Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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TITLE OF THE INVENTION
MATTRESSES WITH REINFORCEMENT INSERTS AND DENSIFIED STITCH ZONES
UNITED STATES PATENT APPLICATION
SEALY TECHNOLOGY, LLC
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Patent Application Serial
Number
12/552,657 entitled "Surface Impression Removal Technology System" filed on
September 9,
2009, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to mattresses, and mattress and foundation sleep
systems.
BACKGROUND OF THE INVENTION
Mattresses have conventionally been constructed with a primary structural
support
system such as wire springs or "innerspring" which is covered by multiple
layers of padding
of foam or fiber materials, all of which is enclosed by upholstery or "tick"
which is
commonly quilt-stitched fabric with a foam or fiber backing. In this type of
mattress
construction, each primary component is largely homogeneous throughout, and
there is no
difference in structure in any particular area of the mattress. Because the
mass and
distribution of the human body varies widely from head to toe, this places
substantially more
pressure on a mattress in areas such as the pelvic and shoulder regions than
in others. This
results in a concentration of pressure on those areas of the mattress and over
a period of time
compresses the structure to a noticeably greater extent than the other areas
of the mattress.
The relatively recent trend to one-sided mattresses compounds this effect.
The most prominent area of concentrated and prolonged pressure is in the
central
region of the mattress between the head and foot ends. The next highest area
of loading is the
shoulder region. In many mattresses, permanent impressions in the top support
surface are
visible and perceptible afler a relatively short period of use. Some attempts
have been made
to reinforce the mattress structure in these areas, such as by reinforcement
of the innerspring.
A particular challenge of such modifications which has not been successfully
met is to modify
an otherwise homogeneous construction in a particular area or areas while
maintaining a
uniform feel across the entire support surface of the mattress.
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SUMMARY OF THE INVENTION
The reinforced mattresses of the present disclosure and related inventions
include a
mattress core, one or more reinforcement pads having a top surface, a bottom
surface which is
opposite the top surface, and four side surfaces which extend between the top
surface and the
bottom surface, the bottom surface being in contact with the mattress core.
The mattress
assembly also includes one or more upholstery layers that are in contact with
a top surface of
the one or more reinforcement pads and a quilted layer which envelopes the
entire mattress
assembly. The first reinforcement pad is placed laterally across the width of
the mattress core
from one side edge to an opposite side edge at approximately the middle 1/3 of
the mattress
core as measured from a top or head of the mattress to the bottom or foot of
the mattress.
In another aspect of the disclosure and related inventions, reinforced
mattress
assemblies are disclosed having an innerspring with a top surface and a bottom
surface, a first
reinforcement pad having a substantially planar top surface that is opposite a
substantially
planar bottom surface and four substantially planar side surfaces extending
between the top
surface and the bottom surface. The first reinforcement =pad is positioned
above the
innerspring and has a width measurement equal to the width of the innerspring
and a length
that is less than the length of the innerspring. Also included in the mattress
assembly is a
second reinforcement pad having a substantially planar top surface that is
opposite a
substantially planar bottom surface and four substantially planar side
surfaces extending
between the top surface and the bottom surface. The second reinforcement pad
is positioned
above the innerspring and has a width equal to the width of the innerspring
and a length that
is less than the length of the innerspring. The mattress assembly also
includes one or more
upholstery layers and a quilted layer which encloses the entire mattress
assembly, a top outer
surface thereof having a first quilting pattern and a second quilting pattern,
the first quilting
pattem located directly above the first and second reinforcement pads.
In another aspect of the present disclosure and related inventions, a
reinforced
mattress has an innerspring having a top surface and a bottom surface; a first
reinforcement
pad having a substantially planar top surface that is opposite a substantially
planar bottom
surface and four substantially planar side surfaces extending between the top
surface and the
bottom surface, the first reinforcement pad having a width dimension that is
equal to or less
than a width of the innerspring and a length dimension that is equal to or
less than a length of
the innerspring, the first reinforcement pad positioned proximate to the
innerspring and
spaced from a first end of the innerspring and a second end of the
innerspring; one or more
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upholstery layers positioned over a support surface of the innerspring; a
quilt package layer
which extends over the one or more upholstery layers and the innerspring and
the first
reinforcement pad, the quilt package layer having a first stitch pattern and a
second stitch
pattern, the first stitch pattern having a greater density of stitches than
the second stitch
pattern, the first stitch pattern in an area of the quilt package layer which
overlies the first
reinforcement pad, and the second stitch pattern in areas of the quilt package
layer which do
not overlie the first reinforcement pad.
These and other aspects of the present disclosure and related inventions are
described
in detail herein with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a preferred embodiment of a reinforced mattress
of the present
disclosure;
FIG. 2A is a cross-sectional view the reinforced mattresses of FIG. 1;
FIG. 2B is a cross-sectional view of an alternate embodiment of a reinforced
mattress of the
present disclosure;
FIG. 3 is an exploded view of an alternate embodiment of the reinforced
mattress of FIG. 1
having a foot reinforcement pad;
FIG. 4 is an exploded view of an altemate embodiment of a reinforced mattress
of the present
disclosure;
FIG. 5 is an exploded view of an alternate embodiment of a reinforced mattress
of the present
disclosure;
FIG. 6 is an exploded view of an altemate embodiment of a reinforced mattress
of the present
disclosure;
FIG. 7 is an exploded view of an alternate embodiment of a reinforced mattress
of the present
disclosure, and
FIG. 8 is a perspective assembled view of the reinforced mattress of FIG. 1.
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DETAILED DESCRIPTION OF PREFERRED AND ALTERNATE EMBODIMENTS
A typical mattress assembly includes a rigid base or mattress foundation (also
referred
to as a "box spring"), a mattress core, one or more insulator pads or layers,
mattress
upholstery or one or more comfort layers and quilting which extends around and
envelops the
mattress assembly components. The reinforced mattress assemblies of the
present invention
and related disclosure include one or more additional layers that are used to
reinforce
particular areas or regions of the mattress, to provide additional structural
support to areas
known to undergo relatively higher loading, and to thereby resist indentation
or permanent
impression from the higher loads.
In an exemplary embodiment, as shown in FIGS. 1 and 8, a reinforced mattress
assembly contains one or more reinforcement pads that reinforce particular
areas or regions of
the mattress, such as for example the head and/or lumbar regions of the
mattress 100. For
example, a reinforcement pad 10 can be positioned across the central region of
the horizontal
surface of the mattress 100, for example in the area of the mattress which
bears the distributed
weight of the pelvic and lumbar regions. The reinforcement pad 10 extends
transversely
across the width of the mattress 100 or across the core 14 of the mattress,
and can extend
across substantially an entire width of the mattress or the core, to each edge
of the innerspring
or to an extent slightly or substantially less than a total width of the core
14, for example one
or more inches from each edge of the core 14. The reinforcement pad 10 has a
substantially
planar top surface and a substantially planar bottom surface which is opposite
the top surface
and four substantially planar side surfaces that extend between the top and
bottom planar
surfaces of the reinforcement pad 10. The reinforcement pad 10 can be made of
visco-elastic
or memory foam, latex, polyurethane or polyethylene foarn or any flexible
polymer or fiber
material, and could be constructed with one or more layers of any of these
materials, and
further including a barrier or skin layer on one or both sides of the pad
which resists the
formation of impressions in the reinforcement pad such as for example from
springs
underneath the reinforcement pad. The reinforcement pad 10 has a preferred
density in a
range of approximately 1.0 lbs. /in2 to 2.0 lbs. /in2 and a preferred density
of approximately
1.5 lb/in2. Other materials and densities can also be used which provide the
described
functions of the reinforcement pads. The thickness of the reinforcement pad 10
is preferably
in a range of approximately 0.125 to 0.75 inches, and more preferably in a
range of 0.25 to
0.75 inches. The reinforcement pad preferably has a width dimension that is
proportional to
or the same as the corresponding width for the core 14 of the mattress 100.
Preferably the
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reinforcement pad 10 covers a substantial portion of the width of the mattress
100 or core 14,
and has a representative length of approximately 30 inches or shorter or
longer in relation the
mattress 100 or core 14 and in order to extend over a lumbar region for most
adult users of
the mattress 100. Also, the reinforcement pads 10 do not necessarily have to
be rectangular in
shape or symmetrical, and do not have to be of uniform thickness, topography
(e.g. planar or
undulated or convoluted) or homogeneous in density or hardness. Reinforcement
pads 10
with different thickness and length dimensions not expressly disclosed herein
are within the
scope of the invention. Since the reinforcement pad 10 preferably extends
generally across a
substantial width of the mattress 100 or core 14, the pad's width is
'dependent upon the sizc of
the mattress 100 or innerspring. The horizontal middle one third (1/3) area of
the mattress
100 includes the pelvic and lumbar support areas of the mattress 100. The
reinforcement pad
or pads 10 located in this area add support to the pelvic and lumbar areas
where higher loads
and pressure occurs. The reinforcement pad 10 also adds additional resistance
to
development of body impressions across this portion of the mattress 100, as
may otherwise
develop in the support surface of the mattress. In this embodiment, the
reinforcement pad 10
is located on top of a mattress core 14 and below the upholstery layer or
layers 15, and a quilt
package layer 16 (sometimes alternatively referred to as a "quilt package",
"quilt layer" or
"quilted layer") which typically includes an outer fabric, a relatively thin
foam layer and a
non-woven backing layer, and quilt stitching which extends through all three
of these layers.
The upholstery layers 15 can be one or more layers of cushioning, as shown for
example in
FIG. 2B, and may include one or more loft and/or wicking materials, woven or
non-woven
and natural or synthetic, such as foam, cotton, wool, animal hair, feathers,
etc. The quilt
package layer 16 is conventionally a layer of fabric such as woven upholstery
fabric which is
quilt-stitched with a backing such as a thin layer of foam or other backing
material. An
insulator pad (not shown) may optionally be placed between the mattress core
and the
reinforcement pad 10, in which case the reinforcement pad 10 is still
considered to be
proximate to the mattress core 14. The insulator pad may be, in one
embodiment, for
example a 5/32-inch thick polyethylene pad that is placed on top of the
mattress core 14, for
example as a primary insulator between the mattress core 14 and the various
layers of the
mattress 100. Alternatively, the reinforcement pad 10 can be placed above the
upholstery
layer(s) 15 and directly below the quilt package layer 16. And as a further
alternate
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embodiment, the reinforcement pad 10 can be located within the upholstery
layer 15, or
between layers of a multi-layer upholstery layer 15, as shown for example in
FIG. 2B.
In a similar manner, a second reinforcement pad 12 may be provided for example
in a
region which bears the next greatest amount of pressure in use which is the
head and shoulder
region, which is generally located at one end of the mattress, for example one
quarter of the
length of the mattress at the head end, as also shown in FIG. 1. Similarly, a
third
reinforcement pad may be provided at a foot end of the mattress, or that
region of the mattress
which bears the weight of the legs which is typically the next or third
greatest amount of
pressure in use.
As further shown in FIG. 1, the quilt package layer 16 has an increased
material
density or higher stitch density in areas which correspond to the locations of
the underlying
reinforcement pad or pads such as pads 10 and 12. The increased material
density in the quilt
packagc layer 16 can be formed in this embodiment by a greater number of quilt-
type stitches,
such as for example in the form of higher density stitches or stitch patterns
161, 162, in any
form, pattern or patterns, and which extend through the upholstery layer or
which are in the
fabric of the quilt package layer 16. The higher density stitches 161, 162 may
be formed in
the quilt package layer 16 by a quilting machine or by hand, or be in the
fabric of the quilt
package layer 16 wherein the fabric would have a greater stitch density or
higher stitch count
in those areas or regions which correspond to the location or locations of the
reinforcement
pads. When formed by a quilting machine, the higher density stitch areas may
be in any
shape or pattern, such as for example in a matrix of evenly spaced and
repeated stitch
patterns. The higher density stitches 161, 162 increase the density of the
quilt package layer
16 in the co-located areas of the reinforcement pad or pads, and cooperate
with the
reinforcement pad(s) to create regions or zones of the mattress which have a
higher density of
support materials and consequently stronger support characteristics and
greater resistance to
formation of permanent deformation of body impressions. The higher density
stitches 161,
162 also serve to pre-compress the quilt package layer in those areas which
may be elevated
and given extra loft by the underlying reinforcement pads 10 and 12 and
thereby reduce or
eliminate crowning of the mattress support surface. The higher density
stitches 161, 162 also
serve to pre-compress those regions of the quilt package layer 16 which
correspond in
location to the reinforcement pads. This results in a substantially level
finish to the top
surface of the quilt package layer 16 and the presence of the reinforcement
pads is not
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telegraphed through the various layers of the mattress or through the quilt
package layer 16.
The combination and cooperation of the reinforcement pads 10 and 12 with
stitches 161, 162
produces a mattress with increased firmness and support in those areas and
which resists
permanent indentation or "body impressions" in those areas. In general, the
combined
structure of the reinforcement pads and the corresponding increased stitch
density produces a
higher density support with a higher indentation load deflection force than
the other areas of
the mattress, and which requires a greater force to compress the mattress
structure.
In another embodiment, a head and shoulders region reinforcement pad 12 or
"head
reinforcement pad" is optionally positioned at one end of the mattress 100 and
extends across
a substantial portion of the width of the core 14. The head reinforcement pad
12 has a
substantially planar top surface, a substantially planar bottom surface
opposite the top surface
and four substantially planar side surfaces that extend between the top and
bottom surfaees of
the head rest pad 12. The head reinforcement pad 12 can be made of visco-
elastic or memory
foam, latex, polyurethane or polyethylene foam or any flexible polymer or
fiber material, and
could be constructed with one or more layers of any of these materials, and
further including a
barrier or skin layer on one or both sides of the pad which resists the
formation of impressions
in the reinforcement pad such as for example from springs underneath the
reinforcement pad.
The head reinforcement pad 12 has a preferred density in a range of
approximately 1.0 lbs.
/in2 to 2.0 lbs. /in2 and a preferred density of approximately 1.5 lb/in2.
Other materials and
densities can also be used which provide the described functions of the
reinforcement pads.
The thickness of the head reinforcement pad 12 is preferably in a range of
approximately
0.125 to 0.75 inches, and more preferably in a range of 0.25 to 0.75 inches.
The head
reinforcement pad 12 has a width dimension that is proportional to, less than,
or the same as
the corresponding width for the core 14 of the mattress 100. The thickness of
the head
reinforcement pad 12 rest is preferably between approximately 0.5 and 0.75
inches with a
width that is dependent upon the size of the mattress. The length of the head
reinforcement
pad 12 is in a representative embodiment approximately 10 inches, although
different
thickness and length measurements and in proportion to the size of the
mattress are within the
scope of the invention. The head reinforcement pad 12 may be the same as pad
10, or of
lesser or greater density, or of a different material or materials than pad
10. The head
reinforcement pad 12 gives added support to a user's head, neck and shoulder
area, distributes
pressures more evenly, and resists permanent indentation. Within the mattress
assembly, the
head reinforcement pad 12 is positioned on top of the mattress core 14 and
below the
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upholstery or comfort 15 and quilt package layer 16. An optional insulator pad
may be placed
between the head reinforcement pad 12 and the mattress core 14.
In addition to the two reinforcement pads 10, 12 described above, an optional
or
additional foot reinforcement pad (hereinafter referred to as "foot
reinforcement pad") 22 can
be positioned at the bottom of the mattress 100 and extend transversely across
the width of
the mattress 100, across a substantial amount of the width of the core 14
although preferably
not thc entire width of the core. The foot reinforcement pad 22 is located in
the foot rcgion of
the mattress which generally experiences the next concentration of loads. The
foot
reinforcement pad 22 may be the same as the other pads 10, 12 or of lesser or
greater density,
or of a different material or materials than pads 10 or 12. A length of the
foot reinforcement
pad 22 can be substantially the same as the head reinforcement pad 12, which
then allows the
mattress 100 to be rotated 180 degrees without changing the overall support
characteristics of
the mattress. In such case the foot reinforcement pad 22 would be the same as
or
substantially the same as the head rest 12, as described above.
In another embodiment, shown in FIG. 4, the reinforced mattress assembly
contains at
least one additional reinforcement pad 24 having one or more raised areas 26
which provide
additional support to certain areas of the mattress 100. For example, as shown
in FIG. 4, the
pad 24 may have at least one raised area 26 for example in a central region of
the pad 24
which corresponds to area of the mattress 100 that supports the pelvic and
lumbar areas. This
raised area 26 provides additional support to the pelvic, back and lumbar
region and also adds
additional padding and support to prevent body impressions in this area of the
mattress 100.
The pad 24 may additionally contain a raised area 26 at the head and/foot ends
of the mattress
100 similar to reinforcement pads 12 and 22 as described. The pad 24 may span
substantially
the entire length and width of the mattress 100 or may have length and width
measurements
that are less than the length and width of the mattress core 14. The pad 24 is
positioned
within the mattress assembly between the mattress core 14 and the one or more
upholstery 15
and quilting 16 layers, or can alternatively be located underneath the
mattress core 14. The
raised areas of the pad such as area 26 may be formed integrally with or as
part of the pad 24,
or may be a separate layer of component which is positioned over and/or
fastened or adhered
to pad 24.
In another embodiment, shown in FIG. 5, a reinforced mattress assembly of the
present disclosure and related inventions may contain a zoned upholstery
component 28
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which includes a center zone 30 and two end zones 32. The center zone 30,
which is
approximately located at the horizontal center 1/3 of the mattress 100, may be
made of a
material or materials that differs form the material or materials of the two
end zones 32, such
as for example foams or other materials of different types and/or densities,
or may contain the
same type of foam but with different foam attributes, such as for example
differing density or
Indentation Load Deflection (ILD), for example of greater density and higher
ILD than the
adjoining end zones 32, or differing dimensional attributes such as sculpting,
convolutions,
perforations or slits. The attributes of the center zone 30 preferably provide
a firmer or more
supportive area ¨ for the pelvic and lumbar support regions of the mattress
100 -- than the two
cnd zones 32. The pad 28 may span substantially the entire length and width of
thc mattress
100 or may have length and width measurements that are less than the length
and width
measurements of the mattress 100. The pad 28 is located within the mattress
assembly
between the mattress core 14 and the quilt 16 layer. The quilt package layer
16 has an area of
higher density stitches 161 which correspond in location to= the higher or
highest density or
firmer or firmest material of the pad 28.
In still another embodiment, shown in FIG. 6, the reinforced mattress assembly
may
contain a base reinforcement pad 34 that is placed at the base of the mattress
assembly
(hereinafter referred to as "base pad"), below the mattress core 14. This base
pad 34 may
contain one or more raised areas 36 which may be, for example, across the
horizontal center
1/3 of the mattress 100 and at the head of the mattress 100 to provide extra
support to the
pelvic and lumbar regions and to prevent body impressions from developing in
those areas.
The base pad 34 may contain length and width measurements that are equal to or
less than the
length and width dimensions of the mattress core 14. The quilt package layer
16 has an area
of higher density stitches 161 which correspond in location to the raised area
or areas 36 of
the base reinforcement pad 34.
In yet another embodiment, shown in FIG. 7, a reinforced mattress assembly of
the
present invention may contain a foundation reinforcement pad 40 which is
located on top of
the mattress foundation 38 (hereinafter referred to as "foundation pad" and
synonymous with
"first reinforcement pad" such as pads 10, 26 and 36 as described). The
foundation
reinforcement pad 40 creates a raised area between the mattress foundation 38
and a mattress
bottom pad 42. The mattress bottom pad 42, and/or the bottom of the mattress
core 14, can
be configured with an opening therein to receive the raised or projecting
profile of the
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foundation reinforcement pad 40 which protrudes into the bottom of the
mattress core 14.
The mattress bottom pad 42 is located between the mattress foundation 38 and
the mattress
core 14. In an altemate construction the mattress bottom pad 42 is excluded,
in which case
the foundation reinforcement pad 40 protrudes directly into the mattress core
14. The
foundation pad 40 may be positioned in a central region of the mattress 100 to
reinforce the
pelvic and lumbar areas of the mattress 100, or the foundation pad 40 may bc
placed at any
location between the head and foot of the mattress 100, or there may be
multiple foundation
pads 40 located on the foundation 38. The higher density stitching 161 in
quilt package layer
16 is preferably of grcater density in the area or areas overlying the
foundation pad(s) 38 as
with the previously described embodiments, to provide thc same or similar
combination of
increased support and density which provides more even distribution of
pressure and
resistance to permanent deformation.
While the raised areas of the pad described in the previous embodiments are
described
as corresponding to the head/neck and lumbar regions of the mattress, the
raised areas may be
located anywhere from head to foot of the mattress. The raised areas may be
achieved by a
mechanical device or assembly to allow for adjustability both vertically and
laterally (head to
foot). This includes pneumatic and fluid mediums. The raised areas may
alternatively be
achieved by materials including, but not limited to: polyethylene foam;
polyurethane foam;
visco-elastic (memory) foam; latex foam; wood; rubber; fibers; cardboard;
cloth/ticking;
blended fabrics; and hard polymers (nylon, delrin, etc.).
The upholstery or comfort layers 15 of the mattress assembly of the present
invention
include one or more foam layers that are placed above the one or more
reinforcement pads, as
described above, and below the quilted package layer 16. The comfort layers 15
can include
anywhere from one to five foam layers of the same or different types of foam.
In one
embodiment, the comfort layer is comprised of one layer of regular or super
soft polyurethane
foam ranging from 1 inch to 3 inches in thickness and ranging in density from
1.10 lbs/ft3 to
1.135 lbs/ft3. In another embodiment, the comfort layers are comprised of two
foam layers
that are made of either regular or super soft polyurethane foam, visco-elastic
foam or a
combination thereof. Each of the two layers ranges in thickness from 1 inch to
3 inches and
each layer range in density from 1.10 lb/ft3 to 2.5 lbs/ft3. In still another
embodiment, the
comfort layers are comprised of three foam layers than can be regular, super
soft or high
performance polyurethane, visco-elastic or a combination thereof. Each of the
three layers
ranges in thickness from 1 to 3 inches and range in density from 1.10 lb/ft3
to 1.45 lb/ft3. In
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still another embodiment, the comfort layers are comprised of four foarn
layers that can be
regular, super soft, or high performance polyurethane, visco-elastic or latex.
Each of the four
layers ranges in thickness from 1 to 3 inches and range in density from 1.10
lb/ft3 to 1.45
lb/ft3. In yet another embodiment, the comfort layers are comprised of five
foam layers that
can be regular, super soft, or high performance polyurethane, visco-elastic or
latex. Each of
the five layers ranges in thickness from 1 to 3 inches and range in density
from 1.10 lb/ft3 to
1.45 lb/ft3. In each of the embodiments described herein, the foam may be
crushed or prc-
compressed during the manufacturing process or before or after being sliced
into layers. This
process, which breaks some of the interstitial bonds in the foam material
network causes the
foam layers to have less of a change in ILD or less change in feel of the
mattress as it is
repeatedly compressed over time. Also, with regard to the comfort layer(s) 15,
a layer or
inner panel of fabric may be placed between the various layers of the comfort
or upholstery
layers, or one or more fabric layers may be placed between the mattress and
the pillow top.
A mattress core 14 provides a distributed, generally homogenous reflexive
support
system to provide underlying support for the mattress. In the present
invention, the mattress
core 14 may be, in one embodiment, an innerspring having a plurality of
interconnected
spring elements or coils. The springs elements are arranged in rows and
columns, each spring
having a body with a first end and a second end, the body of each coil being
generally
cylindrical and having a longitudinal axis and an outer diameter, the springs
being spaced
apart in the rows and columns and connected together in a spaced apart
arrangement with
each spring being spaced from each other spring in the array. The coils may be
connected or
laced together using helical lacing wires. In another embodiment, the coils
may be placed in
individual pockets of fabric and sewn or bonded together.
In an alternate embodiment, a foam support core can be used in place of an
innerspring as the mattress core. A foam support core may consist of a single
monolithic
piece of foam or may contain multiple foam layers of one or multiple types of
foam such as
polyurethane, visco-elastic or latex foam. The foam layers may be made of
different types of
foam having different densities and thickness measurements. Each of the
described mattress
constructions can be implemented with a foam core or an innerspring core.
An optional edge support system 20 may also be used to increased support the
perimeter of the innerspring. In one embodiment, a mattress foundation
perimeter structure
20 is made of one or more foam square or rectangular shaped three-dimensional
components
which extend from a frame of the foundation to a border wire of the
foundation. The foam
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components of the perimeter structure 20 have at least some attributes of
structural rigidity,
flexure and resilience which cooperates with movement or deflection of the
border wire
and/or the grid. In another embodiment, the perimeter wall structure 20 is
made of foam or
other compressible material, and can be formed as a single molded structure
which fits at the
perimeter of a mattress core 14 and extends from the frame to the grid of the
mattress
foundation 18. In another embodiment, the inner wall of the perimeter
structure 20 contains
fingers which extcnd out into the innerspring and mechanically engage the
coils located along
the outer edge or perimeter of the innerspring. In yet another embodiment, the
inner wall of
the perimeter structure 20 may contain a scalloped shape so that portions of
the perimeter
structure 20 do not extend into the coils, but fill in the space between each
of the coils in the
innerspring. In still another embodiment, the edge support system 20 includes
a substantially
planar base pad that is placed below the innerspring. This base pad extends
beyond the length
and width of the innerspring and contains a narrow pre-formed slit or opening
at each of the
four comers of the pad. The slit or opening at each comer allows the excess
material to be
folded in an upward direction, thereby enveloping the perimeter of the
innerspring.
In addition to the optional mattress edge support system 20, as described
above,
various foam inserts may also be used in combination with a mattress
innerspring to provide
additional support and to soften the feel of the innerspring. For example,
individual foam
inserts may be placed between the convolutions of certain coils to provide
additional support
in areas of the mattress that are heavily used or where the most pressure is
concentrated.
Alternatively, foam inserts may be placed in the space between individual
coils of the
innerspring.
In a preferred embodiment, the reinforced mattress assembly of the present
invention
includes a quilt package layer 16 which incorporates zoned stitching, i.e.,
areas of greater
stitch density, as shown for example in FIGS. 1 and 8, wherein zones of
relatively higher
density of stitch density are formed in the quilt package layer 16 in areas or
regions which
correspond with the underlying reinforcement pad or pads. As used herein,
"zoned stitching"
or "zoned quilting" refers to the different densities or patterns of stitches
or the amount of
space between individual stitches in certain areas of the quilt package layer
16. When in the
form of quilt stitches, the higher density stitches may extend entirely
through the upholstery
layer, or from the top surface of the mattress to one or more of the
underlying layers.
Additional density in those areas may also be in the fabric material of the
tick fabric, where
additional yarns are added, or the yam density is increased through the woven
or knit pattern
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of the fabric. Adding additional stitches or creating a more densely arranged
pattern in
certain areas of the outer top surface of the mattress creates zones which are
firmer and more
compressed than the other areas containing fewer stitches or a more openly
spaced stitch
pattern. Higher stitch density in the quilt package layer can also be achieved
by tufting which
extends through the quilt package layer and compresses the layers together.
Tufting can be in
the form of stitches or repeated stitch patterns or designs, or twinc or
string or tape which
extends through the quilt package layer. The zoned quilting selectively pre-
compresses areas
of the mattress beneath which one or more reinforcement pads are positioned,
such as for
example, the reinforcement pad in the central and/or head and/or foot regions
of the mattress
as described. The additional foam components may cause these areas to bc
elevated with
relation to the other areas of the mattress that don't include the extra foam
layers. While the
reinforcement padding raises the elevation of those portions of the mattress,
the zoned
quilting selectively compresses those same areas or regions, thereby creating
relatively more
dense area and an even or level top surface in the quilt package layer of the
mattress, and
providing built-in resistance to any permanent indentation of those areas as
may otherwise
occur in a homogeneous mattress construction. The color or pattern of the
quilt stitching or
outer fabric of the quilt package layer may be varied by zone so that a user
may visually
identify the areas of the mattress that are reinforced or that provide
additional foam padding.
Zone quilting may be used in combination with any of the additional foam
reinforcement
pads, as described above.
It will be appreciated by persons skilled in the art that numerous variations
and/or
modifications may be made to the invention as shown in the specific
embodiments without
departing from the spirit or scope of the invention as broadly described. The
present
embodiments are, therefore, to be considered in all respects as illustrative
and not restrictive.
Other features and aspects of this invention will be appreciated by those
skilled in the art
upon reading and comprehending this disclosure. Such features, aspects, and
expected
variations and modifications of the reported results and examples are clearly
within the scope
of the invention where the invention is limited solely by the scope of the
following claims.
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