Multi-Air Chamber Mattress with Localized Support

This application is a continuation of U.S. application Ser. No. 17/862,817, filed on Jul. 12, 2022, which claims priority to U.S. Provisional Application Ser. No. 63/223,253, filed on Jul. 19, 2021, the disclosure of which is incorporated by reference in its entirety.

This document describes devices, systems, and methods related to mattresses with air chambers and foam support.

In general, a bed is a piece of furniture used for sleeping and relaxing. Many modern beds include a soft mattress on a bed frame. The mattress may include springs, foam material, and/or air chambers to support the weight of one or more users. Various features and systems have been used in conjunction with beds, including pressure adjustment systems for adjusting firmness of one or more users of the bed.

The document generally relates to mattresses with multiple interconnected air chambers that can be spaced by foam or some other intermediary structure other than the air chambers. More specifically, the document relates to air mattress systems with a plurality of air chambers that can be positioned in such a way to provide support and sleeper spine alignment through a full range of firmness pressure settings.

Pressure distribution and support (e.g., spine alignment) can be impacted in differing ways when a firmness is increased or decreased for an air mattress system. In some air mattress systems, when air pressure is decreased in air chambers of the mattress, the mattress can become more comfortable but spine alignment can be reduced. Reduced spine alignment can cause decompression in portions of the user's body, which can negatively impact the user's sleep quality.

Some embodiments described herein include an air mattress system, which can have adjustable air chambers designed to increase or decrease surface firmness while providing spine alignment and comfort for the user. The air chambers can be configured in a way to allow for improved pressure distribution while also targeting a supportive result for one or more users of the mattress system. For example, some embodiments described herein include two separate air chambers, one located below a hip region and the other located below a shoulder region of the mattress. The two air chambers can be fluidly connected and driven or adjusted by a single pressure signal. Space between the two chambers can be filled with a foam support or other similar material and/or structure. In some embodiments, multiple foam supports can be positioned between the two air chambers. In some embodiments, one or more foam inserts can also be positioned between each of the air chambers and head and/or foot ends of the mattress system. In some embodiments, the mattress system can have two sections (i.e. left and right sections) to accommodate two users on the bed. Each of the sections can include a set of air chambers and one or more foam inserts. Pressure can then be adjusted for each section based on preferences of each of the two users.

Some embodiments described herein include a mattress comprising: a first air chamber, a second air chamber fluidly connected to the first air chamber, and a foam insert positioned between the first air chamber and the second air chamber.

In some implementations, the mattress can optionally include one or more of the following features. For example, the first air chamber can be positioned at a shoulder region of the mattress and the second air chamber can be positioned at a hip region of the mattress. The first air chamber and the second air chamber can have a common internal pressure. Decreasing the common internal pressure in the first air chamber and the second air chamber can cause the foam insert positioned between the first air chamber and the second air chamber to increase support at a lumbar region of the mattress.

As another example, one or more additional foam inserts can be positioned between at least one of (i) the first air chamber and a head end of the mattress, (ii) the first air chamber and the second air chamber, and (iii) the second air chamber and a foot end of the mattress. The mattress can also include a foam rail structure including a head portion, a foot portion, and first and second side portions, the foam rail structure configured to extend around a perimeter of the mattress to surround the first air chamber, the foam insert, and the second air chamber. The second air chamber can extend from a hip region of the mattress to a location adjacent to an inner surface of the foot portion of the foam rail structure. The first air chamber can extend from a location adjacent to an inner surface of the head portion of the foam rail structure to a shoulder region of the mattress.

As yet another example, the foam insert can include a foam cushion. The foam insert can include a rectangular open cell foam cushion positioned between the first air chamber and the second air chamber at a location exterior to both the first air chamber and the second air chamber. The foam insert can be positioned between the first air chamber and the second air chamber so as to physically separate the first air chamber from the second air chamber longitudinally.

The mattress can further include a first section extending longitudinally between a head end and a foot end of the mattress and extending laterally between a left side and a midline of the mattress, and a second section extending longitudinally between the head end and the foot end of the mattress and extending laterally between a right side and the midline of the mattress. The first section can include the first air chamber, the second air chamber, and the foam insert, and the second section can include a third air chamber, a fourth air chamber fluidly connected to the third air chamber, and a second foam insert positioned between the third air chamber and the fourth air chamber.

In some implementations, the third air chamber and the fourth air chamber can have a second common internal pressure, wherein the second common internal pressure is different than the common internal pressure of the first air chamber and the second air chamber. The foam insert within the first section can have a first firmness level and the second foam insert within the second section can have a second firmness level, wherein the first firmness level is different than the second firmness level.

In some implementations, the mattress can also include a foam layer positioned between a top surface of the mattress and each of (i) the first air chamber, (ii) the second air chamber, and (iii) the foam insert.

Some embodiments described herein include a mattress extending longitudinally between a head end and a foot end and extending laterally between left and right sides, the mattress including a first air chamber, a second air chamber fluidly connected to the first air chamber so as to have a common internal pressure in the first and second air chambers, and a first foam insert positioned between the first air chamber and the second air chamber so as to physically separate the first air chamber from the second air chamber longitudinally.

In some implementations, the mattress can optionally include one or more of the following features. For example, the mattress can also include a foam rail structure including a head portion, a foot portion, and first and second side portions. The foam rail structure can extend around a perimeter of the mattress, wherein the first air chamber can be positioned at a shoulder region of the mattress and extending laterally between locations adjacent to inner surfaces of the first and second side portions of the foam rail structure, and the second air chamber can be positioned at a hip region of the mattress and extending laterally between the locations adjacent to the inner surfaces of the first and second side portions of the foam rail structure.

The mattress can also include a second foam insert positioned between the first air chamber and a location adjacent to an inner surface of the head portion of the foam rail structure and extending laterally between locations adjacent to inner surfaces of the first and second side portions of the foam rail structure. In some implementations, the mattress can also include a third foam insert positioned between the second air chamber and a location adjacent to an inner surface of the foot portion of the foam rail structure and extending laterally between the locations adjacent to the inner surfaces of the first and second side portions of the foam rail structure. Sometimes, the second air chamber can extend longitudinally between the first foam insert and the location adjacent to the inner surface of the foot portion of the foam rail structure.

Some embodiments described herein include a mattress extending longitudinally between a head end and a foot end and extending laterally between a left side and a right side, the mattress having a first section extending longitudinally between the head end and the foot end and extending laterally between the left side and a midline of the mattress. The first section can include a first air chamber, a second air chamber fluidly connected to the first air chamber so as to have a first common internal pressure in the first and second air chambers, and a first foam insert positioned between the first air chamber and the second air chamber so as to physically separate the first air chamber from the second air chamber longitudinally. The mattress can also have a second section extending longitudinally between the head end and the foot end and extending laterally between the right side and the midline of the mattress. The second section can include a third air chamber, a fourth air chamber fluidly connected to the third air chamber so as to have a second common internal pressure in the third and fourth air chambers, and a second foam insert positioned between the third air chamber and the fourth air chamber so as to physically separate the third air chamber from the fourth air chamber longitudinally.

In some implementations, the mattress can optionally include one or more of the following features. For example, the mattress can further include a pump system having one or more air pumps fluidly connected to the first, second, third, and fourth air chambers. The pump system can be configured to inflate the first and second air chambers to the first common internal pressure and to inflate the third and fourth air chambers to the second common internal pressure, wherein the second common internal pressure can be different than the first common internal pressure.

The mattress can also include means for inflating the first and second air chambers to the first common internal pressure and inflating the third and fourth air chambers to the second common internal pressure. The mattress can also include means for containing the first, second, third, and fourth air chambers, the first and second foam inserts, and a foam layer positioned on top of each of the first, second, third, and fourth air chambers and the first and second foam inserts.

The devices, system, and techniques described herein may provide one or more of the following advantages. For example, the disclosed embodiments provide for improved spine alignment, stability, and surface continuity. For example, as air chamber pressure is uniformly decreased for the two air chambers, hip and shoulder regions can sink into the mattress, all while core and lumbar regions can remain supported by the foam insert between the two air chambers. As the air chambers deflate, the user's body can sink into the mattress more at the air chambers which can result in the foam providing more support to the user in waist/lumbar regions of the user's body. This added increased support in the waist and lumbar regions can enable an improved spine alignment for the user. Moreover, the improved spine alignment can be advantageous to improve overall sleep quality of the user. With better spine alignment, users can experience better sleep and more comfort.

As another example, some disclosed embodiments can provide for user customization of the air mattress system. The air chambers and foam inserts can be movably positioned within a rail structure of the mattress. As a result, the user can move a position or location of any of the air chambers and the foam inserts. The user can also swap out any one of the air chambers and foam inserts with other air chambers and/or foam inserts. For example, the user can insert one or more foam inserts having different firmness levels. The user may desire a firmer foam insert rather than a less firm foam insert. In other words, components of the air mattress system can be interchangeable by the user with increased and/or decreased firmness depending on the user's comfort preferences. The user can also insert multiple foam inserts in one or more regions in the mattress, between one or both of the two air chambers and one or both of the head end of the mattress and the foot end of the mattress. As another example, the components of the air mattress system can be moved or shifted between different zones or regions of the mattress system to accommodate for different user heights and/or comfort preferences. The user can change where each of the air chambers and/or the foam insert(s) is positioned within the mattress system. For example, a taller user can move the second air chamber closer to the foot end of the mattress to accommodate for their height. A shorter user can move the second air chamber closer to the head end of the mattress (e.g. closer to the first air chamber).

As another example, an air mattress system can have two sections, each with air chambers and foam insert(s) that can be customizable by two users of the bed. Therefore, when two users are sleeping in the bed, each user can adjust pressure settings for their respective air chambers. Each user can also move the air chambers and foam inserts in each of their respective sections. The disclosed embodiments can provide for each user to adjust their comfortability preferences independent of the other user.

As another example, the air chambers can be a same size, which can be cost effective in manufacturing and production of the air mattress system. The user can also replace or swap out one or more of the air chambers with differently sized chambers. Doing so can accommodate to the user's comfort preferences. For example, the user can swap out the second air chamber with a longer air chamber that extends from the hip region to the foot end of the mattress.

In embodiments where two (or more) air chambers are fluidly connected, a single pressure setting can be used when adjusting firmness of the mattress, which can provide a relatively simple system for a user to adjust mattress firmness. Using a single pressure setting can also provide for consistent spinal alignment (as opposed to allowing different pressure settings in each chamber which can result in one chamber being undesirably firm as compared to another chamber). Therefore, parts of the user's body can be balanced across the top surface of the mattress system. Moreover, fluid connection of the air chambers can provide for less costly manufacturing and greater case in maintenance or fixing components of the system as described herein.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

Like reference symbols in the various drawings indicate like elements.

This document generally relates to air mattress systems with foam or other suitable support and a plurality of air chambers that can be positioned in such a way to provide support and sleeper spine alignment through a range of firmness pressure settings.

Referring to the figures,is an example mattress systemas described herein. The mattress systemis depicted upside down to show components contained therein. The mattress systemcan include a rail structure, a first air chamberA, a second air chamberB, a first foam insertA, a second foam insertB, a third air chamberA, a fourth air chamberB, a third foam insertA, and a fourth foam insertB. The first and second air chambersA andB and the first and second foam insertsA andB can be part of a first section of the mattressthat extends longitudinally between a head endand a foot endof the mattress systemand extends laterally between a right side and a midline of the mattress system. The third and fourth air chambersA andB and the third and fourth foam insertsA andB can be part of a second section of the mattress systemthat extends longitudinally between the head endand the foot endof the mattress systemand extends laterally between a left side and the midline of the mattress system, as depicted in.

The rail structurecan be a foam structure positioned around a perimeter of the mattress system. The rail structurecan provide some shape and/or structural support to the mattress system. In some implementations, one or more additional foam layers can be inserted between the rail structureand one or more of the chambersA andA at the head endof the mattress system, as depicted and described further in reference to. The additional foam layers can be advantageous to help with positioning the chambersA andA farther away from the head endof the mattress system. Such a configuration can be preferred by a user who is shorter in height in comparison to a taller user.

The first, second, third, and/or fourth foam insertsA,B,A, andB, respectively, can be made of foam or some similar type of cushioning material, such as synthetic support materials (i.e. polymer materials) or natural support materials. In some implementations, all the foam insertsA,B,A, andB can have a same firmness level. Any one or more of the foam insertsA,B,A, andB can also have different firmness levels, based on user preference or as otherwise suitable for the application. For example, foam inserts that are positioned around the lumbar region of the mattress systemcan be more firm than foam inserts positioned around the foot region of the mattress system. Any one or more of the foam insertsA,B,A, and/orB can also include a rectangular open cell foam cushion. Such a foam cushion can, for example, be positioned between the first and second air chambersA andB and/or the third and fourth air chambersA andB at a location exterior to both sets of chambersA andB andA andB. As depicted throughout the disclosure, the foam insertsA,B,A, andB can be positioned between the first and second air chambersA andB and the third and fourth air chambersA andB, respectively, so as to physically separate the first air chamberA from the second air chamberB longitudinally and the third air chamberA from the fourth air chamberB longitudinally. One or more of the foam insertsA,B,A, andB can have different or same firmness levels based on user preference.

One or more of the first, second, third, and fourth foam insertsA,B,A, andB can be insertable and moveable inside the rail structure. Therefore, any one or more of the foam insertsA,B,A, andB can be replaced, switched with other supports, and otherwise moved to different regions or locations within the mattress systemas desired by the user. In some implementations, one or more of the foam insertsA,B,A, andB can be attached to the rail structure. For example, one or more of the foam insertsA,B,A, andB can be attached to a rail structureusing laminate, glue, adhesives, buttons, snaps, hook-and-loop fasteners, and/or zippers. In some implementations, one or more of the foam insertsA,B,A, andB can removably attach to the rail structureto retain it in place but also to provide customization of component arrangement within the mattress system.

The mattress systemcan be sized in a number of suitable mattress sizes, including Full, Queen, and King sized beds. In some of such implementations, the mattress systemcan include a first zone having the first air chamberA, the second air chamberB, the first foam insertA, and the second foam insertB. The mattress systemcan also include a second zone having the third air chamberA, the fourth air chamberB, the third foam insertA, and the fourth foam insertB. The first zone can be used by a first user and the second zone can be used by a second user. In some implementations, such as with Full, Twin, or Single beds, the mattress systemmay only include the first air chamberA, the second air chamberB, the first foam insertA, and the second foam insertB. The second air chamberB can be fluidly connected to the first air chamberA. Similarly, the fourth air chamberB can be fluidly connected to the third air chamberA in the mattress systemthat is Full, Queen, and/or King sized. As a result, a single zone air pressure (e.g., common internal pressure) can be maintained between the first and second air chambersA andB and the third and fourth air chambersA andB, respectively. Maintaining the single zone air pressure can be advantageous to make controlling adjustability settings of the mattress systemeasier for a user or users. Moreover, maintaining single zone air pressures can reduce manufacturing costs of the mattress system. For example, all air chambers can be produced in a same size having same pressure settings and adjustability features. As a result, if air chambers need to be fixed, swapped out, or otherwise replaced, maintenance costs can be lower and more affordable. Fixing any of the air chambers used in the mattress systemcan be easier and faster.

Maintaining a single air pressure between the first and second air chambersA andB and the third and fourth air chambersA andB can further provide spine alignment and lumbar support. Therefore, when air pressure is adjusted, portions of the user's body can be aligned relatively well both before and after the pressure adjustment. As pressure is uniformly decreased from the first and second air chambersA andB, the foam insertsA andB will not deflate with the chambersA andB. Therefore, the foam insertsA andB provide continuous support to waist, and/or lower leg regions to maintain or even improve spine alignment and overall comfortability, even when the user desires to lower pressure levels of the chambersA andB in the mattress system. Therefore, decreasing the common internal pressure in the first and second air chambersA andB can cause the foam insertA positioned between the chambersA andB to maintain or even increase support at the lumbar region of the mattress system.

As shown in, the first and third air chambersA andA can be positioned at the shoulder region of the mattress systemand the second and fourth air chambersB andB can be positioned at the hip region of the mattress system. One or more other configurations can be realized based on user preference and as described throughout this disclosure. The first air chamberA can be positioned at a head endof the mattress systemaround a shoulder region. The first foam insertA can be positioned between the first air chamberA and the second air chamberB and the second foam insertB can be positioned between the second air chamberB and a foot endof the mattress system. The third air chamberA, the fourth air chamberB, the third foam insertA, and the fourth foam insertB are similarly positioned. Any one or more of the components can also be arranged in different configurations, as described throughout this disclosure (e.g., refer to). Furthermore, one or more of the components, such as the first, second, third, and fourth foam insertsA,B,A, andB, respectively, can be removed and/or replaced based on user preference. In some implementations, one or more additional foam inserts can be positioned between at least one of the first air chamberA and the head endof the mattress system, the first air chamberA and the second air chamberB, and the second air chamberB and the foot endof the mattress system(e.g., refer to).

Moreover, as depicted, the components of the mattress systemare arranged inside a perimeter formed by the rail structure. The rail structurecan be a foam structure (or other material suitable for the application) that can maintain the components described herein in place when the mattress systemis moved and used. The rail structurecan therefore be positioned around a perimeter of the mattress system.

The mattress can also include a mattress cover. The mattress covercan cover the components described herein to also maintain the components in place. The mattress covercan be made of one or more fabrics or other similar textile materials. The mattress covercan enclose the entire mattress system. The mattress covercan also contain one or more foam layers (not shown in) that can be positioned on top of each of the first, second, third, and fourth air chambersA,B,A, andB, respectively, as well as the first, second, third, and fourth foam insertsA,B,A, andB, respectively.

As depicted in, the mattress systemcan be in fluid communication (via hoses) to a pump. The pumpcan include one or more air pumps that can be fluidly connected to the first, second, third, and fourth air chambersA,B,A, andB, respectively. The pumpcan be configured to inflate the first and second air chambersA andB to a first common internal pressure. The pumpcan also be configured to inflate the third and fourth air chambersA andB to a second common internal pressure. The first common internal pressure can be different than the second common internal pressure, for example, based on user preference.

depicts the mattress systempositioned upside down with a bottom portion of the coveropen to show various internal components of the mattress system. The mattress systemcan include a layerpositioned between a top surface of the mattress systemand each of the first, second, third, and fourth air chambersA,B,A, andB as well as the rail structure, and the first, second, third, and fourth foam insertsA,B,A, andB. The layercan be made of foam or another similar material or cushion. For example, the layercan be formed of one or more viscoelastic foam materials or other materials suitable for the application. The layercan provide comfort to the user when sleeping in the mattress system. In some embodiments, the layercan be adhered or otherwise attached to the rail structureto form somewhat of a foam tub. The foam tub (formed by a combination of the layerand the rail structure) is, effectively, an upside-down foam tub when the mattress systemis flipped right-side-up.

is an example configuration of components of the mattress system.are additional example configurations of components of the mattress system. Thedepict different air chamber and/or foam insert orientations and placements within the mattress. As shown in the, the foam inserts can be interchangeable, removed, and/or replaced with other types and/or sizes of foam inserts. One or more users of the mattress systemcan customize positioning of the components depicted and described throughout this disclosure. For example, a tall user can prefer to position the second air chamberB closer to a foot end of the mattressto accommodate for their height. A shorter user can prefer to position the first and second air chambersA andB closer together to accommodate for their height. As another example, a user can prefer to position multiple firmer foam inserts between the first and second air chambersA andB to provide more support to their lumbar region.

The air chambersA,B,A, andB can be the same size (or substantially the same size) as each other. This can be advantageous for simplicity and also lower cost for manufacturing, repair, and/or replacement, as well as for maintaining all portions of the body balanced and aligned while the pressure settings of the mattress systemchange. In some implementations, as shown in, one or more of the air chambersA,B,A, andB can be different sizes. For example, the second and fourth air chambersB andB can be longer than the first and third air chambersA andA (e.g., refer to). In some implementations, the first and second air chambersA andB can be first sizes and the third and fourth air chambersA andB can be second sizes, based on user preference. The first and second sizes can be different.

Referring to the, the rail structurecan include a head portion, a foot portion, and first and second side portionsand. The rail structurecan extend around a perimeter of the mattress systemto surround the first, second, third, and fourth air chambersA,B,A, andB, respectively, as well as the foam inserts as described herein (e.g., foam insertsA-C andA-C in;A,C,A, andC in;A-N andA-N in). In some implementations, as shown in, the second and fourth air chambersB andB can extend from a hip region of the mattress systemto a location adjacent to an inner surface of the foot portionof the foam rail structure. Similarly, the first air chamberA can extend from a location adjacent to an inner surface of the head portionof the foam rail structure to a shoulder region of the mattress system.

In some implementations, such as where the mattress systemhas only the first and second air chambersA andB, the first air chamberA can be positioned at the shoulder region of the mattress systemand extend laterally between locations adjacent to inner surfaces of the first and second side portionsandof the rail structure. The second air chamberB can be positioned at the hip region of the mattress systemand extend laterally between the locations adjacent to the inner surfaces of the first and second side portionsandof the rail structure.

As depicted in, one or more foam inserts can be positioned between the first and third air chambersA andA and a location adjacent to an inner surface of the head portionof the rail structureand extend laterally between locations adjacent to inner surfaces of the first and second side portionsandof the rail structureand a midline of the mattress system. As depicted in, one or more foam inserts can be positioned between the second and fourth air chambersB andB at a location adjacent to an inner surface of the foot portionof the rail structureand extend laterally between the locations adjacent to the inner surfaces of the first and second side portionsandof the rail structureand the midline of the mattress system.

depicts a configuration in which foam insertsC andC are positioned between the head portionof the rail structureand the first and third air chambersA andA, respectively. Foam insertsA andA can be positioned between the first and third air chambersA andA and the second and fourth air chambersB andB, respectively. Foam insertsB andB can be positioned between the second and fourth air chambersB andB and the foot portionof the rail structure. In some implementations, the componentsA,B,A,B, andC can be arranged differently than the componentsA,B,A,B, andC, based on user preferences.

is another example configuration of components of the mattress system. As shown and described throughout, the second and fourth air chambersB andB can extend from the waist region of the mattress to the foot portionof the rail structure. Moreover, as described throughout, a first user can set up the air chambersA andB as depicted inand a second user can set up the air chambersA andB as depicted in any of the other configurations described herein.

is another example configuration of components of the mattress system. One or more users can position multiple foam insertsC-N andC-N between the first and second air chambersA andB and the third and fourth air chambersA andB, respectively. Foam insertsC-N andC-N can be relatively short to allow a user to move or remove one or more of them while leaving the others in place, thus adjusting the mattress as appropriate for a given user.

is another example configuration of components of the mattress system. One or more users can position one or more foam insertsA-B andA-B between the head portionof the rail structureand the first and third air chambersA andA, respectively. One or more users can additionally or alternatively position one or more foam insertsD-N andD-N between the first and second air chambersA andB and the third and fourth air chambersA andB, respectively.

depicts the example mattress systemwith a pumpand a controller. The controllercan be configured to operate the pumpto cause increases and decreases in fluid pressure of the first air chamberA, the second air chamberB, the third air chamberA, and the fourth air chamberB. In some implementations, the controlleris integrated into a housing of the pump.

is a block diagram of an example of various components of the mattress systemwith the pump. As shown in, the controllercan include a power supply, one or more processors, memory, a switching mechanism, and an analog to digital (A/D) converter. The switching mechanismcan be, for example, a relay or a solid state switch. In some implementations, the switching mechanismcan be located in the pumprather than the controller. The controllercan be in wired or wireless communication with the pump.

The pumpcan include a motor, a pump manifold, a relief valve, a first control valveA, a second control valveB, and one or more pressure transducers. The pumpis fluidly connected with the first air chamberA via a first tubeA and the third air chamberA via a second tubeB. The first air chamberA can then be fluidly connected with the second air chamberB via a third tubeD. The third air chamberA can be fluidly connected with the fourth air chamberB via a fourth tubeC. The first and second control valvesA andB can be controlled by the switching mechanism, and are operable to regulate the flow of fluid between the pumpand the first air chamberA and also between the pumpthe third air chamberA. The tubeD can fluidly connect the air chamberA to the air chamberB so that the pressure in the air chamberB is the same or substantially the same as the air pressure in the air chamberA. Accordingly, the pumpcan adjust air pressure in air chambersA andB at substantially the same time to substantially the same pressure. The tubeC can fluidly connect the air chamberA to the air chamberB so that the pressure in the air chamberB is the same or substantially the same as the air pressure in the air chamberA. Accordingly, the pumpcan adjust air pressure in air chambersA andB at substantially the same time to substantially the same pressure.