleep system (or at least for the upper foundation cover surface and lower
mattress cover
surface) might all be similar and/or formed of the same material. In some
embodiments, the air
flow unit 130a,b might be configured to allow for forward and reverse
operation (e.g. operable to
allow air to be blown into or sucked out of the mattress 140 by the foundation
120a/b). The
arrows in Fig. 1A illustrate potential airflow in the system, as persons of
skill would understand.
[0045]
Typically, the foundation(s) 120a,b of Fig. 1 A would comprise a hollow
structure
(formed for example by support struts and a structural frame), and air would
be pumped into/out
of the hollow structure cavity (for example by the air flow unit 130a,b). In
other words, in such
embodiments, air would simply flow through the hollow cavity of the foundation
120a/b as it
interacts with the mattress 140 and the outside environment. So for example,
external air might be
drawn into the hollow cavity of the foundation 120a/b through the
inlet/intake/opening 132a,b,
flow through the hollow cavity to the upper surface of the foundation 120a,b,
flow out of the
foundation 120a/b through the upper surface 122a,b and into the mattress 140
through the mattress
bottom 142, and then pass through at least a portion of the mattress 140 (and
in some
embodiments, air might flow all the way through the mattress 140 and
optionally might flow out
the upper surface of the mattress 140). Alternatively, air might flow into the
hollow cavity of the
foundation 120a,b through the upper surface 122a,b (for example, sucking air
from the mattress
18

CA 02956830 2017-01-31
140 through the bottom surface 142 of the mattress 140), through the hollow
cavity of the
foundation 120, and out of the foundation 120 via inlet/intake (which in the
case would actually
serve as an outtake)/opening 132a,b to the external environment.
[0046]
Fig. 1B illustrates an alternative embodiment sleep/bedding system, similar to
that of Fig. 1A. One version of the foundation 120b of Fig. 1B may have an
access panel , which for
example might allow for easy access to change the HEPA filter and/or to
provide maintenance or
repair to the air flow unit 130b. Fig. 1C illustrates in more detail an
exemplary sleep/bedding
system embodiment similar to Fig. 1B, having an internal (e.g. mounted/located
within the
foundation frame/cover) air flow unit 130b, with Fig. 1Ca showing a side view,
Fig. 1Cb showing an
end view of the foot of the bed, and Fig. 1Cc showing a top view. Typically,
in the embodiment of
Fig. 1C the air flow unit 130b might be located at (e.g. in proximity to) the
foot of the bed within the
foundation. For example, the optional HEPA filter might be located over the
air intake, with air then
flowing through the blower to be expelled into the hollow cavity of the
foundation 120b. In some
embodiments, there may be an access panel, for example located on the upper
surface of the
foundation 120b above the HEPA filter or air intake or air flow unit 130b. The
access panel might
be a hinged section (for example, operable to open by pivoting upward) of the
upper foundation
surface (although in some embodiments, the access panel portion of the upper
foundation 120b
cover might not be air permeable, for example to help direct air through the
blower and into the
foundation).
[0047]
Fig. 1D illustrates in more detail an exemplary sleep/bedding system
embodiment
similar to Fig. 1B, having an external (e.g. mounted/located outside the
foundation 120b
frame/cover, for example mounted beneath the foundation 120b) air flow unit
130a (shown in Fig.
1B), with Fig. 1Da showing a side view, Fig. 1Db showing an end view of the
foot of the bed, and
Fig. 1Dc showing a top view. Typically, the air flow unit 130a of Fig. 1D
might be mounted to
19

CA 02956830 2017-01-31
=
tlie bottom surface of the foundation at or in proximity to the foot of the
bed (perhaps located
towards the center between the sides). And again, there may be an access
panel, which for
example might typically be located on the housing of the air flow unit to
allow access to the
HEPA filter and/or blower. Fig. 1E illustrates an exemplary sleep/bedding
system in 3D
perspective view, showing that externally the sleep/bedding system would
resemble a
conventional mattress atop a conventional box-spring foundation unit (e.g. a
typical conventional
bed).
100481
Figs. 2A1 and 2A2 illustrate an exemplary ventilation mattress 240A,
which is an all-
foam (or spring-free) mattress formed of a plurality of foam layers (with the
base layer being a
sculpted foam layer having the sculpted surface (with foam pillars) facing
upward, a middle
sculpted foam layer having the sculpted surface (with foam pillars) facing
downward, a sleep
surface layer, at least one foam layer (e.g. transition layer) between the
middle sculpted foam
layer and the base sculpted foam layer, and/or a foam layer located between
the sleep surface layer
and the middle sculpted foam layer). While Fig. 2A1 shows the foam components
of the mattress
(e.g. with the cover removed) in perspective view, Fig. 2A2 shows a side cross-
section view of the
same mattress. Figs. 2B1 and 2B2 illustrate a similar all foam mattress (e.g.
with the foam
components removed from the cover), and differs primarily in the particular
foam material
selected (with the embodiment of Fig. 2A1 being formed of conventional high
density foam (e.g.
all component foam layers are formed of conventional high density foam), and
the embodiment of
Fig. 2B1 having the top two layers formed of memory foam, for example gel
memory foam, while
the remaining layers are formed of conventional high density foam). And in
some embodiments,
all such foam layers would be adhered into an integrated whole (e.g.
laminated) and/or
enclosed/encased in a cover, thereby forming an integrated mattress.

CA 02956830 2017-01-31
100491 So in Fig. 2A1, the mattress 240A comprises a base layer of foam 242
(which
comprises a sculpted foam element 243 with the sculpted surface (e.g. the foam
pillars)
facing/extending upward) located as the bottom layer of foam in the mattress
240A, a middle
sculpted foam layer 250 with the sculpted surface (e.g. foam pillars)
facing/projecting downward
and located above the base layer (although typically not directly above or in
contact with the base
layer), a transition foam layer 260 located between (and typically in contact
with) the base layer of
sculpted foam 242 and the middle layer of sculpted foam 250, a top/sleep
surface layer of foam
270 (typically located as the uppermost foam layer 250 in the mattress 240),
and (optionally) a
second (e.g. penultimate) layer of foam 280 located between the sleep surface
layer 270 and the
middle sculpted foam layer 250. Fig. 2A1 shows the layers foam of the mattress
240A without the
cover (not shown), illustrating the order and orientation of the foam layers
in this mattress
embodiment. Typically, the foam layers are arranged one atop another in the
order described
above, with proximate layers contacting one another (e.g. the base layer 242
is the bottom layer,
the transition layer 260 is located atop and in contact with the base layer
242, the middle sculpted
foam layer 250 is located atop and in contact with the transition layer, the
second (penultimate)
layer 280 is located atop and in contact with the middle sculpted foam layer
250, and the top
(sleep surface) layer 270 is located atop and in contact with the second
(penultimate) layer 280 and
forms the upper foam layer of the mattress 240A). Typically, the layers would
all be encased
within a cover (not shown here), and typically the cover would have a bottom
surface with means
for airflow (for example, one or more panels of high airflow mesh fabric).
Also, in some
embodiments, the upper surface of the cover might include means for airflow
(for example, an air
permeable element, such as one or more panels of high airflow mesh fabric).
[0050] In Fig. 2A1, the base layer 242 comprises a sculpted foam
element/layer 243 with
upward facing sculpted surface (e.g. foam pillars 248 projecting upward and
separated by a series
21

CA 02956830 2017-01-31
(e.g. grid) of gaps or grooves or cuts 247), and edge perimeter rails of foam
244 which
surround/encase the sculpted foam element 243 on all sides (e.g. about/around
the perimeter of the
sculpted foam element 243). Typically, the edge support perimeter rails 244
might be formed of
the same foam as the base layer sculpted foam element 243 and/or might have
the same
uncompressed height as the sculpted foam element 243 (e.g. the upper surface
of the edge support
perimeter rails 244 might be approximately level with the upper surface of the
foam pillars 248 of
the sculpted foam element 243 when both are uncompressed). In the embodiment
of Fig. 2A1, the
foam pillars 248 would typically have a square rectangular outer surface
(and/or cross-section) of
about 4 inches by 4 inches, and the gaps/grooves 247 forming the grid
resulting in the foam pillars
248 might typically have a width of about 0.75 inches and a depth of about 3
inches. So for
example, the gaps/grooves 247 in the base layer sculpted foam element 243
might typically have a
depth ranging from about 1/2 to 2/3 the total height for the base layer 242,
for example about 60%
in some exemplary embodiments. In addition, the joined bases of the foam
pillars 248 of the
sculpted foam element 243 typically would have a plurality of pinholes (e.g.
essentially vertical air
passageways), as will be described in greater detail below. In alternate
embodiments, the pinholes
might pass through both the base portion and the pillar portion of one or more
of the sculpted
foam layers.
[0051]
In Fig. 2A1, the transition layer of foam 260 would typically be a flat sheet
of foam
with a plurality of pinholes 265 (e.g. essentially vertical air passageways).
In the embodiment of
Fig. 2A1, the transition layer 260 would typically have the same width and
length dimensions (e.g.
depending on whether the mattress 240A is a twin, full/double, queen, king,
etc.) as the base layer
242 (e.g. including both the sculpted foam element 243 and the surrounding
edge support
perimeter rails 244), although in other embodiments (in which the foam pillars
248 are lower than
the surrounding edge support perimeter rails 244, for example by a height
approximately equal to
22

CA 02956830 2017-01-31
the thickness of the transition layer, the transition layer 260 might be sized
to fit over just the
sculpted foam element 243 of the base layer 242 (e.g. so that it would be
located within the edge
support perimeter rails 244 as well).
[0052]
The middle sculpted foam layer 250 of Fig. 2A1 would typically be sized (e.g.
width
and length) approximately the same as the base layer 242 and/or the transition
layer 260 (and
typically the same as the layers atop it as well), and would be oriented with
the sculpted surface
(e.g. foam pillars 258) facing/projecting downward. In the embodiment of Fig.
2A1, the foam
pillars 258 would typically have a square rectangular outer surface (and/or
cross-section) of about
2 inches by 2 inches, and the gaps/grooves 257 forming the grid resulting in
the foam pillars might
typically have a width of about 0.375 inches and a depth of about 1.75 inches.
So for example, the
gaps/grooves 257 in the middle sculpted layer 250 might typically have a depth
ranging from
about 1/2 to 2/3 the total height for the middle sculpted layer, for example
about 55-60% in some
exemplary embodiments.
In addition, the joined bases of the foam pillars 258 of the middle
sculpted layer 250 typically would have a plurality of pinholes 255 (e.g.
essentially vertical air
passageways), as will be described in greater detail below. Typically, the
pinholes 255 of the
middle sculpted foam layer 250 would be spaced and/or oriented/located the
same (identically) as
the pinholes 265 in the transition foam layer 260 (and typically also the same
as the layers located
above it), with the pinholes 255 aligning vertically with the pinholes 265.
And typically, at least
some of the pinholes 255/265 would also align with the pinholes 245 in the
base layer 242 (e.g.
the sculpted foam element 243 of the base layer 242). For example, every other
pinhole 255/265
might align with a pinhole 245 (and groove/gap 247) in the sculpted foam
element of the base
layer.
[0053]
The second (penultimate) foam layer 280 and the upper (sleep surface) foam
layer 270
would typically each be a flat sheet of foam with a plurality of pinholes 285,
275 respectively (e.g.
23

CA 02956830 2017-01-31
e'ssentially vertical air passageways). In the embodiment of Fig. 2A1, both
the second
(penultimate) foam layer 280 and the upper (sleep surface) foam layer 270
would typically have
the same width and length dimensions (e.g. depending on whether the mattress
240A is a twin,
full/double, queen, king, etc.) as the base layer 242, the transition layer
260, and/or the middle
sculpted layer 250. And, the pinholes 285, 275 of the second (penultimate)
foam layer 280 and
the top (sleep surface) layer 270 respectively would typically be spaced
and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer 260 and
the pinholes 255 in the
middle sculpted foam layer 250, with the pinholes 285, 275 aligning vertically
with the pinholes
265, 255. Thus, the pinholes 265, 255, 285, and 275 of Fig. 2A1 would
typically align to form
continuous airflow pathways from the upper surface of the base layer 242
upward to the upper
surface of the mattress 240A (although in other embodiments, only some of the
pinholes might
align). And typically, at least some of the pinholes 285/275 would also align
with the pinholes
245 in the base layer 242 (e.g. the sculpted foam element 243 of the base
layer 242). For example,
every other pinhole 285/275 might align with a pinhole 245 (and groove/gap
247) in the sculpted
foam element 243 of the base layer 242. In other embodiments, the pinholes
265, 255, 285, and
275 might all align with the pinholes 245 in the base layer 242 (e.g. the
pinholes in all the layers
could be spaced equally so they all align to form continuous air flow pathways
from the bottom
surface of the mattress to the upper surface of the mattress 240A).
[0054]
Similarly, Fig. 2A2 shows a cross-section view of the foam elements of the
mattress
240A shown in Fig. 2A1. In this embodiment, the base layer 242 typically would
have an
uncompressed height of about 5 inches, the transition layer 260 typically
would have an
uncompressed height of about 1.25 inches, the middle sculpted foam layer 250
typically would
have an uncompressed height of about 3 inches, the second (penultimate) foam
layer 280 typically
would have an uncompressed height of about 1.75 inches, and the top (sleep
surface) layer 270
24

CA 02956830 2017-01-31
=
' tYpically would have an uncompressed height of about 1.25 inches. In Fig.
2A2, the foam layers
250 would typically vary in firmness, from softest at the top to
hardest/firmest at the bottom. For
example, the top (sleep surface) layer 270 would typically be the softest
layer of foam (for
example, IFD of about 14), the second (penultimate) layer 280 would typically
be somewhat
firmer that the top layer (for example, IFD of about 20), the middle sculpted
foam layer 250 would
typically be somewhat firmer than the second (penultimate) layer 280 (for
example, IFD of about
35), the transition layer 260 typically would be somewhat firmer than the
middle sculpted layer
(for example, IFD of about 45), while the base layer 242 might typically have
the same firmness
as the transition layer 260 (for example, IFD of about 45). In other
embodiments, the base layer
242 might be somewhat firmer than the transition layer 260. Typically, the
edge support perimeter
rails 244 would have the same firmness (e.g. IFD) and/or be formed of the same
foam as the
sculpted foam element 243 of the base layer. In other embodiments, the
firmness of the various
layers may differ and/or may vary differently from the descriptions above. And
in Fig. 2A2, the
thickness (e.g. lateral width) of the edge support perimeter rails typically
would be about 4 inches
(or in other embodiments, about the same size as one of the foam pillar's 248
square rectangular
outer surface (and/or cross-section) sides).
[0055] Fig. 2A2 also shows the alignment of the pinholes 265, 255 (and
gap 257), 285, and
275, and the fact that every other pinhole 265, 255, 285, 275 aligns with a
pinhole 245 (and gap
247) of the base layer 242 in this embodiment. The alignment of pinholes may
allow continuous
airflow upward from the bottom surface of the mattress 240A to the upper
surface of the mattress
240A and/or downward from the upper surface of the mattress 240A to the bottom
surface of the
mattress 240A, as illustrated by the exemplary airflow arrows (except along
the perimeter edges
where the edge support perimeter rails 244 may not have pinholes, in some
embodiments). In
some embodiments, the pinholes may be hole punched into the foam
sheets/layers, while in other

CA 02956830 2017-01-31
embodiments the pinholes might be formed for example by molding of the foam
sheets/layers).
And in some embodiments, the gaps/grooves 247, 257 might be cut/scored into
the foam to form
the sculpted surface(s), while in other embodiments the gaps/grooves 247, 257
might be formed
for example by molding (e.g. due to the shape of the foam mold forming the
layer(s)). The upper
surface of the top layer of foam 270 forms the sleep surface 272 (although
typically there would
be a cover, not shown here, lying atop/encasing the foam).
[0056]
So in some embodiments, the mattress might comprise at least two sculpted foam
layers (with each having a sculpted surface with a plurality of pillars) with
a transition foam layer
(and typically only one such transition foam layer) therebetween. The upper
sculpted foam layer
would typically be oriented with its sculpted surface facing downward
(although in other
embodiments, it could face upward and/or there might not be a foam
(transition) layer between the
two sculpted foam layers), while the lower/bottom sculpted foam layer (e.g.
the base layer) would
typically be oriented with its sculpted surface facing upward. And typically
(although optionally),
there would be one or more foam layers located above the uppermost sculpted
foam layer (e.g. the
middle sculpted foam layer), with these top foam layers having a softer IFD
than that of the
middle sculpted foam layer. A series of pinholes in the foam layers (perhaps
in conjunction with
the gaps/grooves forming the sculpted surface of the sculpted foam layers)
would allow for airflow
vertically throughout the mattress (or at least through a plurality of foam
layers of the mattress).
And typically, the foam layers would be enclosed/encased within a cover, which
typically would
have a bottom/lower surface which is air permeable (for example, formed of or
comprising high
airflow mesh fabric, typically allowing airflow comparable to the upper/top
surface of the
ventilation foundation upon which such a mattress would typically operate). So
as discussed
above, the mattress embodiment would typically have a bottom cover surface
allowing airflow
therethrough (e.g. one or more panels restricting airflow cubic feet per
minute less than about 35%
26

CA 02956830 2017-01-31
at 3 PSI), and the ventilation foundation (upon/atop which the mattress
embodiment would
typically be used) typically would also have an upper/top cover surface
allowing airflow
therethrough (for example, similar to the airflow allowed by the bottom
surface of the cover of the
mattress), such that the joint mattress-foundation sleep/bedding system
embodiment typically
would effectively allow airflow between the foundation and the mattress (for
example, based on
an airflow unit in or on the foundation).
[0057] Figs. 2B1 and 2B2 show a similar foam mattress 240B formed of
multiple layers of
foam (typically within a cover (not shown)). The embodiment of Fig. 2B1 and
2B2 is
substantially the same in structure as the embodiment of Fig. 2A1 and 2A2,
primarily differing in
the foam material used. For example, in Fig. 2B1, the top two layers might be
memory foam (for
example, gel memory foam). Persons of skill will understand that the foam
materials and/or
characteristics of the layers of foam for such exemplary mattresses may
differ, for example being
selected based on the specific needs of the particular mattress.
[0058] Fig. 3 illustrates an exemplary base foam layer 242 (similar to that
of Fig. 2A1, for
example), showing the sculpted surface (e.g. upper surface) of the sculpted
foam element 243
(with foam pillars 248 separated by gaps/grooves 247 in a grid) and the edge
support perimeter
rails 244 in plan view (of the upper, sculpted surface). As noted above, the
foam edge support
perimeter rails 244 surround and abut all four sides of the sculpted foam
element 243, and they
each may typically have a width (e.g. lateral dimension) approximately equal
to one of the sides of
the square rectangular outer surface (and/or cross-section) of the foam
pillars 248. Typically (as
shown in Fig. 3), all of the foam pillars 248 would be equally sized (for
example, they might all be
equally sized with square cross-section, as for example formed by a grid of
grooves/gaps 247 in
which the longitudinal grooves/gaps 247 are equally spaced, and the lateral
gaps/grooves 247 are
also equally spaced apart by the same amount as the longitudinal gaps, for
example forming a grid
27

CA 02956830 2017-01-31
that resembles a checkerboard). So for example in the embodiment of Fig. 3,
the foam pillars 248
would typically have a square rectangular outer surface (and/or cross-section)
of about 4 inches by
4 inches, and the gaps/grooves 247 forming the grid resulting in the foam
pillars 248 might
typically have a width of about 0.75 inches and a depth of about 3 inches.
[0059] Fig. 3 also shows the pinholes 245 in the base layer 242, which are
typically located in
the joined base portion of the foam pillars 248 of the base layer 242 so that
they exit into the
gaps/grooves 247 separating the foam pillars 248. In other words, the pinholes
245 typically do
not pass through the projecting foam pillar 248 portion of the base layer 242
sculpted foam
element 243, but rather pass only though the integral base portion of the
sculpted foam element
243 (e.g. the bottom portion where the foam pillars are joined together into
an integral whole) such
that the pinholes 245 extend upward from the bottom of the base layer 242 to
exit within the
gaps/grooves 247 between the foam pillars 248. The pinholes 245 of Fig. 3
typically might have a
diameter of about 0.5 inches (and typically would all be about the same size),
and typically would
be spaced apart approximately 3.937 inches. So for example, the pinholes 245
typically might be
located within the gaps/grooves 247 at locations in proximity to the corners
of each foam pillar
248 of the base layer 242 (e.g. at the grid groove intersections).
[0060] Similarly, Fig. 4 illustrates an exemplary middle sculpted surface
layer 250 (similar to
that of Fig. 2A1, for example), showing the sculpted surface (e.g. the bottom
surface) (with foam
pillars 258 separated by gaps/grooves 257 in a grid) in plan view (of the
sculpted surface).
Typically (as shown in Fig. 4), all of the foam pillars 258 would be equally
sized (for example,
they might all be equally sized with a square cross-section, as for example
formed by a grid of
grooves/gaps 257 in which the longitudinal grooves/gaps 257 are equally
spaced, and the lateral
gaps/grooves are also equally spaced apart by the same amount as the
longitudinal gaps, for
example forming a grid that resembles a checkerboard). So for example in the
embodiment of Fig.
28

CA 02956830 2017-01-31
4, the foam pillars 258 would typically have a square rectangular outer
surface (and/or cross-
section) of about 2 inches by 2 inches, and the gaps/grooves 257 forming the
grid resulting in the
foam pillars 258 might typically have a width of about 0.375 inches and a
depth of about 1.75
inches. While the embodiment of Fig. 2A1, for example, has the foam pillars
258 of the middle
sculpted foam layer sized to be about 1/4 the size of the foam pillars 248 of
the base layer (e.g. 2
inches by 2 inches versus 4 inches by 4 inches, such that each 4x4 pillar in
the base layer of Fig.
2A1, for example, might have four 2x2 pillars in the middle sculpted layer
located above it); in
other embodiments, the ratio of the foam pillar sizing may vary (for example,
the foam pillars 258
could be the same size as the foam pillars 248 in some embodiments, or the
foam pillars 258 might
be V2, 1/3, 1/8, or 1/16 the size of the foam pillars 248 in other
embodiments). Typically, the
sizing ratio would be such that at least some of the gaps/grooves 257 in the
middle sculpted foam
layer would align with at least some of the gaps/grooves 247 of the base layer
(since that may be
important to aid in alignment of pinholes in some embodiments, as well as
perhaps providing
consistent support and/or comfort characteristics).
100611
Fig. 4 also shows the pinholes 255 in the middle sculpted layer 250, which are
typically
located in the joined base portion of the foam pillars 258 of the middle
sculpted layer 250 so that
they exit into the gaps/grooves 257 separating the foam pillars 258. In other
words, the pinholes
255 typically do not pass through the projecting foam pillar 258 portion of
the middle sculpted
foam layer 250, but rather pass only though the integral base portion of the
middle sculpted layer
250 (e.g. the bottom portion where the foam pillars 258 are joined together
into an integral whole)
such that the pinholes 255 extend downward from the top of the middle sculpted
layer 250 to exit
within the gaps/grooves 257 between the foam pillars 258. The pinholes 255 of
Fig. 4 typically
might have a diameter of about 0.25 inches (and typically would all be about
the same size), and
typically would be spaced apart approximately 1.9685 inches. So for example,
the pinholes 255
29

CA 02956830 2017-01-31
typically might be located within the gaps/grooves 257 at locations in
proximity to the corners of
each foam pillar 258 in the middle sculpted layer 250 (e.g. at the grid groove
intersections). As
discussed above, the pinholes in the foam layers (of an exemplary mattress)
above the middle
sculpted layer 250 (as well as perhaps an underlying transition layer)
typically would be sized and
spaced (e.g. located) identical to those in the middle sculpted layer 250, in
order to form
continuous airflow pathways upward.
[0062] Fig. 5A illustrates an exemplary ventilation mattress 540, which is
an all-foam (or
spring-free) mattress formed of a plurality of foam layers (with the base
layer being a sculpted
foam layer having the sculpted surface (with foam pillars) facing upward, a
middle sculpted foam
layer having the sculpted surface (with foam pillars) facing downward, a sleep
surface layer, at
least one foam layer (e.g. transition layer) between the middle sculpted foam
layer and the base
sculpted foam layer, and/or a foam layer located between the sleep surface
layer and the middle
sculpted foam layer). Fig. 5B illustrates a similar all foam mattress (e.g.
with the foam
components removed from the cover), and differs primarily in the middle layer
construction. In
some embodiments, all such foam layers would be adhered into an integrated
whole (e.g.
laminated) and/or enclosed/encased in a cover, thereby forming an integrated
mattress.
[0063] So in Fig. 5A, the mattress 540 comprises a base layer of foam 242
(which comprises a
sculpted foam element with the sculpted surface (e.g. the foam pillars)
facing/extending upward)
located as the bottom layer of foam in the mattress 540 (wherein the base
layer 242 may be similar
to the base layer 242 described above), a middle sculpted foam layer 550 with
the sculpted surface
(e.g. foam pillars) facing/projecting downward and located above the base
layer 242 (although
typically not directly above or in contact with the base layer 242), a
transition foam layer 260
located between (and typically in contact with) the base layer of sculpted
foam 242 and the middle
layer of sculpted foam 550 (wherein the transition foam layer 260 may be
similar to the transition

CA 02956830 2017-01-31
fo. am layer 260 described above), a top/sleep surface layer of foam 270
(typically located as the
uppermost foam layer in the mattress, wherein the top surface layer 270 may be
similar to the top
surface layer 270 described above), and (optionally) a second (e.g.
penultimate) layer of foam 280
located between the sleep surface layer 270 and the middle sculpted foam layer
550 (wherein the
second layer of foam 280 may be similar to the second layer of foam 280
described above).
[0064] Fig. 5A shows the layers foam of the mattress 540 without the cover
(not shown),
illustrating the order and orientation of the foam layers in this mattress
embodiment. Typically,
the foam layers are arranged one atop another in the order described above,
with proximate layers
contacting one another (e.g. the base layer 242 is the bottom layer, the
transition layer 260 is
located atop and in contact with the base layer, the middle sculpted foam
layer 550 is located atop
and in contact with the transition layer 260, the second (penultimate) layer
280 is located atop and
in contact with the middle sculpted foam layer 550, and the top (sleep
surface) layer 270 is located
atop and in contact with the second (penultimate) layer 280 and forms the
upper foam layer of the
mattress 540). Typically, the layers would all be encased within a cover (not
shown here), and
typically the cover would have a bottom surface with means for airflow (for
example, one or more
panels of high airflow mesh fabric). Also, in some embodiments, the upper
surface of the cover
might include means for airflow (for example, an air permeable element, such
as one or more
panels of high airflow mesh fabric).
[0065] In Fig. 5A, the base layer 242 comprises a sculpted foam
element/layer 243 with
upward facing sculpted surface (e.g. foam pillars 248 projecting upward and
separated by a series
(e.g. grid) of gaps or grooves or cuts 247), and edge perimeter rails of foam
244 which
surround/encase the sculpted foam element 243 on all sides (e.g. about/around
the perimeter of the
sculpted foam element 243). Typically, the edge support perimeter rails 244
might be formed of
the same foam as the base layer sculpted foam element 243 and/or might have
the same
31

CA 02956830 2017-01-31
uncompressed height as the sculpted foam element 243 (e.g. the upper surface
of the edge support
perimeter rails 244 might be approximately level with the upper surface of the
foam pillars 248 of
the sculpted foam element 243 when both are uncompressed).
[0066] In the embodiment of Fig. 5A, the foam pillars 248 would typically
have a square
rectangular outer surface (and/or cross-section) of about 4 inches by 4
inches, and the
gaps/grooves 247 forming the grid resulting in the foam pillars might
typically have a width of
about 0.75 inches and a depth of about 3 inches. So for example, the
gaps/grooves 247 in the base
layer might typically have a depth ranging from about y2 to 2/3 the total
height for the base layer,
for example about 60% in some exemplary embodiments. In addition, the joined
bases of the
foam pillars of the sculpted foam element 243 typically would have a plurality
of pinholes 265
(e.g. essentially vertical air passageways), as will be described in greater
detail below. In alternate
embodiments, the pinholes might pass through both the base portion and the
pillar portion of one
or more of the sculpted foam layers.
[0067] In Fig. 5A, the transition layer of foam 260 would typically be a
flat sheet of foam with
a plurality of pinholes 265 (e.g. essentially vertical air passageways). In
the embodiment of Fig.
5A, the transition layer 260 would typically have the same width and length
dimensions (e.g.
depending on whether the mattress is a twin, full/double, queen, king, etc.)
as the base layer 242
(e.g. including both the sculpted foam element 243 and the surrounding edge
support perimeter
rails 244), although in other embodiments (in which the foam pillars are lower
than the
surrounding edge support perimeter rails, for example by a height
approximately equal to the
thickness of the transition layer, the transition layer 260 might be sized to
fit over just the sculpted
foam element 243 of the base layer 242 (e.g. so that it would be located
within the edge support
perimeter rails 244 as well).
32

CA 02956830 2017-01-31
[0068] The middle sculpted foam layer 550 of Fig. 5A would typically be
sized (e.g. width
and length) approximately the same as the base layer 242 and/or the transition
layer 260 (and
typically the same as the layers atop it as well), and would be oriented with
the sculpted surface
(e.g. foam pillars 554) facing/projecting downward. In the embodiment of Fig.
5A, the foam
pillars 554 would typically have a square/rectangular outer surface (and/or
cross-section) of about
4 inches by 4 inches, and the gaps/grooves 557 forming the grid resulting in
the foam pillars might
typically have a width of about 0.375 inches and a depth of about 1.75 inches.
So for example, the
gaps/grooves 557 in the middle sculpted layer 550 might typically have a depth
ranging from
about IA to 2/3 the total height for the middle sculpted layer 550, for
example about 55-60% in
some exemplary embodiments. In addition, the joined bases of the foam pillars
of the middle
sculpted layer 550 typically would have a plurality of pinholes 555 (e.g.
essentially vertical air
passageways), as will be described in greater detail below.
[0069] In the embodiment shown in Fig. 5A, the pinholes 555 of the middle
sculpted foam
layer 550 may be spaced and/or oriented/located the same (identically) as the
pinholes 245 of the
base layer 242. And typically, at least some of the pinholes 555 may align
with the pinholes 265 in
the transition foam layer 260 (as well as the layers located above it), with
some of the pinholes
265 aligning with the pinholes 555. For example, every other pinhole 265 might
align with a
pinhole 255 in the middle sculpted foam layer 550.
[0070] The middle layer 550 may also comprise an additional set of pillars
552 located on the
top surface of the middle layer 550. In the embodiment of Fig. 5A, the top
pillars 552 may be
sized differently than the bottom pillars 554 (for example, the top pillar 552
might be 1/4 the (cross-
section) size of the bottom pillars 554, with four top pillars 552 for each
corresponding bottom
pillar, although in other embodiments the top and bottom pillars 552/554 could
be the same size).
In the embodiment of Fig. 5A, the pinholes 555 may align with every groove 557
in the bottom
33

CA 02956830 2017-01-31
pillars 554, while the pinholes 555 may align with every other groove 553 in
the top pillars 552. In
some embodiments, the grooves 553 of the top pillars 552 may align with the
pinholes 275, 285 of
the top layer 270 and second layer 280.
[0071]
The second (penultimate) foam layer 280 and the upper (sleep surface) foam
layer 270
would typically each be a flat sheet of foam with a plurality of pinholes 285,
275 respectively (e.g.
essentially vertical air passageways). In the embodiment of Fig. 5A, both the
second
(penultimate) foam layer 280 and the upper (sleep surface) foam layer 270
would typically have
the same width and length dimensions (e.g. depending on whether the mattress
is a twin,
full/double, queen, king, etc.) as the base layer 242, the transition layer
260, and/or the middle
sculpted layer 550. And, the pinholes 285, 275 of the second (penultimate)
foam layer 280 and
the top (sleep surface) layer 270 respectively would typically be spaced
and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer 260 and
optionally the pinholes
555 in the middle sculpted foam layer 550, with the pinholes 285, 275 aligning
vertically with the
pinholes 265, 555. Thus, the pinholes 265, 555, 285, and 275 of Fig. 5A would
typically align to
form continuous airflow pathways from the upper surface of the base layer 242
upward to the
upper surface of the mattress (although in other embodiments, only some of the
pinholes might
align). And typically, at least some of the pinholes 285/275 would also align
with the pinholes
245 in the base layer 242 (e.g. the sculpted foam element 243 of the base
layer). For example,
every other pinhole 285, 275 might align with a pinhole 245 (and groove/gap
247) in the sculpted
foam element 243 of the base layer 242. In other embodiments, the pinholes
265, 555, 285, and
275 might all align with the pinholes 245 in the base layer 242 (e.g. the
pinholes in all the layers
could be spaced equally so they all align to form continuous air flow pathways
from the bottom
surface of the mattress to the upper surface of the mattress).
34

CA 02956830 2017-01-31
[0072]
In Fig. 5A, the foam layers would typically vary in firmness, from softest at
the top to
hardest/firmest at the bottom. For example, the top (sleep surface) layer 270
would typically be
the softest layer of foam (for example, IFD of about 14), the second
(penultimate) layer 280 would
typically be somewhat firmer that the top layer (for example, IFD of about
20), the middle
sculpted foam layer 550 would typically be somewhat firmer than the second
(penultimate) layer
280 (for example, IFD of about 35), the transition layer 260 typically would
be somewhat firmer
than the middle sculpted layer 550 (for example, IFD of about 45), while the
base layer 242 might
typically have the same firmness as the transition layer 260 (for example, IFD
of about 45). In
other embodiments, the base layer 242 might be somewhat firmer than the
transition layer 260.
Typically, the edge support perimeter rails 244 would have the same firmness
(e.g. IFD) and/or be
formed of the same foam as the sculpted foam element 243 of the base layer
242. In other
embodiments, the firmness of the various layers may differ and/or may vary
differently from the
descriptions above. In some embodiments, the thickness (e.g. lateral width) of
the edge support
perimeter rails 244 typically would be about 4 inches (or in other
embodiments, about the same
size as one of the foam pillar 248 square rectangular outer surface (and/or
cross-section) sides).
[0073]
The alignment of pinholes may allow continuous airflow upward from the bottom
surface of the mattress to the upper surface of the mattress 540 and/or
downward from the upper
surface of the mattress to the bottom surface of the mattress 540 (except
along the perimeter edges
where the edge support perimeter rails may not have pinholes, in some
embodiments). In some
embodiments, the pinholes may be hole punched into the foam sheets/layers,
while in other
embodiments the pinholes might be formed for example by molding of the foam
sheets/layers).
[0074]
So in some embodiments, the mattress might comprise at least two sculpted foam
layers (with each having a sculpted surface with a plurality of pillars) with
a transition foam layer
(and typically only one such transition foam layer) therebetween. The upper
sculpted foam layer

CA 02956830 2017-01-31
would typically be oriented with its sculpted surface facing downward
(although in other
embodiments, it could face upward and/or there might not be a foam
(transition) layer between the
two sculpted foam layers and/or the upper sculpted foam layer might have both
an upper and
lower sculpted surface), while the lower/bottom sculpted foam layer (e.g. the
base layer) would
typically be oriented with its sculpted surface facing upward. And typically
(although optionally),
there would be one or more foam layers located above the uppermost sculpted
foam layer (e.g. the
middle sculpted foam layer), with these top foam layers having a softer IFD
than that of the
middle sculpted foam layer. A series of pinholes in the foam layers (perhaps
in conjunction with
the gaps/grooves forming the sculpted surface of the sculpted foam layers)
would allow for airflow
vertically throughout the mattress (or at least through a plurality of foam
layers of the mattress).
And typically, the foam layers would be enclosed/encased within a cover, which
typically would
have a bottom/lower surface which is air permeable (for example, formed of or
comprising high
airflow mesh fabric, typically allowing airflow comparable to the upper/top
surface of the
ventilation foundation upon which such a mattress would typically operate). So
as discussed
above, the mattress embodiment would typically have a bottom cover surface
allowing airflow
therethrough (e.g. one or more panels restricting airflow cubic feet per
minute less than about 35%
at 3 PSI), and the ventilation foundation (upon/atop which the mattress
embodiment would
typically be used) typically would also have an upper/top cover surface
allowing airflow
therethrough (for example, similar to the airflow allowed by the bottom
surface of the cover of the
mattress), such that the joint mattress-foundation sleep/bedding system
embodiment typically
would effectively allow airflow between the foundation and the mattress (for
example, based on
an airflow unit in or on the foundation).
[0075]
Fig. 5B shows a similar foam mattress 542 formed of multiple layers of foam
(typically
within a cover (not shown). The embodiment of Fig. 5B is substantially the
same in structure as
36

CA 02956830 2017-01-31
the embodiment of Fig. 5A, primarily differing in the construction of the
middle layer 560. In the
embodiment of Fig. 5B the middle sculpted foam layer 560 would typically be
sized (e.g. width
and length) approximately the same as the base layer 242 and/or the transition
layer 260 (and
typically the same as the layers atop it as well), and would be oriented with
the sculpted surface
(e.g. foam pillars 556) facing/projecting downward. In the embodiment of Fig.
5A, the foam
pillars 556 would typically have a square rectangular outer surface (and/or
cross-section) of about
2 inches by 2 inches, and the gaps/grooves 557 forming the grid resulting in
the foam pillars might
typically have a width of about 0.375 inches and a depth of about 1.75 inches.
So for example, the
gaps/grooves in the middle sculpted layer might typically have a depth ranging
from about 1/2 to
2/3 the total height for the middle sculpted layer, for example about 55-60%
in some exemplary
embodiments. In addition, the joined bases of the foam pillars of the middle
sculpted layer 560
typically would have a plurality of pinholes 555 (e.g. essentially vertical
air passageways), as will
be described in greater detail below. Typically, the pinholes 555 of the
middle sculpted foam
layer 560 would be spaced and/or oriented/located the same (identically) as
the pinholes 265 in the
transition foam layer 260 (and typically also the same as the layers located
above it), with the
pinholes 555 aligning vertically with the pinholes 265. And typically, at
least some of the
pinholes 555/265 would also align with pinholes in the base layer 242 (e.g.
the sculpted foam
element 243 of the base layer). For example, every other pinhole 555, 265
might align with a
pinhole (and groove/gap 247) in the sculpted foam element 243 of the base
layer 242.
[0076]
The middle layer 560 may also comprise an additional set of pillars 552
located on the
top surface of the middle layer 560. In the embodiment of Fig. 5A, the top
pillars 552 may be
sized the same (identical) as the bottom pillars 554. In the embodiment of
Fig. 5A, the pinholes
555 may align with every groove 557 in the bottom pillars 554, and the
pinholes 555 may align
with every groove 553 in the top pillars 552.
37

CA 02956830 2017-01-31
100771 Figs. 6A-6B illustrate detailed views of the middle sculpted foam
layers 550 and 560.
The middle sculpted foam layer 550 of Fig. 6A may comprise top pillars 552 and
bottom pillars
554 that differ in size. For example, the top pillars 552 may typically have a
square rectangular
outer surface (and/or cross-section) of about 2 inches by 2 inches, while the
bottom pillars 554
may typically have a square rectangular outer surface (and/or cross-section)
of about 4 inches by 4
inches. The middle sculpted foam layer 560 of Fig. 6B may comprise top pillars
552 and bottom
pillars 554 that are the same in size. For example, the top pillars 552 may
typically have a square
rectangular outer surface (and/or cross-section) of about 2 inches by 2
inches, and the bottom
pillars 556 may also typically have a square rectangular outer surface (and/or
cross-section) of
about 2 inches by 2 inches. Typically, the foam pillars of the middle sculpted
foam layer would
be sized with respect to the pillars of the base layer of foam within a range
including 1-to-1 ¨ 4-to-
1 with respect to cross-section (such that the foam pillars of the middle
sculpted foam layer each
range in size from being equally sized to the base layer pillars down to being
a quarter the size of the
base layer pillars (i.e. four middle sculpted layer pillars per one base layer
pillar)), with each top
foam pillar of the middle sculpted foam layer often being equally sized and
each bottom foam pillar
of the middle sculpted foam layer often being equally sized. So for example,
the base layer foam
pillars might be 4x4 inches in cross-section, and the middle sculpted foam
layer might have pillars
that are 4x4 inches or 2x2 inches (for example, the bottom pillars of the
middle sculpted foam layer
could be 4x4 inches or 2x2 inches, while the top pillars of the middle
sculpted foam layer could be
2x2 inches (or 4x4 inches)).
[0078] Additionally, the pinholes 555 in the middle sculpted layers 550 and
560 may align
with the grooves 557 in the bottom pillars 554/556 in both embodiments.
Therefore, the pinholes
555 of the middle sculpted layer 550 of Fig. 6A may be fewer in number and
spaced differently
than the pinholes 555 of the middle sculpted layer 560 of Fig. 6B.
38

CA 02956830 2017-01-31
[0079] In the embodiment shown in Fig. 6A, the middle sculpted foam layer
550 may be
formed of one piece of foam, wherein the pillars 552/554 and pinholes 555 may
be formed by
sculpting and/or molding a single piece of foam. In the embodiment shown in
Fig. 6B, the middle
sculpted foam layer 560 may be formed of one piece of foam, wherein the
pillars 552/556 and
pinholes 555 may be formed by sculpting and/or molding a single piece of foam.
[0080] Figs. 7A-7B illustrate alternative detailed views of the middle
sculpted foam layers 550
and 560. In Figs. 7A-7B, the middle layers 550 and 560 may comprise two
different types of foam
joined together using adhesive. The middle layers 550 and 560 may be similar
to those described
in Figs. 6A-6B, except that the layers may be formed of two pieces of foam
instead of one.
[0081] In the embodiment shown in Fig. 7A, the middle sculpted foam layer
550 may be
formed of two pieces of foam, wherein the pillars 552 and partial pinholes 555
may be formed by
sculpting and/or molding a first piece of foam 720, and the pillars 554 and
partial pinholes 555
may be formed by sculpting and/or molding a second piece of foam 722. Then,
the two pieces of
foam 720 and 722 may be joined together and laminated to form the middle
sculpted foam layer
550.
[0082] In the embodiment shown in Fig. 7B, the middle sculpted foam layer
560 may be
formed of two pieces of foam, wherein the pillars 552 and partial pinholes 555
may be formed by
sculpting and/or molding a first piece of foam 720, and the pillars 556 and
partial pinholes 555
may be formed by sculpting and/or molding a second piece of foam 724. Then,
the two pieces of
foam 720 and 724 may be joined together and laminated to form the middle
sculpted foam layer
560.
[0083] Fig. 8 illustrates an exemplary base foam layer 242 similar to that
shown and described
in Fig. 3.
39

CA 02956830 2017-01-31
[0084] For additional details that may be relevant for some embodiments
(particularly some
mattress embodiments and/or systems having mattress embodiments), U.S. Patent
Application
Serial No. 14/681,278 (entitled "Independent Foam Spring Mattress" and filed
April 8, 2015,
along with related provisional patent application no. 61/977,989 entitled
"Independent Foam
Spring Mattress" and filed April 10, 2014) is hereby incorporated by reference
for all purposes as
if reproduced in its entirety to the extent that it is compatible (e.g. not
inconsistent) with and/or
does not directly contradict disclosure herein (e.g. the explicit disclosure
herein would always
govern/trump in instances of contradiction, inconsistency, or
incompatibility). Specifically,
details about the foam layers and/or formation of the foam layers from the
incorporated by
reference U.S. Patent Applications might be used in some embodiments (for
example, within a
mattress cover as described herein).
[0085] While various embodiments in accordance with the principles
disclosed herein have been
shown and described above, modifications thereof may be made by one skilled in
the art without
departing from the spirit and the teachings of the disclosure. The embodiments
described herein are
representative only and are not intended to be limiting. Many variations,
combinations, and
modifications are possible and are within the scope of the disclosure.
Alternative embodiments that
result from combining, integrating, and/or omitting features of the
embodiment(s) are also within the
scope of the disclosure. Accordingly, the scope of protection is not limited
by the description set out
above, but is defined by the claims which follow, that scope including all
equivalents of the subject
matter of the claims. Each and every claim is incorporated as further
disclosure into the
specification and the claims are embodiment(s) of the present invention(s).
Furthermore, any
advantages and features described above may relate to specific embodiments,
but shall not limit the
application of such issued claims to processes and structures accomplishing
any or all of the above
advantages or having any or all of the above features.

CA 02956830 2017-01-31
[0086] Additionally, the section headings used herein are provided for
consistency with the
suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues.
These headings shall
not limit or characterize the invention(s) set out in any claims that may
issue from this disclosure.
Specifically and by way of example, although the headings might refer to a
"Field," the claims
should not be limited by the language chosen under this heading to describe
the so-called field.
Further, a description of a technology in the "Background" is not to be
construed as an admission
that certain technology is prior art to any invention(s) in this disclosure.
Neither is the "Summary"
to be considered as a limiting characterization of the invention(s) set forth
in issued claims.
Furthermore, any reference in this disclosure to "invention" in the singular
should not be used to
argue that there is only a single point of novelty in this disclosure.
Multiple inventions may be set
forth according to the limitations of the multiple claims issuing from this
disclosure, and such claims
accordingly define the invention(s), and their equivalents, that are protected
thereby. In all
instances, the scope of the claims shall be considered on their own merits in
light of this disclosure,
but should not be constrained by the headings set forth herein.
[0087] Use of broader terms such as "comprises", "includes", and "having"
should be
understood to provide support for narrower terms such as "consisting of',
"consisting essentially
of', and "comprised substantially of'. Use of the terms "optionally," "may,"
"might," "possibly,"
and the like with respect to any element of an embodiment means that the
element is not required, or
alternatively, the element is required, both alternatives being within the
scope of the embodiment(s).
Also, references to examples are merely provided for illustrative purposes,
and are not intended to
be exclusive.
[0088] While several embodiments have been provided in the present
disclosure, it should be
understood that the disclosed systems and methods may be embodied in many
other specific forms
without departing from the spirit or scope of the present disclosure. The
present examples are to be
41

CA 02956830 2017-01-31
considered as illustrative and not restrictive, and the intention is not to be
limited to the details given
herein. For example, the various elements or components may be combined or
integrated in another
system or certain features may be omitted or not implemented.
[0089]
Also, techniques, systems, subsystems, and methods described and illustrated
in the
various embodiments as discrete or separate may be combined or integrated with
other systems,
modules, techniques, or methods without departing from the scope of the
present disclosure. Other
items shown or discussed as directly coupled or communicating with each other
may be indirectly
coupled or communicating through some interface, device, or intermediate
component, whether
electrically, mechanically, or otherwise. Other examples of changes,
substitutions, and alterations
are ascertainable by one skilled in the art and could be made without
departing from the spirit and
scope disclosed herein.
42

Representative Drawing