Mattress reinforcement system

Patent metadata

Field	Value
Publication number	US-11930934-B2
Application number	US-202017139786-A
Country	US
Kind code	B2
Filing date	Dec 31, 2020
Priority date	Jan 3, 2020
Publication date	Mar 19, 2024
Grant date	Mar 19, 2024

Abstract

Reinforcement straps are used to hold a mattress system in place and keep it from bowing outwards when used. The mattress system can include a layer and a rail structure attached to the layer. The layer can have a layer top and a layer bottom opposite to the layer top. The layer can extend between a first layer edge and a second layer edge.

First claim

What is claimed is:

1. A mattress comprising:
a first layer having a first layer top and a first layer bottom and extending from a first layer edge to a second layer edge,
a first side rail attached, to the first layer bottom proximate the first layer edge;
a second side rail attached, to the first layer bottom proximate the second layer edge;
a core positioned under the first layer bottom between the first side rail and the second side rail; and
a first strap connected to the first side rail and the second side rail at a connection locations such that the first strap extends under the core from a bottom surface of the first side rail to a bottom surface of the second side rail; a cutout is defined on at least the first siderail or the second siderail, the cutout receives an air hose, the first strap is attached to the first or second siderail adjacent the cutout.

2. The mattress of claim 1 , and further comprising:
a mattress cover enclosing the first layer, the first side rail, the second side rail, the core, and the first strap.

3. The mattress of claim 1 , and further comprising:
a second strap connected to the first side rail and the second side rail such that the second strap extends under the core from the bottom surface of the first side rail to the bottom surface of the second side rail, wherein the first strap and the second strap are both positioned in a longitudinal middle section of the mattress with the second strap spaced from the first strap.

4. The mattress of claim 1 , and further comprising:
a second strap connected to the first side rail and the second side rail such that the second strap extends under the core from the bottom surface of the first side rail to the bottom surface of the second side rail, wherein the first strap crosses the second strap such that the first strap is connected to the first side rail between a head of the mattress and the second strap, and wherein the first strap is connected to the second side rail between a foot of the mattress and the second strap.

5. The mattress of claim 1 , and further comprising:
a second strap connected to the first side rail and the second side rail such that the second strap extends under the core from the first rail bottom to the second rail bottom, wherein the first side rail defines a first cutout and the second side rail defines a second cutout such that the first and second side rails are structurally weakened at the first and second cutouts, and wherein the first and second straps connect to the first and second side rails on opposite sides of the first and second cutouts.

6. The mattress of claim 1 , wherein the first side rail defines a first cutout and the second side rail defines a second cutout such that the first and second side rails are structurally weakened at the first and second cutouts, and wherein the first strap is connected to the first and second side rails proximate the first and second cutouts.

7. The mattress of claim 1 , wherein the first layer, the first side rail, and the second side rail comprise one or more foam materials.

8. The mattress of claim 1 , wherein the core comprises an inflatable air chamber.

9. The mattress of claim 1 , wherein the first layer, the first side rail, and the second side rail are part of an upside-down foam tub, wherein the upside-down foam tub further comprises a foot rail and a head rail.

10. The mattress of claim 1 , and further comprising:
a second strap connected to the first side rail and the second side rail such that the second strap extends under the core from the first rail bottom to the second rail bottom;
a first air hose extending through the first side rail between the first strap and the second strap; and
a second air hose extending through the second side rail between the first strap and the second strap.

11. A bed comprising:
a mattress including:
a first foam layer having a top surface and an opposite bottom surface;
an inflatable chamber arranged opposite to the top surface of the first foam layer; and
a foam rail structure including top, bottom, and opposite side form rails extending between the top and bottom foam rails, the foam rail structure extending from a periphery of the first foam layer and configured to surround the inflatable chamber;

a plurality of straps, each having opposite ends attached to the opposite side foam rails, respectively, and extending across the inflatable chamber between the opposite side foam rails; and
an air hose fluidly coupled to the inflatable chamber,
wherein the foam rail structure defines a notch that receives a portion of the air hose extending from the inflatable chamber, and
wherein at least one of the plurality of straps is attached to the foam rail structure adjacent to the notch.

12. The bed of claim 11 , wherein the plurality of straps are arranged to extend across a bottom of the mattress.

13. The bed of claim 11 , further comprising a foundation configured to support the mattress, wherein the plurality of straps are disposed between a bottom of the mattress and a top of the foundation.

14. The mattress system of claim 11 , further comprising:
a plurality of fastening elements configured to attach the plurality of straps onto the opposite side foam rails.

15. The mattress system of claim 14 , wherein the plurality of fastening elements includes adhesive tapes applied between the foam rail structure and the ends of the straps.

16. The mattress system of claim 11 , wherein the plurality of straps extend to be parallel with each other between the opposite side foam rails.

17. The mattress system of claim 11 , wherein at least two of the plurality of straps cross over each other between the opposite side foam rails.

18. The mattress system of claim 11 , further comprising a mattress cover at least partially enclosing the foam layer, the inflatable chamber, the foam rail structure, and the plurality of straps.

19. The mattress system of claim 1 , wherein the mattress is configured to be positioned on a foundation, wherein the plurality of straps are disposed between a bottom of the mattress and a top of the foundation.

20. The mattress of claim 1 , further comprising one or more fasteners, the one or more fasteners attach the first side rail or the second side rail to the first layer bottom, wherein the one or more fasteners comprise adhesive.

21. The mattress of claim 1 , further comprising one or more fasteners, the one or more fasteners attach the first side rail or the second side rail to the first layer bottom, wherein the one or more fasteners comprise lamination.

22. The mattress of claim 1 , further comprising:
a bottom layer being separate from the first side rail and the second side rail and configured to cover the core,
wherein the bottom layer has a bottom layer top and a bottom layer bottom opposite to the bottom layer top, the bottom layer top facing the core,
wherein the first strap extends across the bottom layer at the bottom layer bottom, and
wherein, based on the bottom layer covering the core, the bottom layer bottom is flush with the bottom of the first side rail and the bottom of the second side rail.

23. The mattress of claim 5 , wherein the core includes a first inflatable air chamber and a second inflatable air chamber,
wherein the mattress further comprises:
a first air hose fluidly coupled to the first inflatable air chamber and extending through the first cutout of the first side rail, and
a second air

Assignees

• Sleep Number Corp

Inventors

• Karschnik Kody Lee
• Yang Chee Nong
• Rose Eric Stephen

Classifications

• A47C21/048 Primary

  for heating · CPC title

• A47C19/027

  with means for preventing frame from sagging · CPC title

• A47C20/041

  by electric motors · CPC title

• A47C21/044 Primary

  with active means, e.g. by using air blowers or liquid pumps · CPC title

• A47C27/081

  of pneumatic type · CPC title