Composite Mattresses with Air Chambers

This application is a continuation of U.S. patent application Ser. No. 18/236,776, filed Aug. 22, 2023 and titled COMPOSITE MATTRESSES WITH AIR CHAMBERS (“the '776 Application”), which is a continuation of U.S. patent application Ser. No. 17/568,478, filed Jan. 4, 2022 and titled COMPOSITE MATTRESSES WITH AIR CHAMBERS (“the '478 Application”), issued as U.S. Pat. No. 11,730,277 on Aug. 22, 2023, which is a continuation of U.S. patent application Ser. No. 17/176,498, filed on Feb. 16, 2021 and titled COMPOSITE MATTRESSES WITH AIR CHAMBERS (“the '498 Application), issued as U.S. Pat. No. 11,213,139 on Jan. 4, 2022. The '498 Application includes a claim for priority under 35 U.S.C. § 119(e) to the Feb. 13, 2020 filing date of U.S. Patent Application No. 62/976,173, titled COMPOSITE MATTRESSES WITH AIR CHAMBERS (“the '173 Provisional Application”). The entire disclosures of the '776 Application, '478 Application, the '498 Application, and the '173 Provisional Application are hereby incorporated herein.

This disclosure relates generally to mattresses with air chambers and, more specifically, to composite mattresses that include air chambers. Such composite mattresses may comprise modular mattresses, in which a mattress base that includes air chambers may be used with any of a variety of modular tops. Cushioning methods and methods for personalizing a mattress are also disclosed.

A variety of airbed mattresses are currently available. An airbed mattress typically includes a plurality of air chambers supported, laterally surrounded by, and covered by layers of foam. Air pressure within the air chambers may be adjusted to provide the air mattress or a portion (e.g., a side, a head section, a lumbar section, a foot section, etc.) thereof with a desired level of firmness or softness. While existing airbed mattresses enable an individual to choose the firmness or softness of the mattress or various portions thereof, the cushioning options they provide to consumers are limited.

Various embodiments of mattresses are disclosed that combine the air chambers of a conventional airbed mattress with premium cushioning elements.

A mattress according to this disclosure, which may comprise an airbed mattress, may also be referred to herein as a “composite mattress.” Such a mattress may include a pressurizable layer with at least one air chamber, a top layer that comprises a cushioning element over the pressurizable layer, and a cover.

In a specific embodiment, from its base to its upper, supporting surface, a composite mattress according to this disclosure may include a base panel of a cover, or “base cover,” a base layer, the pressurizable layer, an intermediate layer, the top layer, and a top panel of the cover, or “top cover.” A foundation, or rail, may laterally surround the pressurizable layer, at least a portion of the intermediate layer, and the top layer. A periphery of the cover, which may be referred to herein as a “cover periphery,” may laterally surround the foundation, and may extend between the base cover and the top cover. In some embodiments, such a mattress may also include a coiled spring layer, which may comprise an array of mattress springs. Such a coiled spring layer may be located beneath the air chamber(s) or between the top layer and the air chamber(s).

The base layer of such a mattress may comprise a relatively stiff, or firm, element or it may comprise a compressible, resilient cushioning element with a desired rate of return. The base layer may be substantially contiguous, or uninterrupted across its entirety. Alternatively, the base layer may comprise a plurality of resiliently compressible walls that defines a plurality of resiliently buckling columns and a void within each column.

The pressurizable layer may comprise a single air chamber or a plurality of air chambers. In some embodiments, a single column of air chambers that extend substantially from one side of the mattress to the other (i.e., horizontally) may be arranged from substantially one end of the mattress (e.g., a head end of the mattress, etc.) to the other end of the mattress (e.g., a foot end of the mattress, etc.) (i.e., vertically). In other embodiments, a single row of air chambers that extend substantially from one end of the mattress (e.g., the head end of the mattress, etc.) to the other end of the mattress (e.g. the foot end of the mattress, etc.) (i.e., vertically) may be arranged substantially from one side of the mattress to the other side of the mattress (i.e., horizontally). In still other embodiments, an array of air chambers may be organized substantially across the mattress. In these contexts, the term “substantially” has been used to indicate the possible presence of lateral support members, or foundations, at one or more locations around the outer periphery of the composite mattress.

In embodiments where the mattress includes a plurality of air chambers, each air chamber of the plurality may be pressurized (e.g., inflated, deflated, etc.) independently of every other air chamber of the plurality.

The intermediate layer may comprise a cushioning element. The cushioning element may comprise any suitable material. As an example, the intermediate layer may include a material that is compressible and has a desired resilience and rate of return. The intermediate layer may be substantially contiguous, or uninterrupted across its entirety. The base layer may comprise a plurality of resiliently compressible walls that defines a plurality of resiliently buckling columns and a void within each column.

The cushioning element of the top layer may comprise a premium cushioning element, such as a cushioning element formed from an elastomeric gel, a cushioning material that flows non-resiliently under pressure (i.e., a cushioning material that has little or no return), or any other suitable cushioning material. In some embodiments, the base layer may comprise a plurality of resiliently compressible walls that defines a plurality of resiliently buckling columns and a void within each column. In some embodiments, the top layer may be substantially contiguous, or uninterrupted across its entirety.

The top layer may also comprise one or more cushioning elements. In embodiments where the top layer includes a plurality of cushioning elements, the cushioning elements may be superimposed relative to one another. In embodiments where two or more of the cushioning elements include a plurality of resiliently compressible walls that define an array of resiliently buckling columns and a void within each column, the resiliently compressible walls and the resiliently buckling columns may be offset.

The top layer may be laterally surrounded and supported by an upper foundation, or an upper rail. The upper foundation may comprise any suitable material. As an example, the upper foundation may comprise a structured foam.

The foundation, which may also be referred to as a “lower foundation,” may include one or more peripheral foundation members that define a foundation receptacle. In some embodiments, the foundation may include four members that at least partially define a periphery of the mattress (e.g., a head member, a foot member, and two side members, etc.). The foundation receptacle receives the base layer, the pressurizable layer, and the intermediate layer.

The cover periphery laterally surrounds the foundation, the base layer, the pressurizable layer, and the intermediate layer, as well as the top layer. In some embodiments, at least a portion of the cover periphery may extend (e.g., upwardly, etc.) from peripheral edges of the base panel of the cover, which may also be referred to as the “cover base.” In some embodiments, a base portion of the cover periphery may be continuous with peripheral edges of a base panel of the cover, with base portion of the cover periphery and the base panel defining a base portion of the cover. Together, the base and the base portion of the cover periphery may also define a receptacle of the base portion of the cover, which may receive the foundation, any elements carried by the foundation receptacle, and, optionally, at least part of the intermediate layer of the composite mattress.

A coupler or a portion of a coupler may enable the top portion of the cover to be secured to the base portion of the cover. Such a coupler may be located at or adjacent to a top edge of the base portion of the cover. More specifically, one coupling element of the coupler may be located at or adjacent to a top edge of the base portion of the cover, while another complementary coupling element of the coupler may be associated with the top portion of the cover.

In some embodiments, the cover periphery may also include a top portion, which may extend from and even be continuous with peripheral edges of a top panel of the cover. In such embodiments, the top portion of the cover periphery and the top panel may define a top portion of the cover. In such embodiments, the base coupler may be located at or adjacent to a top edge of the base portion of the cover, while the top coupler may be located at or adjacent to a bottom edge of the top portion of the cover.

The base portion of the cover may carry the foundation, the base layer, the pressurizable layer, the intermediate layer, and the base coupler. Together, these elements may define a base of the mattress, or a “mattress base.” The top portion of the cover may carry the top layer and other optional elements (e.g., an upper foundation, an upper frame, one or more additional layers, etc.) that may define a top of the mattress, or a “mattress top.”

The mattress base of this disclosure may be used with and coupled to any of a variety of mattress tops. Likewise, any of a variety of mattress bases of this disclosure may be used with and coupled to a particular mattress top. Thus, mattress bases and mattress tops according to this disclosure may be modular, enabling an individual (or a couple) to select a mattress base with particular characteristics (e.g., a configuration of air chambers; an arrangement of air chambers, coils, and/or other layers; etc.) and a mattress top with particular characteristics (e.g., thickness, cushioning properties, arrangement of top cushioning layers, etc.). In some embodiments, a single mattress base may have a configuration that enables it to receive two or more mattress tops. In other embodiments, two or more mattress bases may collectively receive a single mattress top.

According to another aspect of this disclosure, the modularity of various embodiments of a mattress according to this disclosure may enable various methods for personalizing a mattress. In such a method, an individual (or a couple) may select a mattress base or a plurality of mattress bases. The mattress base may comprise a modular mattress base with one or more desired features and/or characteristics. In some embodiments, the mattress base may include an air chamber or a plurality of air chambers in a desired arrangement. Optionally, the mattress base may include a layer of coil springs, or a “coiled spring layer,” and, in some embodiments, other layers. A coiled spring layer may be located under and/or over the pressurizable layer; in some embodiments, the coiled spring layer(s) may be located adjacent to the pressurizable layer, with only a compliant intervening layer located between each coiled spring layer and the pressurizable layer.

The individual (or the couple) may also select a mattress top or a plurality of mattress tops that is/are compatible with a selected mattress base(s). The mattress top may include a top layer that includes a plurality of compressible walls defining an array of buckling columns and a void within each column.

Once the mattress base(s) and the mattress top(s) have been selected, the mattress top(s) may be positioned over the mattress base(s) and coupled to the mattress base(s).

This disclosure also includes cushioning methods. A cushioning method according to this disclosure may include positioning at least part of an individual's body on a cushioning layer that comprises a plurality of compressible walls defining an array of buckling columns to support at least that part of the individual's body. In addition, one or more air chambers beneath the cushioning layer may be individually pressurized (e.g., inflated, deflated, etc.) to define a contour of the cushioning layer. Individual pressurization of one or more of the air chambers may occur before positioning at least part of the individual's body on the cushioning layer. Alternatively, one or more of the air chambers may be individually pressurized after the cushioning layer supports at least part of the individual. Pressurization of one or more of the air chambers may be adjusted while the cushioning layer and the air chambers support at least part of the individual's body. In some embodiments, pressurization adjustments may occur automatically, in accordance with a program (e.g., based on one or more of a pressure profile of the individual over the cushioning layer, other sensed parameters (e.g., snoring, breathing patterns, etc.), timing (e.g., time of day, time during an individual's sleep cycle, etc.).

Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, should become apparent to those of ordinary skill in the art through the preceding disclosure, the images that follow, and the appended claims.

Referring to, a portion of a composite mattressaccording to this disclosure is depicted. The composite mattressmay include a base layer, a pressurizable layer, an intermediate layer, and a top layerin superimposed relation. Optionally, the composite mattressmay include a base cushion. A foundationmay extend around the optional base cushion, the pressurizable layer, the intermediate layer, and the top layer. A covermay enclose or envelop all of the other components of the composite mattress.

The base layerof the composite mattressmay provide a barrier between the next adjacent element (e.g., the base cushionin, the pressurizable layerin, a coiled spring layerin, etc.) and an exterior, base surface() of the composite mattress. The base layermay also support the elements superimposed over it.

In some embodiments, the base layermay comprise a relatively stiff but somewhat flexible element. As an example, such a base layermay be formed from a layer of a “structured foam,” which may comprise a compressible foam material with an indentation load deflection (ILD) rating of about 40 or greater (e.g., 40, 45, 50, 55, 60, etc.). An ILD rating is the amount of pressure, converted to weight in pounds, it takes to indent a circular area of 50 square inches (i.e., lbs/50 in2) over a four inch thick piece of the structured foam by 25% (i.e., one inch). In a specific embodiment, the base layermay comprise a layer of polyurethane foam with a nominal density of about 2.0 lb/ft3 and an ILD rating of 50-55.

In other embodiments, the base layermay comprise a cushioning element. For example, the base layermay have an ILD rating of 20 or less. Such a base layermay comprise a layer of a readily compressible foam material (e.g., a polyurethane foam, a foam rubber, etc.). Alternatively, such a base layermay be a cushioning element that comprises a plurality of resiliently compressible walls defining an array of resiliently buckling columns and a void within each column, such as the cushioning elements disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750, the entire disclosures of which are hereby incorporated herein. Such a cushioning element may be formed from any of a variety of compressible, resilient materials, including cushioning foams and elastomeric materials, such as the extended A-B-A triblock copolymers disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765 and 7,964,664, the entire disclosures of which are hereby incorporated herein.

An optional base cushionmay be positioned over the base layer, as illustrated by. The optional base cushionmay be a cushioning element with a plurality of resiliently compressible walls defining an array of resiliently buckling columns and a void within each column, such as the cushioning elements disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750, which may be formed from any suitable material, including but not limited to an extended A-B-A triblock copolymer, such as those disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765 and 7,964,664.

The pressurizable layermay also be positioned over the base layer. The pressurizable layermay comprise one or more air chambers(air chambers,, etc., are shown in). The air chamber(s)of the pressurizable layermay be selectively inflated and/or deflated in any suitable manner known in the art. Each air chambermay comprise a material that will enable the air chamberto expand, or inflate, when the air pressure therein is increased; thus, each air chambermay include one or more flexible walls. The material from which each air chamberis formed may be impermeable to air (i.e., it may receive and substantially retain air for prolonged periods of time (e.g., months, years, etc.).

In some embodiments where the pressurizable layerincludes a plurality of air chambers, the air chambersmay be elongated and arranged parallel to one another; elongated air chambersmay be oriented across at least a portion of a width of the composite mattress. For example, elongated air chambersmay be extend across non-peripheral areas of the composite mattress. As another example, elongated air chambersmay extend across non-peripheral and non-midline areas of a side, or half, of the composite mattress. In other embodiments where the pressurizable layerincludes a plurality of air chambers, the air chambersmay have regular polygonal shapes (e.g., square, hexagonal, etc.) and be arranged in an array.

In some embodiments, the air chamber(s)of the pressurizable layermay be removed and replaced. Removal and replacement of the air chamber(s)may be useful in situations where an air chamberfails, an upgraded air chamberis desired, and the like.

A pressurization system (not shown), including one or more air pumps, conduits, electronics, and programming, as known in the art, may be associated with the pressurizable layer.

The intermediate layerof the composite mattressmay be positioned over the pressurizable layer. The intermediate layermay comprise a cushioning element that transmits variations in pressure from the pressurizable layerto the layers (e.g., the top layer, etc.) of the composite mattresslocated over the intermediate layer. By way of example, the intermediate layermay include one or more layers of a compressible, resilient foam (e.g., a foam rubber, a memory foam (e.g., a viscoelastic polyurethane foam, etc.), etc.). As another example, the intermediate layermay comprise a cushioning element with a plurality of resiliently compressible walls defining an array of resiliently buckling columns and a void within each column, such as the cushioning elements disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750, which may be formed from any suitable material, including, but not limited to, an extended A-B-A triblock copolymer, such as those disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765 and 7,964,664.

The top layerof the composite mattressmay be positioned over the intermediate layer. The top layerprovides desired cushioning properties and a desired firmness (e.g., ILD rating, etc.) for an individual as he or she lies on the composite mattress. The top layermay have an ILD rating of about 12 to 16.5 (super-plush), 16.5 to 22.5 (plush), 22.5 to 26.5 (soft), 26.5 to 30.5 (medium), 30.5 to 34.5 (firm), 34.5 to 38.5 (extra-firm), or greater.

As shown in, the top layermay comprise a cushioning element with a plurality of resiliently compressible wallsdefining an array of resiliently buckling columns and a voidwithin each column. Embodiments of such cushioning elements are disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750. The resiliently compressible wallsof the top layermay be formed from any suitable material, including, but not limited to, an extended A-B-A triblock copolymer, such as those disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765 and 7,964,664.

In other embodiments, the top layermay comprise a cushioning material that non-resiliently flows under pressure. Such a cushioning element may include a pliable bladder that contains a plurality of cushioning elements (e.g., hollow acrylic microspheres, etc.) within a flowable (e.g., semisolid, liquid, etc.) lubricant (e.g., a silicone, etc.), similar to the cushioning elements disclosed by U.S. Pat. No. 6,197,099 of Pearce, the entire disclosure of which is hereby incorporated herein.

With continued reference to, the foundationof the composite mattressmay extend around an optional base cushionand the pressurizable layer. In some embodiments, the foundationmay also extend around the intermediate layerand/or the top layer. The foundationmay include a plurality of walls,,,arranged about the periphery of the base layerat the head (wall), foot (wall), and sides (wallsand) of the composite mattress. For the sake of simplicity, each of the walls-may also be referred to herein as a “wall” and two or more of the walls-may be referred to as “walls.” In some embodiments, such as that depicted by, the wallsmay surround an outer periphery of the base layer. In other embodiments, such as that depicted by, the wallsmay be positioned on peripheral portionsof the base layer. Together, the wallsand the base layermay define a receptaclefor an optional base cushion, the pressurizable layer, and, optionally, the intermediate layerand/or the top layer, as well as other interior elements, or interior components, of the composite mattress. As can be seen from, in some embodiments, the wallsof the foundationmay include two or more layers.

The wallsof the foundationmay comprise relatively stiff but somewhat flexible elements. As an example, the wallsmay be formed from a layer of a structured foam. The wallsmay be formed from the same structured foam as the base layeror from a different (e.g., less rigid, etc.) structured foam. An ILD rating of the foundation, or its walls, may exceed the ILD rating of the top layer. In a specific embodiment, the wallsof the foundationmay comprise polyurethane foam with a nominal density of about 2.0 1b/ft3 and an ILD rating of 35-55. In other embodiments, the wallsof the foundationmay comprise a so-called “spacer fabric,” such as that disclosed by U.S. Pat. No. 10,881,217, the entire disclosure of which is hereby incorporated herein.

The coverof the composite mattressmay be placed over and contain all of the interior elements, or interior components, of the composite mattress. Without limitation, the covermay be placed over and contain the base layer, any base cushion, the pressurizable layer, the intermediate layer, the top layer, and the foundation. In some embodiments, the covermay include a base portion, a top portion, and coupling elementsandof a couplerthat secure the base portionto the top portion.

The base portionof the covermay carry or even contain, or enclose or envelop, elements at the baseof the composite mattress, such as the base layer, the pressurizable layer, at least a base portion of the foundation, and, optionally, a portion of the intermediate layer, as depicted by. A first coupling elementof the couplermay be positioned adjacent to or on an upper periphery of the base portionof the cover. The top portionof the covermay carry or even contain, or enclose or envelop, elements at the topof the composite mattress, such as a portion of the intermediate layerand the top layer, as shown in. A second coupling elementof the couplermay be positioned adjacent to or on a lower periphery of the top portionof the cover.

In embodiments where the base portionand top portionof the covercontain their respective elements of the composite mattress, the resulting baseand topof the composite mattressmay be readily assembled with and disassembled from one another. In some embodiments, a single base portionand, thus, a single baseof a composite mattressmay have configurations that enable them to receive two or more top portionsand, thus, two or more portions of a topof the composite mattress. In other embodiments, two or more base portionsand, thus, portions of a baseof a composite mattressmay collectively receive a single top portionof the coverand, thus, a single topof the composite mattress.

The separable base portionand top portionmay impart a composite mattresswith modularity. More specifically, a base portionof the covermay be used with a plurality of different basesand/or the top portionof the covermay be used with a plurality of different topsto enable an individual or a couple to select and basesand/or topswith particular characteristics.

The covermay comprise any suitable material. A top panelof the top portionof the covermay comprise a fabric that carries a resiliently compressible web on a surface (e.g., an underside, etc.) thereof. The resiliently compressible web may define a structured array, or a grid, of regular polygonal openings (e.g., a hexagonal array, or a hexagonal grid, of openings, etc.). The resiliently compressible web may be formed from any suitable material, such as an elastomeric material (e.g., an extended A-B-A triblock copolymer, such as those disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765 and 7,964,664, etc.). In some embodiments, the resiliently compressible web of such a top panelmay be located between a pair of superimposed layers of fabric.

The fabric of the top panel, as well as peripheral portions of the top portionof the cover, peripheral portions of the base portionof the cover, and, optionally, a base panelof the base portionmay comprise a stretchable material (e.g., a stretchable fabric, etc.). The stretchability of the material of the top paneland, optionally, of peripheral portions of the top portionand base portionof the covermay enable an individual to experience the full cushioning effect of the cushioning elements of the composite mattress. Stated another way, the stretchability of the material of the top paneland, optionally, of peripheral portions of the top portionand base portionof the covermay not limit the extent to which the composite mattress(e.g., the top layer, etc., thereof) may cushion an individual sitting or lying on the composite mattressor an object that has been placed on the composite mattress. Additionally, the stretchability of the material of the top paneland, optionally, of peripheral portions of the top portionand base portionof the covermay enable complete or substantially complete (e.g., due to a thickness of the top panel, etc.) transmission of the effects of pressurization of the pressurizable layeron an upper surface of the top layerthrough the top panel. U.S. Patent Application Publication US 2017/0251825 A1, the entire disclosure of which is hereby incorporated herein, provides examples of stretchable materials that may be used to form the coveror parts thereof.

In some embodiments where a base panelof the base portionof the coverdoes not comprise the same material as a remainder of the cover, a non-stretchable material may form the base panel. A fabric that is non-stretchable may stretch due to a weave of the fabric, but lack stretchable fibers. Such a fabric may comprise a so-called “non-skid” fabric.

The couplerand its coupling elementsandmay comprise any apparatus(es) that may enable the baseand topof the composite mattressto be secured to each other. Without limitation, the couplermay comprise one or more zippers, with the first coupling elementcomprising a first side, or ribbon, of the zipper and the second coupling elementcomprising a second side, or ribbon, of the zipper. In addition, such a coupling elementmay include a zipper pull (not shown), the use of which (i.e., movement along the length of the zipper) causes the coupling elementsandto selectively engage and/or disengage each other. Other embodiments of couplersinclude other mutually engaging elements, such as buttons and buttonholes, snap-fit features, touch fasteners (e.g., so-called “velcro” fasteners, etc.), and the like.

depicts an embodiment of composite mattressin which a baseof a composite mattressincludes a bottom portionof a coverthat encloses or envelops a base layer, a foundation, a pressurizable layer, and an intermediate base layer. The foundationsits atop peripheral portionsof the base layerand laterally surrounds the pressurizable layer. The pressurizable layerincludes a plurality of air chambers,, etc. The intermediate base layersits atop the foundationand the pressurizable layer.

The topof the composite mattressshown inincludes a top portionof the coverthat encloses or envelops an intermediate top layer, a top layer, and an upper foundation. The upper foundationsits atop peripheral portionsof the intermediate top layerand laterally surrounds the top layer. The upper foundationmay comprise a relatively stiff but somewhat flexible element. As an example, the upper foundationmay be formed from a foam or a structured foam. An ILD rating of the upper foundationmay exceed the ILD rating of the top layer. In a specific embodiment, the upper foundationmay comprise polyurethane foam with a nominal density of about 2.0 1b/ft3 and an ILD rating of 25-55. In other embodiments, the upper foundationmay comprise a spacer fabric of the type disclosed by U.S. Pat. No. 10,881,217.

When the topof the composite mattressis positioned over the baseof the composite mattress, the intermediate base layerand the intermediate top layermay be positioned in proximity to each other. These layers, as well as portions of the base portionand top portionof the coverbetween them, may comprise an intermediate layerof the composite mattress. As depicted by, the intermediate base layerand the intermediate top layermay comprise a compressible, resilient foam (e.g., a foam rubber, a memory foam, etc.).