Foam mattress with symmetrical wavy foam layers

Patent metadata

Field	Value
Publication number	US-10758058-B2
Application number	US-201916715765-A
Country	US
Kind code	B2
Filing date	Dec 16, 2019
Priority date	Feb 28, 2013
Publication date	Sep 1, 2020
Grant date	Sep 1, 2020

Abstract

A symmetrical zoned foam mattress includes an upper foam layer with a wavy lower side and a lower foam layer with a wavy upper side. The lower layer has top, middle and bottom lateral valleys. The wavy lower side of the upper layer is glued to the wavy upper side of the lower layer. The top lateral valley has a minimum located within eighteen inches of the top head end of the lower layer. The bottom lateral valley has a minimum located within eighteen inches of the bottom foot end of the lower layer. A center plane intersects the lower foam layer at a minimum of the middle lateral valley. The minimum of each of the top and bottom lateral valleys is about fifteen inches from the end of the mattress regardless of whether the consumer chooses to use the top or bottom end as the head of the mattress.

First claim

What is claimed is:

1. A mattress comprising:
an upper foam layer with a planar upper side, a top, a bottom, a top shoulder zone and a bottom shoulder zone, wherein the upper foam layer has a center plane and a wavy side opposite the planar upper side, wherein the center plane is perpendicular to the planar upper side and is disposed midway between the top and the bottom, wherein the wavy side forms a curve, and wherein the curve from the center plane towards the top is a mirror image of the curve from the center plane towards the bottom;
a lower foam layer with a planar lower side, wherein the planar lower side is parallel to the planar upper side; and
means for imparting a lower indentation load deflection (ILD) to the planar upper side above the top shoulder zone and above to the bottom shoulder zone than that exhibited above other lateral regions of the upper foam layer immediately adjacent to the top shoulder zone and to the bottom shoulder zone, wherein the top shoulder zone has a middle that is between twelve and eighteen inches from the top of the upper foam layer, wherein the bottom shoulder zone has a middle that is between twelve and eighteen inches from the bottom of the upper foam layer, and wherein the means imparts a variable thickness to the upper foam layer.

2. The mattress of claim 1 , wherein the upper foam layer has a hip zone, and wherein the hip zone has a middle disposed at the center plane of the upper foam layer.

3. The mattress of claim 1 , wherein the top shoulder zone and the bottom shoulder zone are disposed symmetrically to the center plane of the upper foam layer.

4. The mattress of claim 1 , wherein the means imparts an ILD to the top shoulder zone that allows a person's shoulders to sink into the upper side of the upper foam layer so as to keep the person's spine straight.

5. The mattress of claim 1 , wherein the upper foam layer is made of memory foam, and wherein the lower foam layer is made of high density polyurethane foam.

6. The mattress of claim 1 , wherein the upper foam layer together with the lower foam layer have a combined thickness that remains constant from the top to the bottom of the mattress.

7. The mattress of claim 6 , wherein the combined thickness is greater than six inches.

8. The mattress of claim 1 , wherein the top shoulder zone and the bottom shoulder zone are disposed symmetrically to the center plane.

9. The mattress of claim 1 , further comprising:
a top foam layer, wherein the top foam layer is disposed above the upper foam layer, and wherein the top foam layer is made of memory foam.

10. The mattress of claim 9 , wherein the memory foam of the top foam layer contains green tea.

11. A mattress comprising:
an upper foam layer with a planar upper side, a top, a bottom, a top lateral hill and a bottom lateral hill;
a lower foam layer with a planar lower side, wherein the planar lower side is parallel to the planar upper side; and
means for imparting a lower indentation load deflection (ILD) to the planar upper side above the top lateral hill and above to the bottom lateral hill than that exhibited above other lateral regions of the upper foam layer immediately adjacent to the top lateral hill and to the bottom lateral hill, wherein the top lateral hill has a middle that is between twelve and eighteen inches from the top of the upper foam layer, wherein the bottom lateral hill has a middle that is between twelve and eighteen inches from the bottom of the upper foam layer, and wherein the means imparts a variable thickness to the upper foam layer.

12. The mattress of claim 11 , wherein the lower foam layer has a top lateral valley and a bottom lateral valley, and wherein the top lateral hill of the upper foam layer fits into and is adjacent to the top lateral valley of the lower foam layer.

13. The mattress of claim 11 , wherein the upper foam layer has a hip zone and a center plane, wherein the center plane is perpendicular to the planar upper side and midway between the top and the bottom, and wherein the hip zone has a middle disposed at the center plane of the upper foam layer.

14. The mattress of claim 11 , wherein the upper foam layer has a center plane that is perpendicular to the planar upper side and midway between the top and the bottom, and wherein the top lateral hill and the bottom lateral hill are disposed symmetrically to the center plane of the upper foam layer.

15. The mattress of claim 11 , wherein the means imparts an ILD to the top lateral hill that allows a person's shoulders to sink into the upper side of the upper foam layer so as to keep the person's spine straight.

16. The mattress of claim 11 , wherein the lower foam layer is made of high density polyurethane foam.

17. The mattress of claim 11 , wherein the upper foam layer has a center plane and a wavy side opposite the planar upper side, wherein the center plane is perpendicular to the planar upper side and is disposed midway between the top and the bottom, wherein the wavy side forms a curve, and wherein the curve from the center plane towards the top is a mirror image of the curve from the center plane towards the bottom.

18. The mattress of claim 11 , wherein the upper foam layer together with the lower foam layer have a combined thickness that remains constant from the top to the bottom of the mattress.

19. The mattress of claim 11 , wherein the upper foam layer has a center plane that is perpendicular to the planar upper side and is disposed midway between the top and the bottom, and wherein the top lateral hill and the bottom lateral hill are disposed symmetrically to the center plane.

Assignees

• Zinus Inc

Inventors

• Oh Suk Kan

Classifications

• A47C27/144

  inside the mattress or cushion · CPC title

• A47C27/15

  consisting of two or more layers (A47C27/16 takes precedence) · CPC title

• A47C27/146 Primary

  on the outside surface of the mattress or cushion · CPC title

• A47C27/148

  of different resilience · CPC title