Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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MODULAR COMPONENT MATTRESS
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Cross Reference to Related Application
This application is a continuation in cart. of 12/322,415 filed 02/03/2009
BACKGROUND-field of invention- This invention relates to a modular component
mattress with selectable and interchangeable mattress components, such as
springs, water
bladders, foam or heater that is inserted into each side of a topper cavity or
main core
cuv ity of a mattress cover which can be and easily assembled by customer and
partly
exchanged without returning the entire mattress.
Background -Description of prior art
Generally, mattresses are formed with a mattress central portion or core
surrounded by a
mattress hnrder construction. The mattress central portion, or core, may
comprise a series
of coil springs connected together and encased in a quilted fabric.
Alternatively, the
mattress core portion may consist ofpolyurethane, latex foam layers, or
synthetic or
natural fibers, optionally in combination with springs, and encased in quilted
fabric. The
core portion might also constitute an air mattress or water mattress or other
body-
.supporting mattress structure.
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Mattress border constructions stabilize the edge or border portion of the
mattress. It is
desirable to have a more firm or more rigid border portion surrounding a less
firm, body-
snppc rting mattress central portion. Mattress border constructions of various
types have
been disclosed in the prior art. U.S. Pat. No. 5,537,699 discloses a mattress
border
construction formed with a foam rail. sleeve surrounding a plurality of
springs arranged in
a row. The foam rail sleeve defines a core into which the row of springs is
inserted. The
foam is slit along its length so that it may be opened to permit insertion of
the row of
springs. U.S. Pat. No. 5,101,623 shows a composite mattress topper, as opposed
to a
complete mattress construction. The topper has a latex foam rubber core
section surround
by border sections of urethane foam. The border sections are attached to the
core section
with adhesive to create the finished topper. The topper is placed in a cover
with the
mattress core.
Water beds have used the foam border construction to house bladders in a
traditional
cover so to appear as a conventional mattress. The water bed has a benefit
over other
mattresses in that when you initially enter the water bed it is already warm.
The present
invention.also obtains with non waterbeds by adding a low powered heater under
the air
bladder or mattress core. By using this water bed style of heater in an air
bed would seem
impnssihie because there is seems to be no mass (water) or way of conducting
the heat
through the mattress. As well, the control for water beds typically must be
very precise to
obtain a comfort temperature, requiring a temperature sensor in a remote
location a
distance from the heater placed under the water bed bladder. As well, the
invention's
water bed type of temperature control could not function as a on /off type of
control due
to slow heat transfer of the air, the heater would form an overheated area
causing damage
to bladder or fire, as is the case of an empty water bed bladder. By having a
heater which
has approximately 1 /3 the power of a water bed and a simple control, the
invention can
achieve a warm air mattress upon entry and allow the room temperature to be
reduced in
the evening to save energy. This was not possible in waterbeds since the under
powered
heater would take days to bring the large mass of water up to the temperature
of comfort
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level required- Many wRterhedc have the water bladder in direct contact with
the
person's body, resulting in substantial conduction of heat and a chilled
feeling.
Mutosko US 6,553,591 adds a thin "U" shaped water bladder cushions at the
surface of
the mattress to reduce the bladder weight to one tenth that of conventional
water beds and
under a layer of foam to and eliminate the heater. The desired waterbed effect
may not
be satisfying in terms of feel and depth of support.
} licks US 6,421,589 also has a water bladder on top of an air bladder with
more greater
depth of water but offers no heater for the bladder. This would result in the
patient losing
body heat.
i3oth Mutosko and Hicks have mattresses that are specifically designed custom
components for their mattress.
The prior art shows the general approach to heating a mattress is by heating
and
circulating warm air through the mattress by a blower fan. This is an
expensive method
and would require all or partial replacement with this custom engineered
mattress. This is
seen in art references of US 6,701,552 Suzuki, US 6,711,767 Klamm, US
6,546,576 Lin
and US 6,006,524 Park who show this type of approach. The other type of design
is to
direct heating elcmcnt,5 on the or within the mattress as shown by US
4,455,472 Moss
and US 4,423,308 Callaway. The sealed mattress would not allow access to the
lower
portion of the mattress to make it easy for placement of such, a heater.
This invention simplifies the solution in terms of product cost as well as
reduces power
consumption due to the direct application of heat and the insulated
configuration of
heater as compared to the prior art. A heater can also be inserted under one
side ofquccn
or king mattress to heat one side more than the other using a single beater.
The present modular or component design allows a heater to not only to be used
with a
air bladdcr, but also a spring core, since the heater can be placed inside the
mattress under
the core and then mattress zipped shut.
The mattress has generally been retailed through retail stores where the
mattress could be
lied upon and felt for comfort at the point of sale. Surprisingly, people will
buy
mattresses without ever lying upon it through a.n online, interact or
catalogue purchase.
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The air bed has made delivery by common courier possible due to it's compact
size,
however its greatest feature is the adjustable firmness, so that a firmness
satisfaction is
guaranteed for the...person but also their spouse can adjust the air pressure
to obtain the
firmness for their side bf the mattress.
The main object of this invention is to provide a comfort guarantee, but
without the
associated cost. Some of the larger competitors would offer various
guarantees. The
customer could exchange the mattress for another one and the retailer could
donate the
old one to a charity for a tax write off. The cost would be factored into the
overall
overhead of the store. The cost is significant in terms of return processing
and transport to
the store and then transport or disposal cost from the store. This invention
eliminates the
transport cost since the individual components can be transported in a small
car. A king
mattress has the main core and topper is half the width of the mattress and
will fold or
rull up into a small bundle. The customer can try the different topper and /or
main core
and either purchase the desired component or exchange it, depending on the
guarantee
policy.
A new issue of bed bugs has further complicated the guarantee. Many U.S.
States will not
allow a delivered mattress back into the delivery truck even if it has not
been opened, due
to the tough control measures needed to curb these bed bugs. Some four star
hotels have
had to go to great expense to guard their reputation once these bed bugs were
brought
into their hotel by personal pillows and bcd products ctc. This invention
allows for
washing or replacement of individual components of the mattress but not the
entire
mattress. For instance, the cover can be removed from the cores and foam rails
dry
cle;rnerl, and the air pump, vinyl or rubber air bladders, spring and water
tubes can be
washed.
Some stores tried to resell a barely used mattress to find out that the new
owner was
allergic to cat dander, which contaminated the mattress from the previous
owner's cat
sleeping on the mattress once or twice.
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A second issue concerning comfort with an air bed is the comfort or feel, even
though
the firmness is adjustable, the surface they are lying upon will have a
different feel than
what they prefer. This invention offers a method to allow the customer to
select or change
the sleeping component on top of the air core bladder, thus giving the feel as
well as
adjustability of the firmness they desire. This is accomplished by allowing
the topper core
to be unzipped and a spring, water or various foam topper core inserted on
their side of
the mattress. These topper cores are thin enough to allow the firmness
adjustment of the
air bladder to be felt while still providing the personal preference of say
pocket coil,
memory or latex foam that they are familiar with.
It also allows say a softer pocket coil spring to be placed on top of a firmer
set of springs.
The mattress also is a waterbed that overcomes the main objection of waterbeds
in that
the buttocks sinks down too deep, resulting in back pain. This system would
allow the
thin water bladder or tubes to be placed on the adjustable air bladder so that
their buttocks
will rest on the air bladder main core or any othcr main core that is
selected. These
features of the .invention makes it even less important to actually lay on the
bed before
buying it, thus a safer buy for someone living in a remote area where it would
not be
worth the long drive to purchase a mattress.
Mattresses are now air, coil springs, and memory foam core having a separate
material
in the perimeter for reasons of increased vertical perimeter support. In the
case of coi l
springs, the foam perimeter gives the feel or sensation of a soft mattress
edge or side
when the mattress is compressed laterally when sat or leaned against.
Traditionally, this
feel is made by gluing the coils or rowed sleeve of coils to the foam rail. A
fabric rail
sleeve, as in this invention, was not bossible to sew to the cover as it would
leave a
visible stitch mark on the surface and interfere with quilting patterns. The
invention has
the fabric rail sleeve sewn to the perimeter and the bottom cover of the
mattress.
Mattresses have historically been assembled in the manufacturing facility.
With
manufacturing moving overseas to countries such as China, there was an
economic
advalatage to rcducc the shipping volume, since the shipping containers would
not be
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close to their maximum weight capacity. Compressing components such as spring
assemblies, or complete spring mattresses made economic sense. A problem
occurred
with mattresses using foam rails, in that the foam rail that was glued to the
inner maltres
cover would not return to it's original shape and wrinkles would result. This
invention
eliminates the gluing operation.
A mattress assembly shown in U.S. Pat. No. 5,953,779 has a stack of foam
mattress
elements positioned one atop the other and joined together at their peripheral
edges with
hook and loop fasteners (VELCRO®). The fasteners keep the foam mattress
elements aligned in stacked relation. The mattress so formed does not have a
mattress
border construction, and a retainer rope is secured around the outer edge of
the mattress
to hold the elements together. Additional holding support is provided by
containment
blocks optionally attached with VELCRO® to the head and foot of the
mattress
a.sscrnbty.
U.S. Pat. No. 2,326,441 shows a mattress covering in which strips of fabric
are secured to
the sidewall of a foam sponge nihher mattress core with an adhesive. The
fabric'strips
form an anchor onto which the mattress covering material may be stitched. No
mattress
border construction is provided around the sponge rubber mattress core.
Summary
In acr..orriance with the present invention is a modular component mattress
with
selectable and interchangeable mattress components, such as springs, water
bladders,
foam, lumbar support, or heater that is inserted into each side of a topper
cavity or main
core cavity of a mattress cover which can be and easily assembled and
exchanged by
customer without returning the entire mattress. The smaller retailer can offer
multiple
selection using a single queen size bed, switching components until the
customer is
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satisfied, and then guaranteeing long term comfort at low cost, as well as
replacement of
individual worn or damaged components. The entire king size bed or it's
components will
fit in a compact size car or can becouriered.
Or1LWCTS AND ADVANTAGES OF THE INVENTION
This novel approach has the following advantages in that it:
- Provides a modular corrtponent mattress with selectable and interchangeable
mattress
components, such as springs, water bladders, foam, lumbar support, or heater
that is
inserted into a topper cavity or main core cavity of a mattress cover which
can be and
easily assembled by customer and partially exchanged without returning the
entire
mattress.
- Provides reduced floor space, inventories and warehouse space as several
colors and
fabric designs would be available and rail types and core types would be
compatible with
the different types of mattress cover.
- Provides a comfort guarantee, but without the associated cost. With the
conventional
guarantee, the customer could exchange the mattress for another one and the
retailer
could donate the old one to a charity for a tax write off. The cost would be
factored into
the overall overhead of the store. The cost is significant in terms of return
processing and
transport to the store and then transport or disposal cost from the store.
This invention
eliminates the transport cost since the individual components can be
transported in a.
small car. A king mattress has the main core and topper is half the width of
the mattress
and will fold or roll up into a small bundle. The customer can try the
different topper and
/or main core and either purchase the desired component or exchange it. A
dissatisfied
customer is able to exchange spring with say foam or air cores in the topper
cavity, main
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cute cavity or both, without exchanging the cover (thus preventing full
destruction of
product for hygienic considerations), thus allowing a low cost satisfaction
warranty to be
offered. The invention allows any type of mattress surface or core be
installed by the
customer until they are satisfied. It is difficult to determine if a mattress
is suitable at the
point of sales, and for many, several nights or weeks of sleeping on the
mattress will be
needed to evaluate the mattress and determine satisfaction.
A small skew count for smaller stores to offer a wide range of selection
without taking
up much floor space or inventory space.
- Each side of queen or king mattress can be selected to meet individual
preference.
-Coil springs on air bladders allow for the novel pocket coil firmness
adjustability.
-Airbladders also allow for adjustable water bladder firmness adjustability on
conventional low cost single bladder or tube type water bladders.
-This invention allows for washing or replacement of individual components of
the
mattress but not the entire mattress. For instance, the cover can be removed
from the
cores and foam rails dry cleaned. and the air pump, vinyl or rubber air
bladders, spring
and water tubes can be washed.
- A second issue concerning comfort with an air bed is the comfort or feel,
even though
the firmness is adjustable, the surface they are lying upon will have a
different feel than
what they prefer. This invention ofFers a method to allow the customer to
select or change
the sleeping component on top of the air core bladder, thus giving the feel as
well as
adjustability of the firmness they desire. This is accomplished by allowing
the topper core
to be unzipperl and a spring, water or various foam topper core inserted on
their side of
the mattress. These topper cores are thin enough to allow the firmness
adjustment of the
air bladder to be felt while, still providing the personal preference of say
pocket coil.
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memory or latex foam that they are familiar with. It also allows say a softer
pocket coil
spring to be placed on top of a firmer set of springs.
The mattress also is a waterbed that overcomes the main objection, of
waterbeds in that
the buttocks sinks down too deep, resulting in back pain. This system would
allow the
thin water bladder or tubes to be placed on the adjustable air bladder to that
their buttocks
will rest on the air bladder main core or any other main core that is
selected. What should
be understood about water beds is that someone floating on water would be
mostly
submerged, and would feel weightless without pressure points. This is not the
case. What
is mechanically happening is the weight of the water pushing the perimeter of
the
bladder stretches vinyl surface and effectually hammocks the person. This
causes a
hammocking configuration with a resulting slouched, sore spine. This invention
allows
the underlying air bladder to support the buttocks area and prevent slouching
with an
under-filled water bladder or tubes.
The conventional single air bladder mattress must sacrifice support of the
buttocks high
pressure for conformity (softness) with low pressure. The present invention
has a thin
height air bladder that rests on top of a conventional air bladder, both
having
adjustability. By allowing the pressure to be low enough, in the top air
bladder, to prevent
stretching of the surface vinyl, allows it to conform and shape about the
pressure points
of the body, while providing the lower air bladder to give support to buttocks
area which
tends to sink down.
- Components are designed to fit into. their specific cavities in terms of
height, length and
width, and openings are located in the cover for hoses and heater wires to
provide one
mattress that can be altered into any type of mattress
- Vinyl air or water bladders and spring packs can be cleaned for resale or
exchange.
The customer can eventually replace a damaged or worn out component of the
mattress
rather than the whole mattress.
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-Allows for manufacturer and customer compact transport of mattress, even a
king size
mattress in a small vehicle in it's unassembled state. The foam rails are then
inserted in
the perimeter foam rail sleeves. The core is then placed on the cover or foam
and between
the foam rail assemblies. A layer of foam maybe placed in the mattress cover
if desired.
has a zipper for both topper and main core cavities for easy access.
-The zippers have a cover so that they are not visible or felt
-The foam rail zipper eliminates the glue operation.for securing foam rails
which in turn
prevents wrinkling, as well as incomplete recovery, when the rails are
compressed for
shipping. This is a problem since most adhesives take up to 2.weeks to fully
cure and
once a product it is on the assembly line it must be packaged as the last step
of the
production. To package mattresses with spring cores, the finished mattress arc
put in a
plastic bag which then have the air evacuated resulting in compression of
spring
assembly (core) and rails into a flattened state, which is then rolled and
placed in a box.
Since the adhesive is riot fully cured, it causes the folded or wrinkled outer
cover side
fabric which is glued to the rail or rail enclosure, to adhere to it's self
resulting in
inability to come back to its full height once removed from the plastic bag.
It also reduces
discoloration from glue seepage to the outside of the cover and prevents the
cover
rotating or twisting relative to the foam rails and/or contents of cover
preventing outer
line or edge to remain straight and along the corner of the mattress edge. A
sleeve is
easier to assemble rather than securing with Velcro tabs or strips, between
cover and
foam rail, which require alignment before pressing together. It also allows
the mattress
cover to be folded in a space efficient way over a mattress cover which has
the foam rails
attached.
-The heater can be installed in the topper core or main core cavity.
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-When you initially enter the bed it is already warm- This invention also
solves this
problem by adding a low powered heater under the air bladder. As well, the
control for
water beds must be very precise to obtain a comfort temperature, requiring a
temperature
sensor in a remote location a distance from the heater placed under the water
bed bladder.
This temperature control would not function as a on /off type of control due
slow heat
transfer of the air, the heater would form an overheated area causing damage
to bladder
or combustion, as is the case of an empty water bed bladder. By having a
heater Which
has approximately 1 /3 the power of a water bed and a simple control, the
invention can
achieve a warm air mattress upon entry and allow the room temperature to be
reduced in
the evening to save energy. This was not possible in waterbeds since the under
powered
heater would take days to bring the large mass of water up to the temperature
of Wrnfort
level required, Since many waterbeds have the water in direct contact with the
sleeping
surface resulting in conduction of heat from the person's body.
-This invention simplifies the solution in terms of product cost as well as
reduces power
consumption due to the direct application of heat and the insulated
configuration of
heater as compared to the prior art.
-The multi tap heater elements provide a range of heat settings and eliminates
expensive
power controls that add cost and electrical noise.
-The heater can also vary the heat for each side of the bed by allowing the
user to adjust
the heater position or contact area between the two sides of the bed. The
amount of area
under each bladder will determine the temperature of each side of a king or
queen
mattress which are usually two joined bladders. for adjoining spring cores, a
barrier of
say vinyl or fabric will 'prevent an unwanted heating effect on one side.
- One size heater can be used for all sizes and types of beds due to the low
watt density of
the heater.
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- A foam lumbar or adjustable pneumatic lumbar cushion or support can be
placed on or
under water tubes, spring cores or air cores in either topper core cavity or
main core
cavity in its personally preferred location along the length of the mattress.
Every person
is different in height and preference and can easily access the lumbar to rind
a
comfortable location for their side of the bed.
Brief Drawing-Description
Fig 1- shows an exploded view of the mattress assembly.
Fig 2- shows the topper core cavity with a heater and pneumatic lumbar
Fig 3- shows the main core cavity with a heater
Fig 4- shows a single air core.
Fig 5- shows a double air core in a king or queen size main core cavity.
Fig 6- shows the topper core cavity with a memory foam topper core on one side
and a
multi-zoned latex (middle zone ) and polyurethane (head and foot) inserted in
it.
Fig 7= shows a topper core cavity with spring topper core on one side and
water bed tubes
and foam lumbar on the other.
Fig 8- shows a single spring core. The topper spring core would generally be
thinner than
the main spring core.
Fig 9-shows a single water tube.
Fig 10- shows a mattress cover quitted top panel.
Fig 1 l -'shows a cross sectional view with an air main core and spring topper
core.
Fig 12- shows the sectional view of the mattress cover zipper.
Fig ] 3- shows the main core cavity with a spring cure and a foam core
Fig 14- shows a low thickness topper air core in the topper cavity on an air
core in main
core cavity. An air rail is shown instead of a foam rail.
Fig 15- shows an alternative embodiment of a pillow top design with
interchangeable
foam sheet.
Fig 16- shows the low power heater and heater control.
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REFERENCE NUMERALS OF DRAWINGS
1. main core cavity
2. zipper
3. foam rail
4. topper core cavity
5. quilted top
6. topper spring core
7. water tube
8, air core
9. main core cavity bottom
10. topper core cavity bottom
11 _ heater
12. air core hose
13 _ air core web
14. water tube filling port
l5. memory foam
16. latex foam
17, poly urethane foam
18. foam rail sleeve
19. main spring core
20. mattress tape
21. zipper cover
22. main foam core
23. pocket coil sleeve
24. pillow top cavity
25. foam sheet
26. pillow top base
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27. air rail
28. heater
29. vinyl I beam
30. heater control
31. heater element
32. heater circuit
33. selector switch
34. heater cord
35. pneumatic lumbar
36. pneumatic lumbar hose
37. foam lumbar
Detailed Description of Drawings
Fig I shows an exploded view of the mattress assembly having the main core
cavity I
with a double air bladder 8 inside of it and the air hoses 12 coming out the
bottom of it.
The topper core cavity 4 has a topper spring core 6 and 5 water tubes 7 Inside
of it. The
quilted top 5 has a zipper 2 that can be zipped to the upper zipper 2 of the
topper core 4.
The lower zipper 2 of the topper core 4 can be zipped to the zipper 2 of the
main core
cavity 1. In this configuration both users can adjust the firmness of each of
the water
topper 7 and spring topper 6 by inflating their air core 8 to the desired
pressure.
Fig 2- shows the topper core cavity 4 without any topper cores in it and with
a pneumatic
lumbar 36 and a heater I 'l located partially to one side, and having
pneumatic lumbar hose
36 and the heater cord 34 protrude through an opening in the topper core
cavity bottom
through to the opening in the main core cavity bottom 9. The foam rails 3 are
glued in
the perimeter edge of the topper core cavity 4.
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Fig 3- shows the main core cavity I without any main cores in it and with a
heater
11 having the heater wire protrude through the opening in the main core cavity
bottom 9.
The foam rails 3 are shown inside of the foam rail sleeve 18 which is secured
closed by
foam rail sleeve zipper 2 forming a closed sleeve in the perimeter of the main
core cavity
Fig 4- shows a single air core 8 with its air hose 12. The air hose is
connected to an air
pump so that firmness can be adjusted by the air pressure in the air core 8.
Fig S- shows a double air core 8 in a king or queen size main core cavity I,
and having
the air hose 12 protrude through an opening in the main core cavity bottom 9.
The air
core web 13 is part of the double air core assembly S.
Fig 6- shows the topper core cavity 4 with a memory foam topper core 15 on one
side
and a multi-zoned topper core having a latex foam 17 middle zone, and
polyurethane
foam (head and foot) inserted in it. The foam rail 3 is usually of a firmer
hardness than
either of the uvr- foams in order to prevent sinking in while sitting on the
edge of the bed.
Fig 7- shows a topper core cavity 4 with spring topper core 6 on one side and
water bed
tubes 7 on the other. A thin layer of preferred type of foam can also be
placed on top of
any type topper core or main core. A foam lumbar 37 is placed on the water
tubes 7. It
could also be placed under the water tubes 7 as well as on or under the topper
spring core
6. Any type of lumbar can be placed in either topper core cavity or main core
cavity,
above or below the core in it's personally preferred location along the length
of the
rttattr+:ss-
Fig 8- shows a single side main spring core 6. The topper spring core would
generally be
thinner than the main spring core. The preferred embodiment is a pocket coil
spring
assembly type of spring over Bonnet type of linked spring assembly.
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Fig 9- shows a single water tube 7 with a water tube filling port 14. An
alternative
embodiment is a single water bladder to replace the 7 water tubes. A backup
liner in case
of leak can also be added.
Fig 10- shows a mattress cover quilted top 5 with a zipper 2 along it's
perimeter. The
preferred embodiment has I approximately 1 inch of memory foam 15 quilted in
under
the fabric top. An alternative embodiment uses polyurethane foam 1.7 instead
of memory
foam 15
Fig 11- shows a cross sectional view of the mattress with an air core 8 in the
main core
cavity I and spring topper core 6 consisting of a pocket coil spring in a
pocket coil sleeve
23 assembly. The topper core cavity foam rail 3 may be a different size than
the main
core cavity I foam rail 3. A l inch layer of memory foam 15 is sewn to the
quilted top 5.
This could also be poly urethane foam 17 or latex foam 16.
Fig 12- shows an enlargement of the Fig 11 sectional view of the zipper 2 of
topper core
cavity 4 having mattress tape 20 sewn around, zipper cover 21, quilted top 5,
and one
side of zipper 2. The other side of zipper is sewn to the upper edge of topper
core cavity
4. The zipper 2 of main core cavity having mattress tape 20-sewn around zipper
cover
21, lower edge of topper core cavity 4, topper core bottom 10, foam rail
sleeve 18, upper
edge of main core cavity 1, and one side of zipper 2. The other side of zipper
is sewn to
the upper cdge of main core cavity 1.
No 13- shows the main core cavity 1 with a main spring core 19 and a main foam
core 22.
An alternative embodiment is to replace either or both of these cores with a
water bed
bladder or water tubes or any other type of sleeping surface combination or
single core.
Fig 14- shows a low thickness topper air core 8 in topper cavity 4. This rests
on an air
core 8 in main core cavity 1. An air rail 27 is shown in foam rail sleevel8
instead of foam
rail. The air rail is formed with two internal vinyl T beams 29 to shape sir
rail 27.
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Fig 15- shows an alternative embodiment of a pillow top design having the
zipper 2
along the lower perimeter edge of the pillow top with an exchangeable layer of
different
types of foam sheet 25. This is a sectional view of a pillow top design having
mattress
tape 20 sewn around lower edge of pillow top cavity 24, zipper 2 of pillow top
cavity 24,
and zipper of pillow top inner base. The other side of zipper is sown to the
upper edge of
topper core cavity 4. The topper foam rail 3 and topper air core 8 support the
foam sheet
25.
Fig 16- shows the low power heater 33 with heater wire 34 connecting it to'the
heater
control 36.1 he heater control 36 has-a selector switch to select the desired
heat setting.
The heater has, in this preferred embodiment, 6 independent heater circuits 38
made of
heater element 37. These are heater circuits are electrically configured in
series or parallel
or combination with each other by a selector switch that electrically powers
some or all
of the circuits. Managing the circuit connections eliminates the need for a
variable power
supply, however some high end models would have a variable power supply, as
well
independent heaters for each side of the bed. Although this heater is similar
to a waterbed
heater, in that it has a high temperature cut off switch, it has much lower
watt density and
overall power. However this heater remains with continuous power, with a means
to
reduce power by series circuits and phase shifting.
OPERATION
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The mattress is unpackaged placed with main core cavity I open upwards and
mattress
opening towards the head end of the bed with all zippers 2 unzipped. The foam
rails 3
(whether foam, air, or spring enclosure or any other type or combination of
rail) are
placed in foam rail sleeves 18 and the foam rail zippers 2 are closed.
An air rail 27 has a valve or connector port. The air rail can be inflated
prior to or after
insertion in sleeve. If the air rail is cvrrrrected to the air pump
permanently, then the rails
could be inserted non-inflated at the factory and secured in the rail sleeve
with air hose
available for plugging into.thc pump. Since air rails do not need to be
adjusted for
varying, firmness like the air core, it may be inflated by mouth and sealed
and inserted in
any type of core bed as well as replaced in the event of a leak. A heater 11
can be placed
on the main core cavity bottom 9 in the center of the main core cavity I if
both sides of
the bed are to be heated equally, or to one side of the cavity if one side is
to be heated.
The power cord for the heater 11 is brought out through the opening in the
main core
cavity bottom 9 and plugged into heater control.
A main core is selected and placed in the main core cavity 1 and for a queen
or king size
bed, two main cores are selected. If an air core(s) 8 is selected, the air
core hose 12 is
brought through the opening in main core cavity bottom and 9 and plugged into
air pump.
The topper core cavity 4 is placed onto and zipped to the main core cavity I
by zipper 2.
The zipper cover 21. is pulled and inverted upwards to expose the zipper 2,
and then
folded down after zipped. If a heater is placed on the topper core cavity
bottom 10, the
power cord must be brought through the opening in the topper core cavity
bottom 10 as
well as the main core cavity bottom 9 before zipping closed. Foam rails 3 arc
placed
about perimeter of topper core cavity 4 and then a topper cores selected for
each side and
placed on topper core cavity bottom 10 between foam rails 3. The quilted top 5
is placed
onto and zipped to the topper cavity core by zipper 2. If a pillow top 24 is
used instead of
a quilted top 5, then a foam sheet 25 is selected and placed into the pillow
top cavity 24
and then the pillow top base is zipped closed with it's zipper 2. The pillow
top 24 is
flipped over and zipped onto the topper core cavity 4 with zipper 2. A dual
pillow top
core can also have each side placed and then zippered, similarly as dual
topper and main
cores are sulcutcd and placed in their appropriate cavities.
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The heater control 36 has a selector switch to select the desired heat
setting. Managing
the circuit connections eliminates the need for a variable power supply,
however some
high end models would have a variable power supply, as well independent
heaters for
each side of the bed.
A foam lumbar or adjustable pneumatic lumbar cushion or support can be placed
on or
under water tubes, spring cores or air cores in either topper core cavity or
main core
cavity in it's personally preferred location along the length of the mattress.
Every person
is different in height and preference and can easily access the lumbar to find
a
comfortable location for their side of the bed. The hose for a pneumatic
lumbar support is
placed in the topper core cavity 4 , the pneumatic lumbar hose 36 must be
brought
through the opening in the topper core cavity bottom 10 as well as the main
core cavity
bottom 9 before zipping closed.
CONCLUSIONS RAMIFICATIONS AND SCOPE
In accordance with the present invcntion is a modular component mattress with
selectable
and interchangeable mattress components, such as springs, water bladders,
foam, lumbar
support or heater that is inserted into a topper cavity or main core cavity of
a mattress
cover to allow a customer to easily assemble and exchange components without
returning
the entire mattress. The smaller retailer can offer multiple selection using
the floor space
of one queen size bed, switching components until the customer is satisfied,
and thus
guaranteeing comfort at low cost, as well as long term replacement of
individual worn or
damaged components all with low transportation cost.
