Note: Descriptions are shown in the official language in which they were submitted.
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MATTRESSES, CUSHIONS, AND BODY-SUPPORT PADS OR MATS HAVING VOIDS
AND GROOVES ON AT LEAST ONE SURFACE
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application includes subject matter that is similar to that of
U.S. Provisional Patent
Application No. 63/164,011, filed March 22, 2021, and entitled Foam
Mattresses, Foam
Cushions, and Foam Body-Support Pads or Mats, of U.S. Provisional Patent
Application No.
63/179,813, filed April 26, 2021, and entitled Mattresses, Cushions, and Body-
Support Pads or
Mats Having Polymer Feet, of U.S. Provisional Patent Application No.
63/210,306, filed June
14, 2021, and entitled Mattresses, Cushions, and Body-Support Pads or Mats
Having Voids and
Grooves, and of U.S. Provisional Patent Application No. 63/241,089, filed
September 6, 2021,
and entitled Mattresses, Cushions, and Body-Support Pads or Mats Having Voids
and Grooves
on At Least One Surface, the entire contents of all of which are hereby
expressly incorporated by
reference in their entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure generally relates to mattresses, cushions, and
body-support pads
or mats and more particularly to mattresses, cushions and body-support pads or
mats having
voids and grooves on at least one surface.
BACKGROUND
[0003] Consumers often purchase and utilize bed assemblies with adjustable
bases. Bed
assemblies with adjustable bases can be convenient and enable a user to adjust
the base of the
bed so that a mattress supporting the user and positioned on top of the base
can support the user
at a desired ergonomic position. Movement of the adjustable base will cause a
mattress located
on top of the adjustable base to shift or move. Various techniques have been
used to control
mattress movement so that the mattress maintains its position centered on the
adjustable base.
For example, retainer bar assemblies may be secured to the foot portion of the
adjustable base
and/or at the head portion of the adjustable base in order to prevent the
mattress from sliding or
lifting in response to the adjustable base inclining or folding. Various other
fixation devices are
also used to limit movement of the mattress relative to the adjustable base
and to keep the
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mattress in place so that a user does not have to readjust the mattress
positioning when the
adjustable base inclines or folds. Although this provides many advantages,
these measures
intended to limit the movement of the mattress and keep the mattress in place
may also cause
compression near the midpoint or pivot point of the mattress. In particular,
inclining the head
portion of the adjustable base and/or the foot portion of the adjustable base
past a certain angle
may cause the midpoint or pivot point of the mattress to bunch in the mattress
material due to the
folding or compression of the mattress.
[0004] When the adjustable base is set to incline at a relatively large angle,
the bunching of the
material near the midpoint or pivot point can lead to ridges on the surface of
the mattress that
become more pronounced the larger the incline of the mattress. These ridges
and bunching can
feel uncomfortable to a user resting on the mattress. In some cases, the
ridges formed from the
mattress bunching may not be as soft as the rest of the mattress, and this
harder surface could
potentially even result in a user developing sores or bruising in the regions
of the body that are in
contact with the ridges. Thus, a need exists to reduce the likelihood that
ridges will form on the
surface of the mattress when the mattress is compressed or folded as a result
of inclining the
adjustable base.
[0005] Another disadvantage that results from the ridges formed in a mattress
due to
compression or folding relates to mattress packing. One process often used to
facilitate transport
of a mattress is to fold or roll the mattress into a box for transportation
and shipment. The rolling
or folding can also result in ridges forming on the surface of the mattress.
When the mattress is
rolled or folded the ridges may cause air pockets that can take up space.
These air pockets may
limit the ability of the mattress to be folded or packed into a smaller box or
package. Thus, a
need exists to reduce the likelihood that ridges will form on the surface of
the mattress, which
may cause air pockets to form during folding, rolling, and packing.
[0006] While certain aspects of conventional technologies have been discussed
to facilitate
disclosure of the invention, Applicants in no way disclaim these technical
aspects, and it is
contemplated that the claimed invention may encompass one or more of the
conventional
technical aspects discussed herein.
[0007] In this specification, where a document, act or item of knowledge is
referred to or
discussed, this reference or discussion is not an admission that the document,
act or item of
knowledge or any combination thereof was, at the priority date, publicly
available, known to the
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public, part of common general knowledge, or otherwise constitutes prior art
under the
applicable statutory provisions; or is known to be relevant to an attempt to
solve any problem
with which this specification is concerned.
SUMMARY
[0008] Shortcomings of the prior art are overcome and additional advantages
are provided
through improved mattress, cushions, and body-support pads or mats disclosed
herein. In
particular, disclosed herein are mattresses, cushions, and body-support pads
or mats that include
a polymer such as a polymeric foam (e.g. Toluene Diisocyanate (TDI) foam or
Methylenediphenyl diisocyanate (MDI) foam), or an elastomer. The polymer may
include a first
plurality of voids, gaps, or grooves located on the underside or lower surface
of the polymer.
Advantageously, the first plurality of voids, gaps, or grooves may allow for
the polymer to fold
or bend without causing the bunching and ridges on the top or resting surface
of the mattress that
is the side opposite the bottom side or underside that includes the first
plurality of voids, gaps, or
grooves. The polymer may further include a second plurality of voids, gaps, or
grooves located
on the topside or upper surface of the polymer. Advantageously, the second
plurality of voids,
gaps, or grooves may further allow for the polymer to fold or bend without
causing the bunching
and ridges on the top or resting surface of the mattress that is the side
opposite the bottom side or
underside that includes the first plurality of voids, gaps, or grooves.
[0009] It is also contemplated that the improved mattresses, cushions, and
body-support pads or
mats may prove useful in addressing other problems and deficiencies in a
number of technical
area. Therefore, the disclosed mattresses, cushions, and body-support pads or
mats should not
necessarily be construed as limited to addressing any of the particular
problems or deficiencies
discussed herein.
[0010] Certain embodiments of the presently disclosed mattresses, cushions,
and body-support
pads or mats have several features, no single one of which is solely
responsible for their
desirable attributes. Without limiting the scope of the mattresses, cushions,
and body-support
pads or mats as defined by the claims that follow, their more prominent
features will now be
discussed briefly. After considering this discussion, and particularly after
reading the section of
this specification entitled "Detailed Description," one will understand how
the features of the
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various embodiments disclosed herein provide a number of advantages over the
current state of
the art.
[0011] In one aspect, disclosed herein is a mattress that includes polymer
defining a length and a
width of the mattress. The polymer spans a depth that is perpendicular to the
length and the
width of the mattress and extends from an upper surface of the polymer that is
proximate to
where a user rests to a lower surface of the polymer, where the lower surface
is opposite the
upper surface that is proximate to where the user rests. The mattress further
includes a first
plurality of voids in the polymer that traverse at least a portion of the
width of the mattress,
where the first plurality of voids are located at the lower surface, and where
the first plurality of
voids are defined by polymer walls of the polymer. The mattress also includes
a first plurality of
polymer feet, wherein each polymer foot of the first plurality of polymer feet
is defined by one or
more walls of the polymer walls. Additionally, the mattress includes a
plurality of lower surface
regions, where a first region of the plurality of lower surface regions
includes multiple feet of the
first plurality of polymer feet and at least one foot having a first size, and
a second region of the
plurality of lower surface regions includes at least one other foot of the
first plurality of polymer
feet that has a second size. Further, the at least one other foot having the
second size spans a
greater distance along the length of the mattress than the at least one foot
having the first size.
[0012] In another aspect disclosed herein is a cushion that includes polymer
defining a length
and a width of the cushion. The polymer spans a depth that is perpendicular to
the length and the
width of the cushion and extends from an upper surface of the polymer that is
proximate to
where a user rests to a lower surface of the polymer, where the lower surface
is opposite the
upper surface that is proximate to where the user rests. The cushion further
includes a first
plurality of voids in the polymer that traverse at least a portion of the
width of the cushion, where
the first plurality of voids are located at the lower surface, and where the
first plurality of voids
are defined by polymer walls of the polymer. The cushion also includes polymer
feet, wherein
each polymer foot of the polymer feet is defined by one or more walls of the
polymer walls.
Additionally, the cushion includes a plurality of lower surface regions, where
a first region of the
plurality of lower surface regions includes multiple feet of the polymer feet
and at least one foot
having a first size, and a second region of the plurality of lower surface
regions includes at least
one other foot of the polymer feet that has a second size. Further, the at
least one other foot
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having the second size spans a greater distance along the length of the
cushion than the at least
one foot having the first size.
[0013] In another aspect disclosed herein is a body-support pad or mat that
includes polymer
defining a length and a width of the body-support pad or mat. The polymer
spans a depth that is
perpendicular to the length and the width of the body-support pad or mat and
extends from an
upper surface of the polymer that is proximate to where a user rests to a
lower surface of the
polymer, where the lower surface is opposite the upper surface that is
proximate to where the
user rests. The body-support pad or mat further includes a first plurality of
voids in the polymer
that traverse at least a portion of the width of the body-support pad or mat,
where the first
plurality of voids are located at the lower surface, and where the first
plurality of voids are
defined by polymer walls of the polymer. The body-support pad or mat also
includes polymer
feet, wherein each polymer foot of the polymer feet is defined by one or more
walls of the
polymer walls. Additionally, the body-support pad or mat includes a plurality
of lower surface
regions, where a first region of the plurality of lower surface regions
includes multiple feet of the
polymer feet and at least one foot having a first size, and a second region of
the plurality of lower
surface regions includes at least one other foot of the polymer feet that has
a second size.
Further, the at least one other foot having the second size spans a greater
distance along the
length of the body-support pad or mat than the at least one foot having the
first size.
[0014] In another aspect, disclosed herein is a mattress that includes polymer
defining a length
and a width of the mattress. The polymer spans a depth that is perpendicular
to the length and
the width of the mattress and extends from an upper surface of the polymer
that is proximate to
where a user rests to a lower surface of the polymer, where the lower surface
is opposite the
upper surface that is proximate to where the user rests. The mattress further
includes a first
plurality of voids in the polymer that traverse at least a first portion of
the width of the mattress,
where the first plurality of voids are located at the lower surface, and where
the first plurality of
voids are defined by polymer walls of the polymer. The mattress also includes
a first plurality of
polymer feet, wherein each polymer foot of the first plurality of polymer feet
is defined by one or
more walls of the polymer walls. Additionally, the mattress includes a
plurality of lower surface
regions, where a first region of the plurality of lower surface regions
includes multiple feet of the
first plurality of polymer feet and at least one foot having a first size, and
a second region of the
plurality of lower surface regions includes at least one other foot of the
first plurality of polymer
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feet that has a second size. Further, the at least one other foot having the
second size spans a
greater distance along the length of the mattress than the at least one foot
having the first size.
The mattress further includes a second plurality of voids in the polymer that
traverse at least a
second portion of the width of the mattress, where the second plurality of
voids are located at the
upper surface, and where the second plurality of voids are defined by the
polymer walls of the
polymer. The mattress also includes a second plurality of polymer feet,
wherein each polymer
foot of the second plurality of polymer feet is defined by one or more walls
of the polymer walls.
Additionally, the mattress includes a plurality of upper surface regions,
where a first region of
the plurality of upper surface regions includes multiple feet of the second
plurality of polymer
feet and at least one foot having a third size, and a second region of the
plurality of upper surface
regions includes at least one other foot of the second plurality of polymer
feet that has a fourth
size. Further, the at least one other foot having the fourth size spans a
greater distance along the
length of the mattress than the at least one foot having the third size.
[0015] In another aspect, disclosed herein is a cushion that includes polymer
defining a length
and a width of the cushion. The polymer spans a depth that is perpendicular to
the length and the
width of the cushion and extends from an upper surface of the polymer that is
proximate to
where a user rests to a lower surface of the polymer, where the lower surface
is opposite the
upper surface that is proximate to where the user rests. The cushion further
includes a first
plurality of voids in the polymer that traverse at least a first portion of
the width of the cushion,
where the first plurality of voids are located at the lower surface, and where
the first plurality of
voids are defined by polymer walls of the polymer. The cushion also includes a
first plurality of
polymer feet, wherein each polymer foot of the first plurality of polymer feet
is defined by one or
more walls of the polymer walls. Additionally, the cushion includes a
plurality of lower surface
regions, where a first region of the plurality of lower surface regions
includes multiple feet of the
first plurality of polymer feet and at least one foot having a first size, and
a second region of the
plurality of lower surface regions includes at least one other foot of the
first plurality of polymer
feet that has a second size. Further, the at least one other foot having the
second size spans a
greater distance along the length of the cushion than the at least one foot
having the first size.
The cushion further includes a second plurality of voids in the polymer that
traverse at least a
second portion of the width of the cushion, where the second plurality of
voids are located at the
upper surface, and where the second plurality of voids are defined by the
polymer walls of the
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polymer. The cushion also includes a second plurality of polymer feet, wherein
each polymer
foot of the second plurality of polymer feet is defined by one or more walls
of the polymer walls.
Additionally, the cushion includes a plurality of upper surface regions, where
a first region of the
plurality of upper surface regions includes multiple feet of the second
plurality of polymer feet
and at least one foot having a third size, and a second region of the
plurality of upper surface
regions includes at least one other foot of the second plurality of polymer
feet that has a fourth
size. Further, the at least one other foot having the fourth size spans a
greater distance along the
length of the cushion than the at least one foot having the third size.
[0016] In another aspect, disclosed herein is a body-support pad or mat that
includes polymer
defining a length and a width of the body-support pad or mat. The polymer
spans a depth that is
perpendicular to the length and the width of the body-support pad or mat and
extends from an
upper surface of the polymer that is proximate to where a user rests to a
lower surface of the
polymer, where the lower surface is opposite the upper surface that is
proximate to where the
user rests. The body-support pad or mat further includes a first plurality of
voids in the polymer
that traverse at least a first portion of the width of the body-support pad or
mat, where the first
plurality of voids are located at the lower surface, and where the first
plurality of voids are
defined by polymer walls of the polymer. The body-support pad or mat also
includes a first
plurality of polymer feet, wherein each polymer foot of the first plurality of
polymer feet is
defined by one or more walls of the polymer walls. Additionally, the body-
support pad or mat
includes a plurality of lower surface regions, where a first region of the
plurality of lower surface
regions includes multiple feet of the first plurality of polymer feet and at
least one foot having a
first size, and a second region of the plurality of lower surface regions
includes at least one other
foot of the first plurality of polymer feet that has a second size. Further,
the at least one other
foot having the second size spans a greater distance along the length of the
body-support pad or
mat than the at least one foot having the first size. The body-support pad or
mat further includes
a second plurality of voids in the polymer that traverse at least a second
portion of the width of
the body-support pad or mat, where the second plurality of voids are located
at the upper
surface, and where the second plurality of voids are defined by the polymer
walls of the polymer.
The body-support pad or mat also includes a second plurality of polymer feet,
wherein each
polymer foot of the second plurality of polymer feet is defined by one or more
walls of the
polymer walls. Additionally, the body-support pad or mat includes a plurality
of upper surface
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regions, where a first region of the plurality of upper surface regions
includes multiple feet of the
second plurality of polymer feet and at least one foot having a third size,
and a second region of
the plurality of upper surface regions includes at least one other foot of the
second plurality of
polymer feet that has a fourth size. Further, the at least one other foot
having the fourth size
spans a greater distance along the length of the body-support pad or mat than
the at least one foot
having the third size.
[0017] These and other features and advantages of the disclosure and
inventions will become
apparent from the following detailed description of the various aspects of the
invention taken in
conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Aspects described herein are particularly pointed out and distinctly
claimed as examples
in the claims at the conclusion of the specification. The foregoing and other
objects, features,
and advantages of the disclosure are apparent from the following detailed
description taken in
conjunction with the accompanying drawings, which are not necessarily drawn to
scale, wherein:
[0019] FIG. 1 depicts an elevational perspective view of a mattress and
adjustable base,
according to the prior art;
[0020] FIG. 2 depicts an elevational perspective view of a polymer of a
mattress and an
adjustable base, according to the present disclosure;
[0021] FIG. 3A depicts an elevational perspective view of a polymer of a
mattress and an
adjustable base, according to the present disclosure;
[0022] FIG. 3B depicts an elevational perspective view of the polymer of the
mattress and
adjustable base of FIG. 3A with an additional void at the foot portion of the
polymer of the
mattress, according to the present disclosure;
[0023] FIG. 3C depicts an elevational perspective view of the polymer of the
mattress and
adjustable base of FIG. 3A with a plurality of additional voids at the foot
portion of the polymer
of the mattress, according to the present disclosure;
[0024] FIG. 4A depicts a bottom view of a polymer of a mattress with a
plurality of voids
extending the width of the polymer of the mattress, according to the present
disclosure;
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[0025] FIG. 4B depicts a bottom view of the polymer of the mattress of FIG. 4A
with an
additional void extending the length of the polymer of the mattress, according
to the present
disclosure;
[0026] FIG. 4C depicts a bottom view of the polymer of the mattress of FIG. 4A
with multiple
voids extending the length of the polymer of the mattress, according to the
present disclosure;
[0027] FIG. 4D depicts a bottom view of the polymer of the mattress of FIG. 4A
with multiple
voids extending the length of the polymer of the mattress, according to the
present disclosure;
[0028] FIG. 4E depicts a bottom view of the polymer of the mattress of FIG. 4A
with multiple
voids extending the length of the polymer of the mattress, according to the
present disclosure;
[0029] FIG. 5A depicts a side view of a polymer of a mattress with a plurality
of voids along the
length of the polymer of the mattress, according to the present disclosure;
[0030] FIG.5B depicts a side view of a polymer of a mattress with a plurality
of voids along the
length of the polymer of the mattress, according to the present disclosure;
[0031] FIG. 5C depicts a side view of a polymer of a mattress with a plurality
of voids along the
length of the polymer of the mattress, according to the present disclosure;
[0032] FIG. 5D depicts a side view of a polymer of a mattress with a plurality
of voids along the
length of the polymer of the mattress, according to the present disclosure;
[0033] FIG. 6A depicts a side view of a polymer of a mattress with multiple
grooves situated
along the width of the polymer of the mattress, according to the present
disclosure;
[0034] FIG. 6B depicts a side view of a polymer of a mattress with multiple
grooves situated
along the width of the polymer of the mattress, according to the present
disclosure;
[0035] FIG. 6C depicts a side view of a polymer of a mattress with multiple
grooves situated
along the width of the polymer of the mattress, according to the present
disclosure;
[0036] FIG. 7 depicts a side view of a polymer of a mattress with a plurality
of dual-sided voids
along the length of the polymer of the mattress, according to the present
disclosure; and
[0037] FIG. 8 depicts a side view of a polymer of a mattress with a plurality
of dual-sided voids
along the length of the polymer of the mattress, according to the present
disclosure.
DETAILED DESCRIPTION
[0038] Aspects of the present disclosure and certain features, advantages, and
details thereof,
are explained more fully below with reference to the non-limiting embodiments
illustrated in the
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accompanying drawings. Descriptions of well-known materials, fabrication
tools, processing
techniques, etc., are omitted so as to not unnecessarily obscure the details
of the inventions. It
should be understood, however, that the detailed description and the specific
example(s), while
indicating embodiments of inventions of the present disclosure, are given by
way of illustration
only, and are not by way of limitation. Various substitutions, modifications,
additions and/or
arrangements within the spirit and/or scope of the underlying inventive
concepts will be apparent
to those skilled in the art from this disclosure.
[0039] Approximating language, as used herein throughout disclosure, may be
applied to
modify any quantitative representation that could permissibly vary without
resulting in a change
in the basic function to which it is related. Accordingly, a value modified by
a term or terms,
such as "about" or "substantially," is not limited to the precise value
specified.
[0040] Described herein are mattresses, cushions and body-support pads or mats
that include a
polymer. The polymer defines a length and a width of the respective mattress,
cushion, or body-
support pad or mat. Further, the polymer spans a depth that is perpendicular
to the length and the
width, where the depth extends from an upper surface of the polymer that is
proximate to where
a user rests to a lower surface of the polymer that is opposite the upper
surface. The polymer
includes a first plurality of voids, gaps, or grooves that traverse a portion
of the width and/or the
length of the respective mattress, cushion, or body-support pad or mat, where
the first plurality of
voids, gaps, or grooves are located in the lower surface and are defined by
polymer walls of the
polymer. The first plurality of voids, gaps, or grooves in the polymer allow
for the respective
mattress, cushion, or body-support pad or mat to fold or bend in a manner that
reduces bunching
and ridges that typically form on the top or resting surface that supports the
user when
folding/bending the respective mattress, cushion, or body-support pad or mat.
The first plurality
of voids, gaps, or grooves in the polymer also allow for the respective
mattress, cushion, or
body-support pad or mat to be packed in a reduced volume and/or weight, which
can lower
shipping cost.
[0041] The polymer may further include a second plurality of voids, gaps, or
grooves located
in the upper surface of the polymer that traverse a portion of the width
and/or the length of the
respective mattress, cushion, or body-support pad or mat. The second plurality
of voids, gaps, or
grooves are located in the upper surface and are defined by polymer walls of
the polymer.
Advantageously, the second plurality of voids, gaps, or grooves may further
allow for the
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polymer to fold or bend without causing the bunching and ridges on the top or
resting surface of
the respective mattress, cushion, or body-support pad or mat that is the side
opposite the lower
surface that includes the first plurality of voids, gaps, or grooves. The
second plurality of voids,
gaps, or grooves in the polymer also allow for the respective mattress,
cushion, or body-support
pad or mat to be packed in a reduced volume and/or weight, which can lower
shipping cost.
[0042] For instance, as depicted in FIG. 1, existing mattresses such as
mattress 100 that are
folded or bent in response to an adjustable base/frame 150 being inclined
typically causes
bunching or ridges 199 near the midpoint or pivot point of the mattresses as
depicted in mattress
100. The bunching and ridges 199 can cause discomfort and provide a hardened
surface that can
cause bedsores or bruising to a user.
[0043] In contrast, mattresses, cushions, and body-support pads or mats that
include polymers
having a plurality of voids, gaps and/or grooves that traverse a portion of
the width and/or length
of the mattress reduce the likelihood that ridges or bunching will form on the
upper/resting
surface from folding or bending the mattress.
[0044] Referring now to FIG. 2, a mattress 200 and adjustable base/frame 250
are depicted. In
particular, the mattress 200 includes one or more polymer. Although not
depicted in FIG. 2, the
one or more polymer may be at least partially enclosed by a mattress cover
according to various
embodiments. For instance, the one or more polymer may be fully enclosed by
the mattress
cover. Further, the mattress cover may form the uppermost surface of the
mattress that is
proximate to where a user of the mattress rests as well as the bottommost
surface that is in
contact with the base 250. According to some embodiments, a fire-resistant
material may be
located near the uppermost surface, and in particular located between the
mattress cover and the
upper surface of the one or more polymer. According to various embodiments,
the mattress
cover may include a fabric that has a stretch capacity within a range of about
1% stretch to about
50% stretch, or more particularly within a range of about 10% stretch to about
40% stretch, 20%
stretch to about 35% stretch, or at about 35% stretch. According to various
embodiments, the
fabric having the stretch capacity may be positioned along one or more sides
that span the depth
of the mattress. According to various embodiments, the fabric having the
stretch capacity may
additionally, or alternatively, be positioned along a bottom surface of the
mattress 200. Further,
the one or more polymer may be formed of isocyanate and polyol. In some
embodiments, the
one or more polymer may include polyisocyanurate and/or polyurethane. In
various
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embodiments, the one or more polymer (or portions thereof) may additionally,
or alternatively,
include an elastomer such as latex.
[0045] As shown in FIG. 2, at least one of the one or more polymer of the
mattress 200
includes a first plurality of voids 214 that traverse at least a portion of
the width W1 of the
mattress 200. Further, the first plurality of voids 214 are located about or
in the lower surface
203 of the polymer of the mattress 200, where the lower surface 203 is
opposite the upper
surface 201 of the polymer or the mattress 200. The polymer spans a depth D1
that extends from
the upper surface 201 to the lower surface 203. Various embodiments of the
polymer may
include one or more layers such as a first layer 234 proximate the upper
surface 201 and a second
layer 230 proximate the lower surface 203. Further, a third layer 232 may be
located between
the first layer 234 and the second layer 230. According to various
embodiments, at least one
layer of the multiple layers may include a different density than at least one
other layer of the
multiple layers. For instance, the first layer 234 may be less dense and
softer than the second
layer 230 and/or third layer 232. Also according to various embodiments, one
or more of the
layers of the multiple layers may include an additive such as, for example, a
phase change
material, calcium carbonate, silica, fly ash, barium sulfate, hydrocarbon
gels, magnetic or
magnetizable materials, foam digesters, etc. The one or more layers may also
comprise different
material compositions. For example, the first layer 234 may include a
polymeric foam, and the
second layer 230 and/or third layer 232 may include an elastomer. Various
other modifications
and configurations are also contemplated herein.
[0046] The first plurality of voids 214 are defined by polymer walls such as
walls 290, 292
depicted in FIG. 2 that define void 218. The voids 214 allow for separation of
the walls when
the mattress 200 is folded or bent, which is why the void 218 depicted near
the axis point or the
point of the mattress 200 corresponding to the location 252 where the base 250
inclines appears
wider than the other voids 214. The first plurality of voids 214 depicted in
FIG. 2 are
substantially congruent and traverse the width W1 of the mattress 200.
However, when the
mattress 200 is not bent and the base 250 is flat, the void 218 is the same
width as the other voids
214. In various embodiments, the first plurality of voids 214 form a crease
separating a first wall
(e.g. wall 290) from a second wall (e.g. wall 292) where the one or more walls
that define the
first plurality of voids 214 further define polymer feet and the first wall
forms a first foot that is
separate from a second foot defined by the second wall. Specifically, each
polymer foot of the
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polymer feet is defined by one or more walls of the polymer walls. Further,
the crease may
extend in the depth direction away from the lower surface 203 towards the
upper surface 201 and
stop at a cylindrical internal pocket 216 that is devoid of polymer and may be
proximal to the
upper surface 201.
[0047] The thickness of the voids 214 and the number of voids 214 directly
influence the size
of the polymer feet and the number of polymer feet. During formation of the
mattress 200, the
polymer may initially be devoid of any voids 214. After the polymer is cut or
molded to the
desired length Li and width Wl, portions of the polymer may be cut out and
removed from the
mattress 200 to form the voids 214. For example, if five voids are formed in
the lower surface
203 of the polymer, then the walls defining the voids would further define six
feet along the
lower surface 203 of the polymer. According to various embodiments, multiple
voids of the first
plurality of voids 214 may be regularly spaced at set intervals. In other
embodiments, the voids
214 may be placed at irregular intervals. According to various embodiments, at
least some of the
first plurality of voids 214 may be congruent and/or parallel, and according
to one embodiment,
all of the voids 214 may be congruent and/or parallel. The size of the voids
214 may also
determine of the polymer feet. For instance, if the voids 214 are relatively
thick, then the size
and thickness of the polymer feet may be smaller. According to various
embodiments, the voids
214 may be parallel channels that traverse the width of the mattress, and the
thickness of the
parallel channels may be within a range of about 0.1 inch to about 6 inches, a
range of about 1
inch to about 5 inches, a range of about 2 inches to about 4 inches, or more
specifically about 4
inches thick.
[0048] Additionally, the first plurality of voids 214 may have various
heights. According to
one embodiment, one void of the first plurality of voids 214 may be taller
than one or more other
voids of the first plurality of voids 214. In other embodiments, the first
plurality of voids 214
may be the same height or there may be one or more voids having a first height
and one or more
other voids having a second height. Further, in some embodiments, one or more
additional voids
may have a third height. The height of the first plurality of voids 214 may
extend in a depth
direction that corresponds to the depth D1 of the mattress 200. For example,
the one or more of
the voids 214 may extend away from the lower surface 203 and towards the upper
surface 201 a
height of at least one inch. In various embodiments, each of the voids 214 may
have a height of
at least one inch. Further, one or more of the voids of the first plurality of
voids 214 may extend
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in a depth direction corresponding to the depth D1 a distance/height within a
range of about 1
inch to about 5 inches, or more particular a distance of about 5 inches. For
instance, the total
depth D1 of the polymer of the mattress 200 may be 10 total inches, with the 4
inches most
proximate to the upper surface 201 having one or more layers and the lowermost
6 inches of the
polymer including a base material (e.g. polymeric foam, an elastomer, etc.)
into which the first
plurality of voids 214 are cut. One or more of the first plurality of voids
214 may extend the
entire height of the 6-inch base, or may only extend a height of 5 inches
extending from the
lower surface 203 towards the upper surface 201.
[0049] Advantageously, the larger (i.e. thicker and taller) the voids 214 and
the more polymer
that is removed, the more compactly the mattress 200 can fold or roll during
packing so that the
mattress 200 can be transported and shipped less expensively. Additionally, by
packing the
mattress into a smaller box or packaging, shipping and transportation costs
are reduced, the
mattress takes up less space on the shelves in stores, and it is easier for
consumers or delivery
companies to transport the mattress to homes. In some embodiments, the first
plurality of voids
214 may remove at least 5% volume of the polymer that defines the length and
width of the
mattress 200. In particular, the first plurality of voids 214 may remove
between 5% volume and
60% volume of the polymer that defines the length and width of the mattress,
between 10%
volume and 30% volume of the polymer defined by the length and width of the
mattress,
between 15% volume and 20% volume of the polymer defined by the length and the
width of the
mattress, or about 19% volume of the polymer defined by the length and the
width of the
mattress. Additionally, the first plurality of voids 214 may enable a cleaner
fold 240 when the
mattress 200 is inclined. By having a single fold 240 that bends inward rather
than forming
ridges that protrude from the upper surface 201 of the mattress 200, the
mattress 200 may be
more comfortable when positioned in an inclined position.
[0050] Further, the mattress 200 may include a plurality of regions, where
each region is
defined by the polymer feet and the plurality of regions correspond to a
plurality of lower surface
regions. For instance, a first region 202 may include a first lower surface
region of the polymer
that includes multiple polymer feet with at least one foot 210 of the multiple
polymer feet that
has a first size that is different from another polymer foot 212 of a lower
surface region that
corresponds to a second region 204 of the mattress 200. In particular, the
other foot 212 of the
polymer feet has a size that spans a greater distance along the length Li of
the mattress 200 than
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the at least one foot 210 that has the first size. Specifically, the other
foot 212 is thicker than the
at least one foot 210. According to various embodiments, the first region 202
may include
multiple voids, and the multiple voids may be parallel and/or congruent. In
various
embodiments, the second region 204 may include multiple voids defining the
feet such that the
second region 204 has one or more feet 212 that are larger in size than the
feet 210 of the first
region 202. According to various embodiments, the mattress 200 may also
include a third region
206 that includes at least two feet of the polymer feet 210. In one embodiment
the at least two
feet of the third region 206 may mirror, in size and in shape, multiple feet
of the first region 202
such that a foot of first region 202 is the same size as a foot of the third
region 206. In various
embodiments, one or more feet 212 of the second region 204 may be larger than
one or more feet
210 of the third region 206. In particular, at least one foot of the at least
two feet of the third
region 206 may have a size that is smaller and spans less of a distance along
the length of the
mattress 200 than at least one foot of the second region 204.
[0051] Further, according to various embodiments at least one polymer foot of
the polymer
feet extends the width of the mattress, multiple feet of the polymer feet
extend the width of the
mattress, or each foot of the polymer feet extends the width of the mattress.
[0052] FIGS. 3A-3C depict a mattress 300 that may comprise and/or may be
similar to the
mattress 200 described above with reference to FIG. 2, and the description
contained herein
directed thereto equally applies to mattress 300 but may not be repeated
herein for brevity sake.
Like or similar components and aspects of mattress 200 to mattress 300 of
FIGS. 3A-3C are
thereby indicated by like reference numerals preceded with "3". Mattress 300
is depicted with
the first region 302 being inclined and the third region 306 being raised but
to a lesser extent than
the first region 302. The first region 302 is inclined at a larger angle than
the third region 306,
and the two inclines still provide clean folds 340 near the midpoint of the
mattress 300. As
described above, the clean folds prevent ridges from protruding from the upper
surface 301 of
the mattress 300. The manner in which the base 350 is inclined with the larger
angle for the first
region 302 resulted in one void 318 widening due to the compressive forces
applied to the
polymer. In contrast, the manner in which the base 350 is inclined in the area
about the third
region 306 causes a void 320 to narrow such that one of the feet 310 of the
third region 306
contacts one of the feet 312 of the second region 304.
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[0053] Further, as depicted in FIGS. 3B and 3C, in addition to a plurality of
voids 314 that at
least partially traverse the width W1 of the mattress 300, the mattress 300
also includes at least
one groove 360 about or in the lower surface 303, where the at least one
groove 360 extends the
length Li of the mattress 300. According to various embodiments, the at least
one groove 360
includes multiple grooves. Further, according to various embodiments, a groove
of the at least
one groove 360 may have a height that extends in a depth direction
corresponding to the depth
D1 extending away from the lower surface 303 that is a height/distance of at
least one inch.
More particularly, according to various embodiments, one or more grooves of
the at least one
groove 360 may extend in the depth direction a height/distance within a range
of about 1 inch to
about 5 inches, or a height/distance of 5 inches. As described above with
respect to mattress
200, if the mattress 300 has a depth D1 of 10 inches with the base layer being
6 inches, the at
least one groove 360 may extend the full height of the base layer or traverse
the lower 5 inches
of the base layer. According to various embodiments where the at least one
groove 360 includes
multiple grooves, the multiple grooves may be the same height/distance, or one
or more of the
grooves have a first height and one or more other grooves have a second
height. Further,
multiple grooves of the at least one groove 360 may have a height of at least
one inch, a height
within a range of about 1 inch to about 5 inches, or have a height of about 5
inches. In some
embodiments, each groove of the multiple grooves may have a height of at least
one inch, a
height within a range of about 1 inch to about 5 inches, or have a height of
about 5 inches. As
depicted in FIG. 3C, the at least one groove 360 may include one or more first
grooves 362
having a first height and one or more other grooves 364 having a second
height. Additionally,
although not shown, one or more additional grooves may include a third height.
[0054] Additionally, the at least one groove 360 may include a thickness
within a range of
about 0.1 inch to about 6 inches, within a range of about 1 inch to about 5
inches, within a range
of about 2 inches to about 4 inches, or be about 4 inches. Advantageously, by
removing volume
from the polymer by the at least one groove 360, the mattress 300 may further
be more tightly
packed or compressed into a box or package for transportation and shipment.
According to one
embodiment, the at least one groove 360 may remove an additional volume beyond
the volume
already removed by the plurality of voids 314. According to various
embodiments, based on the
thickness, height, and number of grooves, the at least one groove 360 may
remove between 1%
volume and 60% volume of the polymer defined by the length Li and width W1 of
the mattress
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300, may remove between 5% and 30% volume, may remove between 10% and 20%
volume, or
may remove 19% volume.
[0055] Referring now to FIGS. 4A-4E, various embodiments of lower surfaces 403
of a
mattress 400 are depicted. Mattress 400 may comprise and/or may be similar to
the mattress 200
and/or mattress 300 described above with reference to FIGS. 2-3C, and the
description contained
herein directed thereto equally applies to mattress 400 but may not be
repeated herein for brevity
sake. Like or similar components and aspects of mattress 200 and mattress 300,
to mattress 400
of FIGS. 4A-4E are thereby indicated by like reference numerals preceded with
"4". The
mattress 400 includes a first region 402, a second region 404, and various
embodiments may
further include a third region 406. The first region 402 and third region 406
include smaller feet
410 than the larger feet 412 of the second region 404. The mattress 400 also
includes a plurality
of voids 414, where the number, thickness, and shape of the voids determine
the number, shape,
and size of the feet. As depicted in FIGS. 4B-4E, the mattress 400 may further
includes at least
one groove 460 that extends the length Li of the mattress 400. The number,
thickness, and
shape of the at least one groove 460 may impact the amount of polymer that is
removed, which
can allow for the mattress 400 to be folded and compressed to a greater extent
for packaging and
shipment.
[0056] FIGS. 5A-5D depict side views of a mattress 500 with a plurality of
voids 514 along the
length of the mattress 500. Mattress 500 may comprise and/or may be similar to
mattresses 200,
300 and/or 400 described above with reference to FIGS. 2-4E, and the
description contained
herein directed thereto equally applies to mattress 500 but may not be
repeated herein for brevity
sake. Like or similar components and aspects of mattresses 200, 300, 400, to
mattress 500 of
FIGS. 5A-5D are thereby indicated by like reference numerals preceded with
"5". Mattress 500
includes a first region 502, a second region 504 and a third region 506 with
the first region 502
and the third region 506 having feet 510 of a first size that are smaller than
the feet 512 of the
second region. The feet 510 of the first region 502 and/or third region 506
may not be identical
and may have various thicknesses, depths, shapes, etc. either within each
respective region (i.e.,
within first region 502 or within third region 506) or when comparing feet 510
of the first region
502 to feet 510 of the third region 506. Similarly the feet 512 of the second
region 504 may have
varying sizes, shapes, depths, etc., but all feet 512 of the second region 504
would span a greater
distance along the length Li of the mattress 500 (i.e., would be thicker) than
any of the feet 510
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of the first region 502 and/or third region 506. For example, referring to
FIG. 5A, foot 524 is
smaller in thickness than foot 522, which is also smaller in thickness than
foot 526. However,
feet 524, 522, and 526 are all larger than feet 510. Advantageously, by having
thicker feet 512 in
the second region 504, more support is provided to a user of the mattress 500
at the heaviest
areas of the user (e.g., the hips, midsection, and/or shoulders). The voids
514 can be more
frequent, thicker, deeper, larger, etc. in the first region 502 and the third
region 506 because there
is less weight applied by the user to these regions of the mattress 500.
Further, according to
various embodiments, the voids 514 may not traverse certain layers, such as
layers 532 or 534 of
the mattress 500 in order to provide a smooth resting surface upon which the
user rests.
[0057] As depicted in FIG. 5B, the shape of foot 525 of feet 512 is slightly
different than foot
523 of feet 512, even though both are larger than feet 510. The different
shapes may allow for
different amounts of support to the user at the user's pressure points in
order to provide
maximum support. Referring now to FIG. 5C, as depicted, the voids 514 may
include
rectangular channels 527, and the rectangular channels may have varying
thickness, which may
determine the size of the feet. For instance, the mattress 500 may include
rectangular channels
527 of a larger thickness 515 to form the smaller feet 510, and the mattress
500 may include
rectangular channels 527 of a smaller thickness 517 to form the larger feet
512. Referring now
to FIG. 5D, the voids 514 may include circular channels 519, which
advantageously may allow
the smaller feet 510 and/or the larger feet 512 to have more surface area in
contact with the base
situated below the mattress 500.
[0058] Referring now to FIGS. 6A-6B, a side view of a mattress 600 is depicted
that has
multiple grooves 660 situated along the width W1 of the mattress 600. Mattress
600 may
comprise and/or may be similar to mattresses 200, 300, 400 and/or 500
described above with
reference to FIGS. 2-5D, and the description contained herein directed thereto
equally applies to
mattress 600 but may not be repeated herein for brevity sake. Like or similar
components and
aspects of mattresses 200, 300, 400, 500 to mattress 600 of FIGS. 6A-6C are
thereby indicated
by like reference numerals preceded with "6". The mattress 600 may include
multiple layers
630, 632, 634, according to various embodiments, with the grooves 660 being
cut into the base
layer 630. The grooves 660 may include various heights such as height 662 or
height 664. The
different heights may be determined based on the amount of folding or rolling
that may occur
during packing at the various locations. For example, if the mattress 600
needs only a partial
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fold at a particular location, then a smaller height such as height 662 may be
preferred for that
particular location, whereas if a full fold is needed for packing then a
larger height such as height
664 may be preferred. Further, the mattress 600 may include a single groove or
a plurality of
grooves, and the grooves may have varying thicknesses.
[0059] According to various embodiments of mattresses 200, 300, 400, 500,
and/or 600
described above, any one of the aforementioned mattresses may further include
one or more
polymers having one or more perforations. For example, the one or more
perforations may at
least partially traverse the depth of the one or more polymers, or more
particularly may extend
the full depth of the one or more polymers. Further, the one or more
perforations may include a
diameter within a range of about 0.25 inches to about 3 inches, a range of
about 0.5 inches to
about 2 inches, a range of about 0.75 inches to about 1.5 inches, or more
particularly a diameter
of about 1 inch. The one or more perforations may remove at least 1% of a
total volume of the
one or more polymers. For instance, the one or more perforations may remove a
total volume of
the one or more polymers that is within a range of about 1% to about 20%, a
range of about 5%
to about 15%, a range of about 8% to about 12%, or about 10% total volume of
the one or more
polymers.
[0060] In some embodiments, the mattresses, cushions, and body-support pads or
mats disclosed
herein may comprise dual-sided voids, gaps and/or grooves. That is, a
respective mattress,
cushion, or body-support pad or mat may comprise a first plurality of voids,
gaps and/or grooves
located about or in the lower surface of the polymer of the respective
mattress, cushion, or body-
support pad or mat, and a second plurality of voids, gaps and/or grooves
located about or in the
upper surface of the polymer of the respective mattress, cushion, or body-
support pad or mat.
[0061] In one embodiment, the second plurality of voids, gaps, and/or grooves
may differ from
the first plurality of voids, gaps, and/or grooves in terms of at least one of
dimension,
configuration, and quantity of the voids, gaps and/or grooves, such as shape,
thickness, height,
number, and layout or arrangement of the voids, gaps and/or grooves. For
example, the first
plurality of voids, gaps and/or grooves located about or in the lower surface
of the polymer of the
respective mattress, cushion, or body-support pad or mat can be any one of the
voids and grooves
or combinations thereof described above in FIGS. 2-6C; and the second
plurality of voids, gaps
and/or grooves located about or in the upper surface of the polymer of the
respective mattress,
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cushion, or body-support pad or mat can be any other one of the voids and
grooves or
combinations thereof described above in FIGS. 2-6C.
[0062] In another embodiment, the second plurality of voids, gaps, and/or
grooves may be the
same as the first plurality of voids, gaps, and/or grooves in terms of at
least one of dimension,
configuration, and quantity of the voids, gaps and/or grooves, such as shape,
thickness, height,
number, and layout or arrangement of the voids, gaps and/or grooves. For
example, the first
plurality of voids, gaps and/or grooves located about or in the lower surface
of the polymer of the
respective mattress, cushion, or body-support pad or mat, and the second
plurality of voids, gaps
and/or grooves located about or in the upper surface of the polymer of the
respective mattress,
cushion, or body-support pad or mat, can both be any same one of the voids and
grooves or
combinations thereof described above in FIGS. 2-6C. For instance, the second
plurality of voids
and/or grooves may mirror the first plurality of voids and/or grooves with
respect to a middle
surface of the polymer of the respective mattress, cushion, or body-support
pad or mat. The
middle surface is located between and parallel to the upper surface and the
lower surface of the
polymer of the respective mattress, cushion, or body-support pad or mat.
[0063] In some embodiments, the second plurality of voids, gaps, and/or
grooves may be
arranged in the upper surface to offset the first plurality of voids, gaps,
and/or grooves in the
direction of the length and/or width of the respective mattress, cushion, or
body-support pad or
mat, such that the middle, center or symmetry line of at least one of the
second plurality of voids,
gaps, and/or grooves does not overlap with the middle, center or symmetry line
of corresponding
one of the first plurality of voids, gaps, and/or grooves. The middle, center
or symmetry line is a
vertical line in the direction of depth of the respective mattress, cushion,
or body-support pad or
mat. Such offset can provide a balanced pressure distribution on the polymer
of the respective
mattress, cushion, or body-support pad or mat when a user sits or lies on the
respective mattress,
cushion, or body-support pad or mat, which can provide desired load support
and comfort while
allowing for reducing the volume and/or weight of the respective mattress,
cushion, or body-
support pad or mat for decreasing shipping cost, in addition to prevention of
the bunching and
ridges caused by folding or bending without causing the respective mattress,
cushion, or body-
support pad or mat.
[0064] As disclosed herein, the description of the first plurality of voids,
gaps and/or grooves
located about or in the lower surface of the polymer of the respective
mattress, cushion, or body-
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support pad or mat as described above with reference to FIGS. 2-6C equally
applies to the
second plurality of voids, gaps and/or grooves located about or in the upper
surface of the
polymer of the respective mattress, cushion, or body-support pad or mat.
Therefore, detailed
description of the second plurality of voids, gaps and/or grooves may not be
repeated herein for
brevity sake.
[0065] Specifically, in addition to the first plurality of voids, gaps and/or
grooves located about
or in the lower surface of the polymer of the respective mattress, cushion, or
body-support pad or
mat as disclosed above in FIGS 2-6C, the respective mattress, cushion, or body-
support pad or
mat may further comprise a second plurality of voids, gaps and/or grooves
located about or in the
upper surface of the at least one polymer of the one or more polymers of the
respective mattress,
cushion, or body-support pad or mat. The second plurality of voids and/or
grooves may traverse
at least a second portion of the width and/or length of the respective
mattress, cushion, or body-
support pad or mat. The second plurality of voids and/or grooves are also
defined by the
corresponding polymer walls located about or in the upper surface of the at
least one polymer of
the one or more polymers of the respective mattress, cushion, or body-support
pad or mat.
[0066] Accordingly, the second plurality of voids and/or grooves define a
second plurality of
polymer feet, wherein each polymer foot of the second plurality of polymer
feet is defined by
one or more walls of the corresponding polymer walls located about or in the
upper surface.
[0067] Similarly, the respective mattress, cushion, or body-support pad or mat
may further
comprise a plurality of upper surface regions, wherein a first region of the
plurality of upper
surface regions includes at least one foot of the second plurality of polymer
feet that has a third
size, and wherein a second region of the plurality of upper surface regions
includes at least one
other foot of the second plurality of polymer feet that has a fourth size. The
at least one other
foot having the fourth size spans a greater distance along the length of the
respective mattress,
cushion, or body-support pad or mat than the at least one foot having the
third size.
[0068] Accordingly, in some embodiments, a mattress, cushion, or body-support
pad or mat
disclosed herein may comprise: one or more polymers at least partially
defining a length and a
width of the respective mattress, cushion, or body-support pad or mat, wherein
the one or more
polymers span a depth that is perpendicular to the length and the width of the
respective
mattress, cushion, or body-support pad or mat, and that extend from an upper
surface of at least
one polymer of the one or more polymers that is proximate to where a user
rests to a lower
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surface of the at least one polymer of the one or more polymers, and wherein
the lower surface is
opposite the upper surface that is proximate to where the user rests; a first
plurality of voids in
the at least one polymer of the one or more polymers, the first plurality of
voids traversing at
least a first portion of the width of the mattress, wherein the first
plurality of voids are located
about the lower surface, and wherein the first plurality of voids are defined
by polymer walls of
the at least one polymer of the one or more polymers; a first plurality of
polymer feet, wherein
each polymer foot of the first plurality of polymer feet is defined by one or
more walls of the
polymer walls; a plurality of lower surface regions, wherein a first region of
the plurality of
lower surface regions includes at least one foot of the first plurality of
polymer feet that has a
first size, and wherein a second region of the plurality of lower surface
regions includes at least
one other foot of the first plurality of polymer feet that has a second size;
a second plurality of
voids in the at least one polymer of the one or more polymers, the second
plurality of voids
traversing at least a second portion of the width of the respective mattress,
cushion, or body-
support pad or mat, wherein the second plurality of voids are located about
the upper surface,
and wherein the second plurality of voids are defined by the polymer walls of
the at least one
polymer of the one or more polymers; a second plurality of polymer feet,
wherein each polymer
foot of the second plurality of polymer feet is defined by one or more walls
of the polymer walls;
and a plurality of upper surface regions, wherein a first region of the
plurality of upper surface
regions includes at least one foot of the second plurality of polymer feet
that has a third size, and
wherein a second region of the plurality of upper surface regions includes at
least one other foot
of the second plurality of polymer feet that has a fourth size. The at least
one other foot having
the second size spans a greater distance along the length of the respective
mattress, cushion, or
body-support pad or mat than the at least one foot having the first size; and
the at least one other
foot having the fourth size spans a greater distance along the length of the
respective mattress,
cushion, or body-support pad or mat than the at least one foot having the
third size.
[0069] The second plurality of voids may mirror the first plurality of voids
with respect to a
middle surface of the at least one polymer, the middle surface located between
and parallel to the
upper surface and the lower surface of the at least one polymer. The second
plurality of voids
may differ from the first plurality of voids in terms of at least one of
dimension, configuration,
and quantity. The one or more polymers of the respective mattress, cushion, or
body-support pad
or mat may further comprise at least one groove in the upper surface of the at
least one polymer
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that extends the length of the respective mattress, cushion, or body-support
pad or mat. The at
least one groove in the upper surface of the at least one polymer may mirror
the at least one
groove in the lower surface of the at least one polymer with respect to the
middle surface of the
at least one polymer. The at least one groove in the upper surface of the at
least one polymer
may differ from the at least one groove in the lower surface of the at least
one polymer in terms
of at least one of dimension, configuration, and quantity.
[0070] FIG. 7 depicts a side views of an example mattress (cushion, or body-
support pad or mat)
700 having dual-sided voids, gaps and/or grooves in various embodiments. The
mattress 700
may comprise a first plurality of voids 714 and a second plurality of void 724
along the length of
the mattress 700. Mattress 700 may comprise and/or may be similar to
mattresses 200, 300, 400,
500 and/or 600 described above with reference to FIGS. 2-6C, and the
description contained
herein directed thereto equally applies to mattress 700 but may not be
repeated herein for brevity
sake. Like or similar components and aspects of mattresses 200, 300, 400, 500,
600, to mattress
700 of FIG. 7 are thereby indicated by like reference numerals preceded with
"7".
[0071] The mattress 700 may include a plurality of lower surface regions
including, for example,
a first lower surface region 702 and a second lower surface region 704 having
feet 710. The feet
710 of the first lower surface region 702 and/or second lower surface region
704 may not be
identical and may have various thicknesses, depths, shapes, etc. either within
each respective
region (i.e., within the first lower surface region 702 or within the lower
surface second region
704) or when comparing feet 710 of the first lower surface region 702 to feet
710 of the second
lower surface region 704. For example, the foot 710a of the second lower
surface region 704
may span a greater distance along the length Li of the mattress 700 (i.e.,
would be thicker) than
the foot 710b of the first lower surface region 702.
[0072] The mattress 700 may include a plurality of upper surface regions
including, for example,
a first upper surface region 732 and a second upper surface region 734 having
feet 720. The feet
720 of the first upper surface region 732 and/or second upper surface region
734 may not be
identical and may have various thicknesses, depths, shapes, etc. either within
each respective
region (i.e., within the first upper surface region 732 or within the upper
surface second region
734) or when comparing feet 720 of the first upper surface region 732 to feet
720 of the second
upper surface region 734. For example, the foot 720a of the first upper
surface region 732 may
span a greater distance along the length Li of the mattress 700 (i.e., would
be thicker) than the
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foot 720b of the first upper surface region 732. As another example, the foot
720c is shaped
differently than other feet 720.
[0073] The second plurality of voids 724 are, as depicted, different from the
first plurality of
voids 714. The second plurality of voids 724 including widthwise channels of a
parallelogram
cross-section are arranged at an angle with respect to the upper surface of
the polymer so that
displacement is minimal to provide maximum support but weight and packing size
of the
mattress 700 could be decreased when a user rests on the mattress 700.
[0074] In various embodiments, the second plurality of voids may comprise
voids of any suitable
configurations. For example, FIG. 8 depict a side view of an example mattress
(cushion, or
body-support pad or mat) 800 having dual-sided voids, gaps and/or grooves. The
mattress 800
may comprise a first plurality of voids 814 and a second plurality of void 824
along the length of
the mattress 800. Mattress 800 may comprise and/or may be similar to
mattresses 200, 300, 400,
500, 600 and/or 700 described above with reference to FIGS. 2-67, and the
description contained
herein directed thereto equally applies to mattress 800 but may not be
repeated herein for brevity
sake. Like or similar components and aspects of mattresses 200, 300, 400, 500,
600, 700, to
mattress 800 of FIG. 8 are thereby indicated by like reference numerals
preceded with "8".
[0075] The mattress 800 may include a plurality of lower surface regions
including, for example,
a first lower surface region 802 and a second lower surface region 804 having
feet 810. The feet
810 of the first lower surface region 802 and/or second lower surface region
804 may not be
identical and may have various thicknesses, depths, shapes, etc. either within
each respective
region (i.e., within the first lower surface region 802 or within the lower
surface second region
804) or when comparing feet 810 of the first lower surface region 802 to feet
810 of the second
lower surface region 804.
[0076] The mattress 800 may include an upper surface region 832 having feet
820. The second
plurality of voids 824 are, as depicted, different from the first plurality of
voids 814. The second
plurality of voids 824 including widthwise channels of a zigzag cross-section
are arranged in the
upper surface of the polymer so that displacement is minimal to provide
maximum support but
weight and packing size of the mattress 800 could be decreased when a user
rests on the mattress
800.
[0077] In some embodiments, at least one of the first and/or second plurality
of voids may be
partially filled with at least one material having a density lower than and a
stretchability greater
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than a density and a stretchability of the polymer of the one or more
polymers, respectively. The
at least one material may include, but not limited to, another polymer, a
foam, a latex, and/or any
other suitable material. For example, the at least one material may fill the
at least one of the
plurality of voids partially in the height of the at least one void, in the
thickness of the at least
one void, and/or in the width of the mattress.
[0078] In some embodiments, at least one of the first and/or second plurality
of voids may be
fully filled with the at least one material. For example, the at least one
material may fill the at
least one of the plurality of voids fully in the height of the at least one
void, in the thickness of
the at least one void, and/or in the width of the mattress.
[0079] In some embodiments, the at least one groove in the upper surface
and/or the lower
surface of the polymer may be partially filled with the at least one material.
For example, the at
least one material may fill the at least one groove partially in the height of
the at least one
groove, in the thickness of the at least one groove, and/or in the length of
the mattress.
[0080] In some embodiments, the at least one groove in the upper surface
and/or the lower
surface of the polymer may be fully filled with the at least one material. For
example, the at
least one material may fill the at least one groove fully in the height of the
at least one groove, in
the thickness of the at least one groove, and/or in the length of the
mattress.
[0081] In some embodiments, at least one of the first and/or second plurality
of voids may be
partially filled with at least one gas pocket. The at least one gas pocket may
be configured to
have at least one gas release valve and at least one gas filling valve, and
the at least one gas
pocket may be filled with a gas selected from the group consisting of air,
nitrogen, argon, and/or
any other suitable gas. For example, the at least one gas pocket may fill the
at least one of the
plurality of voids partially in the height of the at least one void, in the
thickness of the at least
one void, and/or in the width of the mattress.
[0082] In some embodiments, at least one of the first and/or second plurality
of voids may be
fully filled with the at least one gas pocket. For example, the at least one
gas pocket may fill the
at least one of the plurality of voids fully in the height of the at least one
void, in the thickness of
the at least one void, and/or in the width of the mattress.
[0083] In some embodiments, the at least one groove in the upper surface
and/or the lower
surface of the polymer may be partially filled with the at least one gas
pocket. For example, the
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at least one gas pocket may fill the at least one groove partially in the
height of the at least one
groove, in the thickness of the at least one groove, and/or in the length of
the mattress.
[0084] In some embodiments, the at least one groove in the upper surface
and/or the lower
surface of the polymer may be fully filled with the at least one gas pocket.
For example, the at
least one gas pocket may fill the at least one groove fully in the height of
the at least one groove,
in the thickness of the at least one groove, and/or in the length of the
mattress.
[0085] In some embodiments, the first and/or second plurality of voids may be
formed by
layering a plurality of sub-layer polymers of the polymer of the one or more
polymers, along the
width or the length or both the width and the length.
[0086] In some embodiments, the at least one groove in the upper surface
and/or the lower
surface of the polymer may be formed by layering a plurality of sub-layer
polymers of the one or
more polymers, along the width or the length or both the width and the length.
[0087] In some embodiments, the mattresses, cushions, or body-support pads or
mats disclosed
herein may include at least one non-skid bottom material coupled to the lower
surface of the one
or more polymers. In some embodiments, the at least one non-skid bottom
material may be
coupled to a bottom surface of the mattress cover that is in adjacent to the
lower surface of the
one or more polymers. The bottom surface of the mattress cover or the lower
surface of the one
or more polymers may be in contact with a top surface of the adjustable bed
frame, such that the
at least one non-skid bottom material can prevent the mattress from
unnecessary sliding with
respect to the top surface of the adjustable bed frame.
[0088] In some embodiments, the at least one non-skid material may include,
but not limited to,
selectively placed grips/adhesives, a full sheet of non-skid material, hook-
and-loop fasteners,
buttons, zippers, creases, or any other suitable materials/patterns/mechanisms
that would
increase the coefficient of friction between the mattress and the adjustable
bed frame. For
example, the at least one non-skid materials may be slip resistant fabric that
offers grip in wet,
dry, hot and cold conditions. The slip resistant fabric may include Polyvinyl
chloride (PVC).
[0089] In some embodiments, the lower surface of the one or more polymers may
be configured
to have perforations that might facilitate stretch if the non-skid material is
not very flexible and
stretchable. In some embodiments, the non-skid material may be a laminate
positioned along the
bottom of each individual polymer foot. Portions of the polymer feet may be
exposed and the
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27
mattress cover attaches or hooks to the sidewalls of the polymer feet so that
the polymer feet
provide the coefficient of friction that would be missing with a standard
mattress cover.
[0090] The descriptions provided above for mattresses 200, 300, 400, 500, 600,
700, and/or
800 are equally applicable to any cushion and/or body-support pad or mat.
[0091] The terminology used herein is for the purpose of describing particular
embodiments
only and is not intended to be limiting of the invention. As used herein, the
singular forms "a",
"an" and "the" are intended to include the plural forms as well, unless the
context clearly
indicates otherwise. It will be further understood that the terms "comprise"
(and any form of
comprise, such as "comprises" and "comprising"), "have" (and any form of have,
such as "has"
and "having"), "include" (and any form of include, such as "includes" and
"including"),
"contain" (and any form contain, such as "contains" and "containing"), and any
other
grammatical variant thereof, are open-ended linking verbs. As a result, a
method or article that
"comprises", "has", "includes" or "contains" one or more steps or elements
possesses those one
or more steps or elements, but is not limited to possessing only those one or
more steps or
elements. Likewise, a step of a method or an element of an article that
"comprises", "has",
"includes" or "contains" one or more features possesses those one or more
features, but is not
limited to possessing only those one or more features.
[0092] As used herein, the terms "comprising," "has," "including,"
"containing," and other
grammatical variants thereof encompass the terms "consisting of' and
"consisting essentially
of"
[0093] The phrase "consisting essentially of' or grammatical variants thereof
when used herein
are to be taken as specifying the stated features, integers, steps or
components but do not
preclude the addition of one or more additional features, integers, steps,
components or groups
thereof but only if the additional features, integers, steps, components or
groups thereof do not
materially alter the basic and novel characteristics of the claimed
compositions or methods.
[0094] All publications cited in this specification are herein incorporated by
reference as if
each individual publication were specifically and individually indicated to be
incorporated by
reference herein as though fully set forth.
[0095] Subject matter incorporated by reference is not considered to be an
alternative to any
claim limitations, unless otherwise explicitly indicated.
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[0096] Where one or more ranges are referred to throughout this specification,
each range is
intended to be a shorthand format for presenting information, where the range
is understood to
encompass each discrete point within the range as if the same were fully set
forth herein.
[0097] While several aspects and embodiments of the present invention have
been described
and depicted herein, alternative aspects and embodiments may be affected by
those skilled in the
art to accomplish the same objectives. Accordingly, this disclosure and the
appended claims are
intended to cover all such further and alternative aspects and embodiments as
fall within the true
spirit and scope of the invention.
* * * * *
