FIELD OF INVENTION
[0001] The present invention generally relates to a mattress for providing comfort to the
user. More particularly, the present invention relates to a hybrid mattress with a
plurality of coiled springs enclosed between foams.
BACKGROUND OF INVENTION
[0002] Various attempts have been made in providing comfortable hybrid mattresses for users
which also impart healthcare benefits. Further, a number of specific materials have
also been used in manufacturing mattresses in order to provide comfort, such as wool,
spring mattresses, sole fabric materials, natural and synthetic latex foam, polyurethane
(PU) foam, or other synthetic materials, with or without supports or components such
as springs, or air pockets and the like.
[0003] Generally, the attempts made to manufacture comfortable mattresses are complex and
labor intensive such as, manufacturing a sole piece of latex foam with springs either
glued to the surface of the foam or stuck with a holding material. These methods incur
more time and labor in making, which eventually increases the manufacturing cost of
the mattresses. Additionally, glue provides an undesired stiffness to the mattress
and can reduce the mattress life, as the adhesiveness of the glue tends to fade away
with time. Furthermore, there are present methods to manufacture hybrid mattresses
which involve enclosing springs between the two upper and lower panels of the foam
material, and then finally closing the edges with gluing side panels to prepare a
final mattress. In such cases, the side panels glued or attached otherwise impart
a rough uncomfortable touch feeling to a user/sleeper. In addition to this, the process
of additionally attaching the side panels increases the time and cost and is labor
intensive.
[0004] Most of the present methods and products include mattresses which have pocket springs
encased inside the mold of the foam, where the individual springs are surrounded by
a fabric. In such products, the springs are mechanically connected with the foam material,
for example, with the help of seaming, clips, metallic spirals, metallic stitches,
etc. Also, there exist other methods where the springs are maintained inside the foam
by surrounding them with foam and/or fabric. Such methods may be expensive and time
taking owing to the complexity of the process.
[0005] As is clear from the above , present technologies fail to produce mattresses with
simpler manufacturing process, which is not complex and expensive. Hence, there arises
a need to provide a mattress which is simpler in manufacturing and provides equal
comfort to a user. The present invention meets the above.
SUMMARY OF INVENTION
[0006] Therefore, it is an objective of the present invention to provide a hybrid mattress
which is simple and easy to manufacture and hence less expensive.
[0007] It is also an objective of the present invention to provide a hybrid mattress which
is equally comfortable on the sides, and do not have a rough and rigid uncomfortable
touch feeling to a user.
[0008] It is further an objective of the present invention to provide a method of manufacturing
a mattress, such that the mattress is composed of two separate halves of a foam material,
each half being molded as a single continuous piece of foam material along with edges.
[0009] It is an objective of the present invention to not compromise with the comfort and
healthcare benefits in order to provide a simple manufacturing process and the device
thereof for reducing the cost.
[0010] An aspect of the present invention provides a mattress comprising foam panels, an
upper foam panel and a lower foam panel, with integrally side walls; preferably integrally
molded side walls and an assembly of a plurality of spring units placed and secured
within or on the surface of the lower foam panel; wherein the upper foam panel, when
secured above the lower foam panel, covers the assembly of the plurality of spring
units and wherein the side walls of the upper and the lower foam panels collectively
form edges of the of the mattress.
[0011] In accordance with a specific embodiment, the present invention provides a mattress
comprising two foam panels, an upper foam panel and a lower foam panel, both produced
out of a foam material in a continuous quadrilateral shape with integrally produced
side walls; and an assembly of a plurality of spring units placed and secured on surface
of the lower foam panel; wherein the upper foam panel, when secured above the lower
foam panel, covers the assembly of the plurality of spring units and resultantly,
forms a box-type structure of the mattress; and wherein the side walls of the upper
and the lower foam panels collectively form edges of the box-type structure of the
mattress when secured together, and provide a tight packed arrangement to the assembly
of the plurality of spring units inside the mattress.
[0012] Another aspect of the present invention provides a method of manufacturing a mattress,
comprising two foam panels, preferably molded foam panels, an upper foam panel and
a lower foam panel with integrally, preferably molded, side walls; placing and securing
an assembly of a plurality of spring units within or on the surface of the lower foam
panel; and placing and securing the upper foam panel over the lower foam panel to
fully cover the assembly of the plurality of spring units wherein the side walls of
the upper and the lower foam panels collectively form edges of the mattress when secured
together.
[0013] Another specific aspect of the present invention provides a method of manufacturing
a mattress, comprising molding two foam panels, preferably two identical, either in
shape and/or size and/or material, foam panels , an upper foam panel and a lower foam
panel, both molded out of a foam material from a mold, in a continuous quadrilateral
shape with integrally molded side walls; placing and securing an assembly of a plurality
of spring units on surface of the lower foam panel; and placing and securing the upper
foam panel over the lower foam panel to fully cover the assembly of the plurality
of spring units and form a box-type structure of the mattress; wherein the side walls
of the upper and the lower foam panels collectively form edges of the box-type structure
of the mattress when secured together, and provide a tight packed arrangement to the
assembly of plurality of spring units inside the foam panels.
[0014] Another aspect of the present invention provides the method of manufacturing including
placing each spring unit on the surface of the lower foam panel, such that each spring
unit is supported, in their respective position, by the adjacent ones and also supported
and tightly packed by the side walls.
[0015] The foregoing and other objects, features and advantages of the invention will be
apparent from the following more particular description of exemplary embodiments of
the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0016]
FIG. 1 illustrates a perspective view of a mattress showing two molded panels of a
foam material, in accordance with an embodiment of the present invention;
FIG. 2 illustrates a perspective view of a lower molded cover panel of the mattress,
in accordance with an embodiment of the present invention;
FIG. 3 illustrates a perspective view of the lower molded panel with an assembly of
springs tightly packed into it, in accordance with an embodiment of the present invention;
FIG. 4 illustrates an open view of the mattress showing an upper molded panel folded
to expose the packed assembly of springs, in accordance with an embodiment of the
present invention; and
FIG. 5 illustrates a flow chart showing a method of manufacturing the mattress with
two molded foam panels, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0017] This patent describes the subject matter for patenting with specificity to meet statutory
requirements. However, the description itself is not intended to limit the scope of
this patent. The principles described herein may be embodied in many different forms.
[0018] Illustrative embodiments of the invention now will be described in more detail hereinafter
with reference to the accompanying drawings, in which some, but not all embodiments
of the invention are shown. Indeed, the invention may be embodied in many different
forms and should not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will satisfy applicable
legal requirements. Like numbers refer to like elements throughout.
[0019] The present invention is directed to a mattress comprising an upper foam panel and
a lower foam panel, said panels having integrally produced side walls; and an assembly
of a plurality of spring units placed and secured on or within the lower foam panel;
wherein the upper foam panel, when secured above the lower foam panel, covers the
assembly of the plurality of spring units and resultantly, forms the mattress. By
integrally produced or integrally molded is meant that the side walls of the foam
panel do form part of the foam panel as a single continuous structure. Produced also
includes cutting the foam panel out of a foam block. Examples of cutting processes
are disclosed in
US5992633,
US3757617 and
US8397387. Preferred producing is the process of molding. Molding processes include those as
described in
US5397225,
US2643233,
US2809172,
US5804113,
US9085125 and
EP1878553.
[0020] According to one embodiment the present invention is directed to a mattress comprising
an upper foam panel and a lower foam panel, said panels molded out of a foam material
with integrally molded side walls; and an assembly of a plurality of spring units
placed and secured on or within the lower foam panel; wherein the upper foam panel,
when secured above the lower foam panel, covers the assembly of the plurality of spring
units and resultantly, forms the mattress.
[0021] According to a second embodiment the present invention is directed to a mattress
comprising an upper foam panel and a lower foam panel, said panels produced out of
a foam material in a continuous quadrilateral shape with integrally produced side
walls; and an assembly of a plurality of spring units placed and secured on surface
of the lower foam panel; wherein the upper foam panel, when secured above the lower
foam panel, covers the assembly of the plurality of spring units and resultantly,
forms a box-type structure of the mattress; and characterized in that the side walls
of the upper and the lower foam panels collectively form edges of the box-type structure
of the mattress, and provide a tight packed arrangement to the assembly of plurality
of spring units when the upper foam panel is secured over the lower foam panel.
[0022] In the mattress in accordance with the present invention, the upper and lower foam
panels can be identical either in shape and/or size and/or material.
[0023] Preferably the upper and lower foam panels are produced from a number of foam materials
such as including and not limited to natural and synthetic latex foam material, polyurethane
foam, and other synthetic foam material manufactured by crude oil, and the like including
composite foams.
[0024] Preferably the foam panels are molded into a continuous rectangular, square or any
other suitable quadrilateral/geometrical shape.
[0025] The mattress in accordance with the present invention comprise a spring unit wherein
each spring unit further comprises a coiled spring enclosed in a fabric cover and
behaves independently of each other to provide resilience to the mattress.
[0026] The coiled spring may be helical or conical in shape and the spring units can be
pocket springs.
[0027] Typically the spring units are secured to the surface of the lower foam panel using
a glue; or metallic stitches; or clips; or any other securing mechanism.
[0028] The upper foam panel and the lower foam panel are attached with each other, via a
number of methods including and not limited to using a glue, metallic stitches, clips,
or any other mechanical connections.
[0029] In accordance with a further embodiment of the present invention a method of manufacturing
a mattress is provided, comprising producing an upper foam panel and a lower foam
panel with integrally produced side walls; placing and securing an assembly of a plurality
of spring units within the surface of the lower foam panel; and placing and securing
the upper foam panel over the lower foam panel to fully cover the assembly of the
plurality of spring units.
[0030] A method of manufacturing a mattress is further provided, comprising producing two
identical foam panels, an upper foam panel and a lower foam panel, both produced out
of a foam material from a mold, in a continuous quadrilateral shape with integrally
produced side walls; placing and securing an assembly of a plurality of spring units
on surface of the lower foam panel; and placing and securing the upper foam panel
over the lower foam panel to fully cover the assembly of the plurality of spring units
and form a box-type structure of the mattress; characterized in that the side walls
of the upper and the lower foam panels collectively form edges of the box-type structure
of the mattress, and provide a tight packed arrangement to the assembly of the plurality
of spring units, when the upper foam panel is secured over the lower foam panel.
[0031] The method as described above further comprises placing each spring unit within the
surface of the lower foam panel, such that each spring unit is supported, in their
respective positions, by the adjacent ones and also supported and tightly packed by
the side walls.
[0032] Preferred method is provided whereby the foam panels may be molded into a rectangular,
square or any other suitable quadrilateral/geometrical shape and wherein the foam
is selected from a number of foam materials such as including and not limited to natural
and synthetic latex foam material, polyurethane foam, and other synthetic foam material
manufactured by crude oil, and the like including composite foams, the foam panels
being identical in either shape and/or size and/or material. Said foam panels optionally
independently comprising perforations and/or profiles.
[0033] The present invention discloses a spring mattress for providing tailored comfort
to a user/human. The spring mattress, as provided in the preferred embodiment of the
present invention, is a combination of a spring assembly incorporated within two molded
foams. The mattress comprises two half panels of molded foams, an upper molded panel
and a lower molded panel, that are attached together to form one single mattress.
Within the two half molded panels, an assembly of a plurality of springs are tightly
packed to provide resilience to the mattress. Further, both the half panels of foam
are separately molded as one single continuous structure, along with the edges. The
molded edges may be referred to as 'side foam walls'. Therefore, each of the upper
and lower molded panel, when joined together form a closed cuboid (box)-type structure,
with the side foam walls covering the edges. Hence, the mattress does not need additional
separate side panels to seal the mattress from the edges. Hereinafter, the upper and
lower molded panels may also be exchangeably referred to as 'upper and lower cover
panel' or 'upper and lower foam panel' or 'upper and lower molded foam' or simply
'upper and lower panel' without deviating from the meaning and scope of the present
invention.
[0034] The upper and lower panels may be molded from a number of materials, such as including
and not limited to natural and synthetic latex foam material, polyurethane foam, and
other synthetic foam material manufactured by crude oil, and the like including composite
foams such as disclosed in
US 9085125 (assigned to Latexco) and functionalized foams such as disclosed in
EP2613927 (assigned to Latexco). Preferably, the upper and lower panels are molded from latex
foam.
[0035] Further, the mattress also comprises an assembly of a plurality of springs tightly
enclosed and packed within the upper and lower foam panels. In an embodiment, each
of the spring in the assembly is packed in a fabric case, such that each spring is
separated from the other and works independently to provide elasticity to the mattress.
Owing to the molded structure of the mattress with the continuous molded side foam
walls, the springs can be easily placed within the lower foam panel, where the springs
get tightly packed and hence, are restricted to fall or move out of the lower foam
panel. Therefore, placing and packing individual spring unit inside the lower foam
panel becomes easy and simpler without adopting complex methods of connecting springs
with the foam panels to avoid movement of the springs.
[0036] In an embodiment, the springs are coiled pocket springs. In another embodiment, the
springs may be helical or conical in nature, depending on the requirements of the
mattress, without deviating from the meaning and scope of the present invention.
[0037] FIG. 1 illustrates a perspective view of the mattress 100 showing two molded foam
panels 102 and 104, in accordance with an embodiment of the present invention. As
described above, the mattress 100 comprises of two half foam panels, the upper foam
panel 102 and the lower foam panel 104, which when joined together form a box-type
structure, shown as the mattress 100. This is because both the half foam panels 102
and 104 are individually molded as one single continuous structure along with the
side walls. Therefore, the side walls are the integral molded part of the foam panels
102 and 104. The upper and the lower foam panels 102 and 104 behave as an upper and
lower cover, making a box-type mattress 100 with a space enclosed in it by the upper
foam panel 102, the lower foam panel 104 and the side edges 106 of the resulting box-type
mattress 100. Hence, the mattress 100 does not need separate side panels to close
it from the edges.
[0038] FIG. 2 illustrates a perspective view of the lower foam panel 104 of the mattress
100, in accordance with an embodiment of the present invention. The lower foam panel
104 acts as a lower half of the mattress 100, and is molded out of a foam material,
such as latex. The lower foam panel 104 is molded as single continuous structure along
with the side walls 200 molded as integral part of the foam panel 104. Similarly,
the upper foam panel 102 is molded along with the similar side walls 200.
[0039] FIG. 3 illustrates a perspective view of the lower foam panel 104 with an assembly
of springs tightly packed into it, in accordance with an embodiment of the present
invention. As shown in the FIG. 3, the assembly of springs 300 is tightly packed inside
the lower foam panel 104. The assembly of springs comprises a plurality of spring
units 302, where each spring is enclosed inside a fabric cover. Hence, each spring
unit 302 acts independently of each other in providing elasticity to the mattress
100.
[0040] Each spring unit 302 is placed inside the lower foam panel 104 one by one, in such
a way that the spring units 302 are supported by the side foam walls 200 of the upper
and the lower foam panel 102 and 104. The side walls 200 restrict the movement of
the spring units 302, and provide a tightly packed arrangement of the spring units
302 inside the mattress 100.
[0041] In the process of putting spring units 302, each spring unit 302 may be simply placed
inside the lower panel 104. When each spring unit 302 is placed inside the lower panel
104, they are secured and supported, in their respective positions, by each other
and together as an assembly by the side walls 200 (or edges 106 of the mattress).
In an embodiment, the spring units may additionally be secured using glue on the surface
of the lower foam panel 104. In another embodiment, the spring units may additionally
be secured using metallic stitches for connecting them with the surface of the lower
foam panel 104. It may be apparent to a person skilled in the art, that there are
other mechanisms provided in the art to secure the spring units 302 on the lower foam
panel, which can also be adopted in the present invention, without deviating from
the meaning and scope of the present invention.
[0042] FIG. 4 illustrates an open view 400 of the mattress 100 showing the upper foam panel
102 folded to expose the packed assembly of the spring units 302, in accordance with
an embodiment of the present invention. Once all the spring units 302 are secured
firmly on the surface of the lower foam panel 104, the upper foam panel 104 is placed
above the lower foam panel 104 to cover the spring units 302 and form the full spring
mattress 100. The side foam walls of the upper foam panel 102 also provide additional
support and restriction to the assembly of the spring units 300. In an embodiment,
the upper foam panel 102 may be glued to the lower foam panel to close the mattress
100. In another embodiment, the upper foam panel 102 may be attached to the lower
foam panel using metallic stitches, or any other mechanism, such as clips etc. to
close the mattress 100. It may be apparent to a person skilled in the art that the
present invention may adopt a number of other mechanisms to attach the upper and the
lower foam panels with each other, without deviating from the meaning and scope of
the present invention.
[0043] FIG. 5 illustrates a flow chart showing a method of manufacturing the mattress 100
shown in the FIGs. 1-4. As described by the method 500, at step 502 an upper foam
panel 102 and a lower foam panel 104 are molded out from a mold, both with integral
side foam walls 200. The upper and the lower foam panels 102 and 104 are continuous
one molded piece of a foam material, such as latex foam, with side walls. Further,
at step 504, an assembly 300 of a plurality of spring units 302 is secured and tightly
packed on the surface of the lower foam panel 104, where the assembly of the spring
units 302 is supported by the side walls 200 of the lower foam panel 104. In securing
the assembly of the spring units on the lower foam panel 104, each spring unit 302
is placed on the surface of the lower foam panel 104. Eventually, each spring unit
302 supports each other, and is also supported and packed by the side walls 200.
[0044] Thereafter, at step 506, once all the spring units 302 are placed on the lower foam
panel 104, the upper foam panel 102 is placed and secured over the lower foam panel
104; resultantly forming a mattress 100 into which the assembly of a plurality of
spring units 302 is tightly packed due to the presence of molded edges 106 of the
mattress 100, which are formed by the side walls 200 of the upper and the lower foam
panels 102 and 104.
[0045] Advantageously, the present invention provides a mattress and method of manufacturing
thereof, where the mattress is a simple combination of two molded foam panels and
an assembly of spring units packed inside the two molded foam panels. The two panels
are molded as continuous structures along with side walls integral to them. Hence,
the mattress does not need extra separate side panels glued to it for covering the
edges. Also, since no additional side walls are glued to the upper and lower foam
panels, no rough uncomfortable touch feeling is felt by the user.
[0046] Further, the assembly of spring units is able to be tightly packed inside the mattress,
secured and supported by the upper, the lower and the side walls of the mattress.
The spring units may not be necessarily glued to the surface of the lower foam panel,
since they are supported by the side walls. Therefore, the mattress is inexpensive
and the manufacturing process is not complex and not labor intensive.
[0047] Preferred latex foam for the upper and/or lower foam panel is a latex foam. "Latex"
is herein defined as a dispersion of polymeric particles in a continuous phase, the
polymeric particles preferably having a size range of from 10 to 1000 nm. The latex
foam material can be prepared from natural rubber latex or from one or more of such
synthetic latexes as polybutadiene/styrene latex, polybutadiene/acrylonitrile latex,
polychloroprene latex and the like or from a mixture of natural rubber latex and one
or more such synthetic latexes. The later foam includes conventional latex foam as
well as visco-elastic latex foam. The solids content of suitable aqueous latexes is
from 20 to 75% by weight. Preferred latexes have a solid content of from 50 to 75%
by weight. Suitable polymer latexes are all dispersions in which the solid is dispersed
in a liquid phase and this phase in turn forms an emulsion with a further liquid phase.
Examples are latexes of polymers consisting of dienes or olefinically unsaturated
monomers and copolymers thereof, such as polystyrene-butadiene latex, polybutadiene
latex, polyisoprene latex, natural rubber latex, acrylonitrile-butadiene latex, polychloroprene
latex, polydichlorbutadiene latex, latex of a copolymer of chloroprene and dichlorobutadiene,
polyisoprene latex, latex of chlorinated polyisoprene or (meth)acrylate latex. Dispersions
of polyurethanes or other dispersions in which polymers are dispersed in water with
the aid of emulsifiers or dispersing agents are also suitable, however.
[0048] Preferred latexes include latexes of natural rubber, styrene-butadiene rubber (SBR),
SBR having low styrene content (up to 27%), nitrile rubber (NBR), isoprene rubber,
neoprene rubber, polybutadiene rubber, isobutylene-isoprene rubber (IIR), copolymers
of acrylonitrile, methacrylonitrile, acrylates, methacrylates, vinylpyridine with
butadiene or 2-chloro-1,3-butadiene and chlorinated polyethylene or mixtures of any
of these. Highly preferred are latexes of natural rubber, styrene-butadiene rubber,
nitrile rubber, polybutadiene rubber, isoprene rubber or copolymers comprising acrylates.
Polymer-containing latexes, such as e.g. SBR (styrene-butadiene rubber) or NBR (acrylonitrile-butadiene
rubber), polychloroprene, polybutadiene, polyisoprene, natural rubber latex, polyvinyl
chloride, (meth)acrylate dispersions or dispersions of copolymers thereof, are conventionally
available commercially in solids concentrations of more than 50%. These concentrations
can be achieved e.g. by increasing the concentration of low-concentration polymer
latexes. The concentration of natural rubber latex is increased from 30% to 60% solids,
for example. Other preferred latexes are combinations of synthetic and natural latex.
Preferred proportions of natural latex to synthetic latex can be varied from 1:4 to
6:4. Highly preferred proportions of natural to synthetic latex are more than 1:1.
The proportions should be optimized according to the latex used.
[0049] Methods of obtaining latex foam are known in the art and can be those where latex
being poured into a closed mold provided with aluminium pins to ensure good heat conduction,
and subsequently being vulcanised, washed and dried into an end product. An alternative
preferred method in accordance with the present invention for producing the latex
foam upper and lower foam panel is the pouring of latex foam on an endless conveyor
belt, followed by vulcanisation, washing and finally drying.
[0050] Other foams to be used are foams selected from polyolefin, polyurethane, polystyrene
or polyester or visco-elastic latex or mixtures thereof. The foam can be visco-elastic
foam.
[0051] The foam offers a firm yet resilient support. Preferred foams to be used in accordance
with the present invention are those having a lower indentation load deflection value
than the latex foam.
[0052] The foam can comprise any natural or synthetic foam. The foams are typically open
cell. The foam may also comprise recycled foam, foam impregnated fiber mats or micro-cellular
elastomer foam. Additionally, the foam may include organic and/or inorganic fillers.
Furthermore, additional additives may be incorporated into the foam composition, such
as, but not limited to, flame retardants, anti-fogging agents, ultraviolet absorbers,
thermal stabilizers, pigments, colorants, odor control agents, perfumes and the like.
[0053] Other preferred foams are polyurethane foam. Polyurethane foams with varying density
and hardness may be formed. Tensile strength, tear strength, compression set, air
permeability, fatigue resistance, support factor, and cell size distribution may also
be varied, as can many other properties. Specific foam characteristics depend upon
the selection of the starting materials, the foaming process and conditions, and sometimes
on the subsequent processing.
[0054] Cellular polyurethane structures typically are prepared by generating a gas during
polymerization of a liquid reaction mixture comprised of polyester or polyether polyol,
an isocyanate, a surfactant, catalyst and one or more blowing agents. The gas causes
foaming of the reaction mixture to form the cellular structure. The surfactant stabilizes
the structure.
[0055] Latex foam inherently provides a greater independent support characteristic relative
to foams such as polyurethane or urethane foams. This difference is attributable to
the compositional differences between the materials and is reflected, at least in
part, in the typical load deflection curves for each type of material. A load-deflection
curve is typically a graph of the force in lbs. required to indent a flat disk of
50 sq. in. (8" diameter) into the foam or other material being tested for any given
percentage of deflection. Latex foam is typically characterized by having a more gradual
slope in the lower portion of the curve, that is in the range of 5-10% deflection,
which typically becomes steeper in the higher portion of the curve, that in the range
of 50-70% of deflection. Polyurethane foams, on the other hand, typically have a steeper
initial portion of the curve, in the range of 5-10% deflection, which typically decreases
in the higher deflection ranges.
[0056] Thus, while latex foam has a softer initial feel, it resists deflection at heavier
loads. This contributes, at least in part to the latex foam offering greater independent
support relative to urethane foam.
[0057] The present invention also provides additional tailoring of the comfort to the user
by combining different foams to be used in either the lower foam panel and /or upper
foam panel.
[0058] Preferred foam panel according to the present invention contain perforations. Preferably
said perforations are formed in the mattress in a pattern of rows of perforations
and/or columns of perforations, the spacing between two adjacent rows of perforations
and/or columns of perforations. Preferably the interface between the spacing of the
perforations are less than 40, more preferably less 20 mm, most preferably ranging
between 10 and 15 mm.
[0059] Combinations of perforations having different sizes can also be used. Sizes of the
perforations are between 0.5 and 2 cm. Preferred hybrid mattress according to the
present invention are characterized in that the surface of the foam layer above the
array of springs are provided with perforations in at least one zone of the upper
surface thereof and with a profile in at least one zone of said upper surface.
[0060] In addition, the aforesaid perforations are formed in zones near those parts of a
user's body that secrete the most sweat, mainly the neck, the back and the thighs.
[0061] Preferred upper and/or lower foam panels according to the present invention contain
profiles.
[0062] The profiles when combined with the foam panels of the present invention present
in specific zones at the upper side of the upper layer of the foam panel enhance the
sleeping comfort of the user, because the bedding when formulated with the composite
foam of the present invention feels softer in said zones, depending on the shape and
the dimensions of said profiles.
[0063] A suitable selection of the zones comprising perforations alternating with zones
comprising profiles will lead to an upper mattress, which meets each and every requirement
of an exacting user as regards sleeping comfort.
[0064] According to yet another embodiment of the present invention, there is provided a
foam including a convoluted top or convoluted second layer, which enhances user comfort.
[0065] In accordance with a further preferred aspect of the foam panel according to the
present invention there is provided convoluted foam, which increases comfort or softness.
The elongated convoluted foam in case of use for bedding, supports a recumbent human
body. The bedding comprises an elongated body including an area formed by generally
longitudinally extending ribs arranged in rows. Each rib is separated from any adjacent
rib by a channel. Each rib includes a plurality of first peaks having a first height
and a plurality of second peaks having a second height, different from the first height.
The first and second peaks are alternatively disposed along each rib. Preferred feature
of the foam panel according to the present invention that each rib is generally sinusoidal
about a longitudinal axis to define sinusoidal channels there between. The first peaks
are formed at crests of the sinusoidal ribs. The second peaks are formed at the longitudinal
axis of each rib. The ribs are wider in areas proximate the first and second peaks.
The first and second peaks are rounded. Another preferred feature of the foam panel
according to the present invention is that the first height is greater than the second
height. It is a further preferred feature of the present invention that the channels
have a first thickness in areas proximate the first peaks and a second thickness in
areas proximate the second peaks. The second thickness is greater than the first thickness.
[0066] While certain embodiments have been described, these embodiments have been presented
by way of example only, and are not intended to limit the scope of the present disclosure.
Indeed, the novel methods, devices, and systems described herein may be embodied in
a variety of other forms. Furthermore, various omissions, substitutions, and changes
in the form of the methods, devices, and systems described herein may be made without
departing from the spirit of the present disclosure.
1. A mattress comprising:
an upper foam panel and a lower foam panel, said panels having integrally produced
side walls; and an assembly of a plurality of spring units placed and secured on or
within the lower foam panel; wherein the upper foam panel, when secured above the
lower foam panel,
covers the assembly of the plurality of spring units and resultantly, forms the mattress.
2. A mattress comprising according to claim 1:
an upper foam panel and a lower foam panel, said panels molded out of a foam material
with integrally molded side walls; and an assembly of a plurality of spring units
placed and secured on or within the lower foam panel; wherein the upper foam panel,
when secured above the lower foam panel, covers the assembly of the plurality of spring
units and resultantly, forms the mattress.
3. A mattress according to claims 1-2 comprising:
an upper foam panel and a lower foam panel, said panels produced out of a foam material
in a continuous quadrilateral shape with integrally produced side walls; and an assembly
of a plurality of spring units placed and secured on surface of the lower foam panel;
wherein the upper foam panel, when secured above the lower foam panel, covers the
assembly of the plurality of spring units and resultantly, forms a box-type structure
of the mattress; and
characterized in that the side walls of the upper and the lower foam panels collectively form edges of
the box-type structure of the mattress, and provide a tight packed arrangement to
the assembly of plurality of spring units when the upper foam panel is secured over
the lower foam panel.
4. The mattress in accordance with claims 1-3, whereby the upper and lower foam panels
are identical either in shape and/or size and/or material.
5. The mattress in accordance with claims 1-4, wherein the upper and lower foam panels
are produced from a number of foam materials such as including and not limited to
natural and synthetic latex foam material, polyurethane foam, and other synthetic
foam material manufactured by crude oil, and the like including composite foams.
6. The mattress in accordance with claims 1-5, wherein the foam panels are molded into
a continuous rectangular, square or any other suitable quadrilateral/geometrical shape.
7. The mattress as claimed in claims 1-6, wherein each spring unit further comprises
a coiled spring enclosed in a fabric cover and behaves independently of each other
to provide resilience to the mattress.
8. The mattress as claimed in claim 7, wherein the coiled spring may be helical or conical
in shape.
9. The mattress as claimed in claims 1-8, wherein the spring units are pocket springs.
10. The mattress as claimed in claims 1-9, wherein the spring units are secured to the
surface of the lower foam panel using a glue; or metallic stitches; or clips; or any
other securing mechanism.
11. The mattress as claimed in claims 1-10, wherein the upper foam panel and the lower
foam panel are attached with each other, via a number of methods including and not
limited to using a glue, metallic stitches, clips, or any other mechanical connections.
12. A method of manufacturing a mattress, comprising:
producing an upper foam panel and a lower foam panel with integrally produced side
walls;
placing and securing an assembly of a plurality of spring units within the surface
of the lower foam panel; and placing and securing the upper foam panel over the lower
foam panel to fully cover the assembly of the plurality of spring units.
13. A method of manufacturing a mattress according to claim 12, comprising:
producing two identical foam panels, an upper foam panel and a lower foam panel, both
produced out of a foam material from a mold, in a continuous quadrilateral shape with
integrally produced side walls; placing and securing an assembly of a plurality of
spring units on surface of the lower foam panel; and placing and securing the upper
foam panel over the lower foam panel to fully cover the assembly of the plurality
of spring units and form a box-type structure of the mattress;
characterized in that the side walls of the upper and the lower foam panels collectively form edges of
the box-type structure of the mattress, and provide a tight packed arrangement to
the assembly of the plurality of spring units, when the upper foam panel is secured
over the lower foam panel.
14. The method as claimed in claims 12-13 further comprises placing each spring unit within
the surface of the lower foam panel, such that each spring unit is supported, in their
respective positions, by the adjacent ones and also supported and tightly packed by
the side walls.
15. The method as claimed in claims 12-14, wherein the foam panels may be molded into
a rectangular, square or any other suitable quadrilateral/geometrical shape and wherein
the foam is selected from a number of foam materials such as including and not limited
to natural and synthetic latex foam material, polyurethane foam, and other synthetic
foam material manufactured by crude oil, and the like including composite foams, the
foam panels being identical in either shape and/or size and/or material. Said foam
panels optionally independently comprising perforations and/or profiles.