Configurable foam comfort system

A configurable foam mattress comfort system includes a firm foam mattress foundation including an upper surface having a triangular grooves disposed across a width thereof, and foam elongate cells configured to fit partially within corresponding triangular grooves from among the triangular grooves disposed across the width thereof. A length of each of the foam elongate cells is substantially equal to the width of the firm foam mattress foundation. The foam elongate cells are configured to be custom-stacked on each other and on the firm foam mattress foundation in accordance with a user's desired comfort configuration.

TECHNICAL FIELD

This application pertains to foam mattresses, and more particularly, to a configurable foam comfort system.

BACKGROUND

People spend more time on their mattresses than anywhere else. This includes periods of relaxation, sleep, watching television, surfing the web, among other activities. Mattresses have become integral to nearly every person's life in our modern world of comforts and conveniences. Yet, while the materials used to construct mattresses have improved over time, the quality of mattresses varies widely, and even the best-quality conventional mattresses are nonetheless lacking in one or more areas such as comfort, configurability, or price point.

Accordingly, a need remains for an improved mattress, and in particular, a need remains for a configurable foam comfort system. Embodiments of the inventive concept address these and other limitations in the prior art.

The foregoing and other features of the inventive concept will become more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to embodiments of the inventive concept, examples of which are illustrated in the accompanying drawings. The accompanying drawings are not necessarily drawn to scale. In the following detailed description, numerous specific details are set forth to enable a thorough understanding of the inventive concept. It should be understood, however, that persons having ordinary skill in the art may practice the inventive concept without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first foam layer could be termed a second foam layer, and, similarly, a second foam layer could be termed a first foam layer, without departing from the scope of the inventive concept.

FIG. 1illustrates an example perspective view of a firm foam mattress foundation105of a configurable foam comfort system in accordance with various embodiments of the present inventive concept.FIG. 2illustrates an example foam hexagonal cell100configurable on the firm foam mattress foundation105ofFIG. 1.FIG. 3illustrates multiple foam hexagonal cells100in a stacked honeycomb configuration110in accordance with various embodiments of the present inventive concept. Reference is now made toFIGS. 1 through 3.

The foam hexagonal cells100can lay horizontally on the firm foam mattress foundation105. The foam hexagonal cells100can be stacked so they fit together in a honeycomb configuration as shown in the configuration110. As such, the foam hexagonal cells100can be quickly and easily fit together in a non-shifting and stable arrangement. The horizontal cells100create a nesting-like pattern that supports each of the surrounding cells100. Thus, the surrounding cells100in any particular configuration can directly support each near-by cell100.

Each of the foam hexagonal cells100can include a first hexagonal face side160and a second hexagonal face side161opposite thereof. In addition, the foam hexagonal cells100can each include a first side wall162, a second sidewall163, a third sidewall167, a fourth sidewall165, a fifth sidewall164, and a sixth sidewall166. Each of the foam hexagonal cells100can be an elongate having a length that is substantially equal to a width of the firm foam mattress foundation105.

The firm foam mattress foundation105can include form-fit walls125, which are cut or otherwise formed so that they conform to the shape of the hexagonal cells100, as further described below. This provides a secure and stable configuration of the foam hexagonal cells100within and on the firm foam mattress foundation105.

The foam hexagonal cells100can have three different foam characteristics: 1) firm, 2) medium firm, and 3) soft. This allows a user to create a personalized support level by arranging the foam hexagonal cells100in various configurations depending on the characteristics of the cells. For example, firmer cells can be placed in the middle of the mattress foundation105to support the back, while softer cells can be placed near the area where the head rests. The shape of the configurable foam comfort system is modular and can be adjusted based on how many cells100are stacked in a given region. The cells100can be rearranged to create a customized comfort level and shape.

Moreover, individual hexagonal cells100can be replaced if warn or defective. For example, if the mid-section of the configurable foam comfort system creates a “sag” the user can swap cells in the mid-section with cells from other sections of the mattress that don't have any significant load baring need, such as the foot section. The structure of the foam hexagonal cells100allows the user to replace or repair broken-down components within the mattress foundation105. In doing so, life of the mattress is extended. And for those components that must be replaced entirely, the manufacture can send smaller pieces of foam, instead of having to replace the entire sheet of foam, because of the modular design of the foam comfort system.

Moreover, the multiple density foams in the foam hexagonal cells100can provide different comfort levels. The surrounding cells of a particular cell can directly affect each cell. The multiple density or firmness levels of the cells100allows the user to create many different comfort levels by positioning and arranging the cells in unique orders and configurations.

FIG. 4illustrates another example perspective view of a firm foam mattress foundation105of a configurable foam comfort system in accordance with various embodiments of the present inventive concept.FIG. 5illustrates triangular grooves102in the firm foam mattress foundation105ofFIG. 4.FIG. 6illustrates a form-fit wall125of the firm foam mattress foundation ofFIG. 4. Reference is now made toFIGS. 4 through 6.

The firm foam mattress foundation105can include any suitable number of triangular grooves102. For example, the firm foam mattress foundation105can include an upper surface having a plurality of triangular grooves102disposed across a width thereof. Each of the triangular grooves102can provide a base for a corresponding foam hexagonal cell100. In some embodiments, every triangular groove102is occupied by a corresponding foam hexagonal cell100. In some embodiments, a subset of the total triangular grooves102is occupied by a corresponding foam hexagonal cell100, and a remaining subset is unoccupied. Because the cell points of the foam hexagonal cells100face upwards and downwards, the triangular grooves102prevent the foam hexagonal cells100from moving around or shifting. With the vertical apex points of the foam hexagonal cells100facing upwards, additional foam pieces can be added to the structure in the event of a major repair on the base mattress foundation105. In other words, the {circumflex over ( )}{circumflex over ( )}{circumflex over ( )}{circumflex over ( )}{circumflex over ( )} shape allows similar shapes to be used to fit within the {circumflex over ( )}{circumflex over ( )}{circumflex over ( )}{circumflex over ( )}{circumflex over ( )} groves to give the mattress a non-shifting surface. The additional pieces can have a base that looks like vvvvv, and can fit together such that they are prevented from shifting.

The form-fit wall125can include a nook127and an overhang portion129. The nook127can be configured to easily receive and fit a foam hexagonal cell100. The overhang portion129can partially overhang and secure the foam hexagonal cell100in place, but without creating an undue burden to rearrangement of the cells. Accordingly, the nook127and the overhang129of the form-fit wall125can provide stability to the foam hexagonal cells100, particularly on the ends of the configurable foam comfort system, but without impeding the ease of reconfiguration of the foam hexagonal cells100.

The nook127can receive and fit a particular foam hexagonal elongate cell100. The overhang portion129can partially overhang and secure the particular foam hexagonal elongate cell100in place. The nook127can include a vertical side wall150, a lower wall152oriented obliquely relative to the vertical side wall150, and an upper wall154oriented obliquely relative to the vertical side wall150. The overhang portion129can include a vertical side wall156and the upper wall154of the nook127. The vertical side wall150of the nook127can make contact with a first side wall (e.g.,162ofFIG. 2) of the particular foam hexagonal elongate cell100. The lower wall152of the nook127can make contact with a second side wall (e.g.,163ofFIG. 2) of the particular foam hexagonal elongate cell100. The upper wall154of the nook127can make contact with a third side wall (e.g.,167ofFIG. 2) of the particular foam hexagonal elongate cell100. The vertical side wall156of the overhang portion129can make contact with a first side wall (e.g.,162ofFIG. 2) of a different foam hexagonal elongate cell100.

The firm foam mattress foundation105includes a first side180and a second side182. The width188of the firm foam mattress foundation105extends from the first side180to the second side182. The firm foam mattress foundation105includes a third side184and a fourth side186. A length of the firm foam mattress foundation105extends from the third side184to the fourth side186.

The third side184of the firm foam mattress foundation105can include a first form-fit wall (e.g.,125) which can conform to a shape of each of the foam hexagonal elongate cells100. The fourth side186of the firm foam mattress foundation105can include a second form-fit wall (e.g.,125) which conforms to a shape of each of the foam hexagonal elongate cells100.

FIG. 7illustrates an example perspective view of multiple foam hexagonal cells100in a stacked configuration toward one end of and atop the firm foam mattress foundation105ofFIG. 4.FIG. 8illustrates another example perspective view of multiple foam hexagonal cells100in a stacked configuration toward the one end of and atop the firm foam mattress foundation105ofFIG. 4.FIG. 9illustrates an example perspective view of multiple foam hexagonal cells100in a stacked configuration in a central region of and atop the firm foam mattress foundation105ofFIG. 4. Reference is now made toFIGS. 7 through 9.

As shown in these figures, the foam hexagonal cells100fit snuggly against the form-fit wall125. Each of the foam hexagonal cells100has a length that substantially matches a width of the firm foam mattress foundation105. In other words, face sides of the foam hexagonal cells100are substantially flush with sides of the firm foam mattress foundation105. Although shown as stacked two-deep, it will be understood that the foam hexagonal cells100can be stacked one-deep, two-deep, three-deep, four-deep, five-deep, or more, or even zero-deep, depending on the desired mattress contours of the user. Accordingly, the configurable foam comfort system provides a configurable shape based on the preferences of the user.

The configurable foam comfort system can include multiple foam hexagonal elongate cells100configured to fit partially within corresponding triangular grooves (e.g.,102) disposed across the width of the firm foam mattress foundation105. In some embodiments, a length of each of the foam hexagonal elongate cells100is substantially equal to the width of the firm foam mattress foundation105. The foam hexagonal elongate cells100are configured to be custom-stacked on each other and on the firm foam mattress foundation105in accordance with a user's desired comfort configuration.

FIG. 10illustrates multiple foam hexagonal cells100in a uniform stacked configuration atop the firm foam mattress foundation105, along with multiple top layers120disposed on the foam hexagonal cells100in accordance with various embodiments of the present inventive concept. Although multiple top layers120are shown, it will be understood that one or more top layers120can be disposed atop the hexagonal cells100and the firm foam mattress foundation105. The one or more top layers120can include memory foam and/or latex materials. As described above, the foam hexagonal cells100can be arranged with different cells having different firmness characteristics in different sections of the configurable foam comfort system. The base mattress foundation105supports any suitable number of foam layers120on top of the customized foam hexagonal cell configuration, thereby providing a unique base configuration and shape according to the preferences of the user.

The foam hexagonal elongate cells100can include a first plurality of foam hexagonal elongate cells (e.g.,172) and a second plurality of foam hexagonal elongate cells (e.g.,170) configured to fit atop the first plurality of foam hexagonal elongate cells172. The first plurality of foam hexagonal elongate172cells and the second plurality of foam hexagonal elongate cells170can form a honeycomb pattern when viewed from the side.

The first plurality of foam hexagonal elongate cells172collectively form an upper surface having a plurality of triangular grooves158. The second plurality of foam hexagonal elongate cells170are configured to fit partially within corresponding triangular grooves158of the upper surface of the first plurality of foam hexagonal elongate cells172.

The first plurality of foam hexagonal elongate cells172are configured to extend horizontally from the first side (e.g.,180ofFIG. 4) to the second side (e.g.,182ofFIG. 4) of the firm foam mattress foundation105when the first plurality of foam hexagonal elongate cells172are fit partially within the corresponding triangular grooves102disposed across the width of the firm foam mattress foundation105. The second plurality of foam hexagonal elongate cells170are configured to extend horizontally from the first side180to the second side182of the firm foam mattress foundation105when the second plurality of foam hexagonal elongate cells170are fit partially within the corresponding triangular grooves158of the upper surface of the first plurality of foam hexagonal elongate cells172. In some embodiments, each of the second plurality of foam hexagonal elongate cells170have a length that is substantially equal to the width (e.g.,188ofFIG. 4) of the firm foam mattress foundation105.

In some embodiments, one or more rectangular foam top layers120are disposed atop a plurality of foam hexagonal elongate cells170. The one or more rectangular foam top layers120can each include a planar upper surface and a planar lower surface. The planar lower surface (e.g.,187) can be in contact with an apex185of each of the plurality of foam hexagonal elongate cells170. In some embodiment, the one or more rectangular foam top layers120include a first foam top layer and a second foam top layer disposed atop the first foam top layer. At least one of the first foam top layer or the second foam top layer can include or otherwise be constructed from memory foam.

FIG. 11illustrates multiple foam hexagonal cells100in a uniform stacked configuration with a foam body support section130disposed over a subset of the foam hexagonal cells100to provide a raised arcuate upper surface section in accordance with various embodiments of the present inventive concept. The foam body support section130can be disposed atop the foam hexagonal cells100to provide a raised arcuate upper surface section194in any suitable location according to the preferences of the user. The foam body support section130can provide support for parts of a human body, such as a human head, a human back, human legs, or human feet. The length of the foam body support section130can extend width-wise horizontally from one side of the foam mattress foundation to another. Alternatively, the length of the foam body support section130can be less than the width of the foam mattress foundation.

The foam body support section130can be disposed atop a subset (e.g.,192) of foam hexagonal elongate cells100and under the one or more rectangular foam top layers120. In some embodiments, the foam body support section130includes a raised arcuate upper surface section194. The subset192of foam hexagonal elongate cells100can collectively form an upper surface having a plurality of triangular grooves. The foam body support section130can include a lower section196having a plurality of triangular grooves configured to fit together with the triangular grooves of the upper surface of the subset192of foam hexagonal elongate cells100.

The configurable foam mattress comfort system can include various layers (e.g.,197,198, and199) of foam hexagonal elongate cells100. Each layer of hexagonal elongate cells100are configured to extend horizontally from the first side to the second side of the firm foam mattress foundation105. The top layer199is configured to fit partially within corresponding triangular grooves159of an upper surface of the middle layer198of foam hexagonal elongate cells100. The middle layer198is configured to fit partially within corresponding triangular grooves158of an upper surface of the lower layer198of foam hexagonal elongate cells100. A combination of the first, the second, and the third layers of foam hexagonal elongate cells is rearrangeable to create a customized comfort level and shape.

One or more foam hexagonal elongate cells from among the bottom layer197, the middle layer198, and the top layer199of foam hexagonal elongate cells100can include a first firmness characteristic such as firm. One or more foam hexagonal elongate cells from among the bottom layer197, the middle layer198, and the top layer199of foam hexagonal elongate cells100can include a second firmness characteristic such as medium firm. One or more foam hexagonal elongate cells from among the bottom layer197, the middle layer198, and the top layer199of foam hexagonal elongate cells100can include a third firmness characteristic such as soft.

FIG. 12illustrates an example side elevation view of multiple foam hexagonal cells100in a uniform stacked configuration filling a firm foam mattress foundation105in accordance with various embodiments of the present inventive concept.FIG. 13illustrates an example perspective view of multiple foam hexagonal cells100in a uniform stacked configuration filling a firm foam mattress foundation105in accordance with various embodiments of the present inventive concept. Reference is now made toFIGS. 12 through 13.

One or more top layers120can be disposed atop the hexagonal cells100and the firm foam mattress foundation105. The one or more top layers120can include memory foam and/or latex materials. The configurable foam comfort system can include the firm foam mattress foundation105, the foam hexagonal cells100, and the one or more top layers120.

FIG. 14illustrates an example side elevation view of a configurable foam comfort system including multiple stacked foam ‘M’ shaped cells135atop a firm foam mattress foundation145, with one or more top layers120disposed thereon, in accordance with various embodiments of the present inventive concept.FIG. 15illustrates a top view of the configurable foam comfort system ofFIG. 14.FIG. 16illustrates a close-up view of the stacked foam ‘M’ shaped cells135, along with a foam body support section130to provide a raised arcuate upper surface section194, in accordance with various embodiments of the present inventive concept. Reference is now made toFIGS. 14 through 16.

The foam ‘M’ shaped cells135fit together and provide a non-shifting and stable arrangement, such that the foam ‘M’ shaped cells135can be stacked on top of each other to form a different firmness according to preference, and according to a modular design. The firm foam mattress foundation145can include vertical walls155, which need not be cut to conform to the shape of the ‘M’ shaped cells135, since edges of the ‘M’ shaped cells135form a vertical wall themselves. In other words, the ‘M’ shaped cells135can fit against the ends of the firm foam mattress foundation145without any nooks or overhangs. This provides a secure and stable configuration of the ‘M’ shaped cells135on the firm foam mattress foundation145. As shown inFIG. 16, a foam body support section130can be added to provide a raised arcuate upper surface section194. The foam body support section130can include an angled underside196that fits atop the ‘M’ shaped cells135at any suitable location along the ‘M’ shaped cells135.

The firm foam mattress foundation145can include an upper surface having a plurality of triangular grooves147disposed across a width thereof. A plurality of foam ‘M’ shaped elongate cells135from layer176can be configured to fit partially within corresponding triangular grooves147disposed across the width thereof. In some embodiments, a length of each of the plurality of foam ‘M’ shaped elongate cells is substantially equal to the width of the firm foam mattress foundation145.

In some embodiments, the configurable foam comfort system includes a first layer176of foam ‘M’ shaped elongate cells135and a second layer177of foam ‘M’ shaped elongate cells135configured to fit atop the first layer of foam ‘M’ shaped elongate cells. The first layer176of foam ‘M’ shaped elongate cells135collectively form an upper surface having a plurality of triangular grooves148. The second layer177of foam ‘M’ shaped elongate cells135are configured to fit partially within corresponding triangular grooves148of the upper surface of the first layer176of foam ‘M’ shaped elongate cells135. The second layer177of foam ‘M’ shaped elongate cells135collectively form an upper surface having a plurality of triangular grooves149. The third layer178of foam ‘M’ shaped elongate cells135are configured to fit partially within corresponding triangular grooves149of the upper surface of the second layer177of foam ‘M’ shaped elongate cells135.

The firm foam mattress foundation145can include a first side121and a second side122. The width of the firm foam mattress foundation145extends from the first side121to the second side122. The firm foam mattress foundation145can include a third side123and a fourth side124. A length of the firm foam mattress foundation extends from the third side123to the fourth side124.

The first layer176of foam ‘M’ shaped elongate cells135are configured to extend horizontally from the first side121to the second side122of the firm foam mattress foundation145when the first layer176of foam ‘M’ shaped elongate cells135are fit partially within the corresponding triangular grooves147disposed across the width of the firm foam mattress foundation145. The second layer177of foam ‘M’ shaped elongate cells135are configured to extend horizontally from the first side121to the second side122of the firm foam mattress foundation145when the second layer177of foam ‘M’ shaped elongate cells135are fit partially within the corresponding triangular grooves148of the upper surface of the first layer176of foam ‘M’ shaped elongate cells135. The third layer178of foam ‘M’ shaped elongate cells135are configured to extend horizontally from the first side121to the second side122of the firm foam mattress foundation145when the third layer178of foam ‘M’ shaped elongate cells135are fit partially within the corresponding triangular grooves149of the upper surface of the second layer177of foam ‘M’ shaped elongate cells135.

Each of the second layer177of foam ‘M’ shaped elongate cells135have a length that is substantially equal to the width of the firm foam mattress foundation145. The third side123of the firm foam mattress foundation145includes a first vertical wall155, which conforms to a shape of each of the foam ‘M’ shaped elongate cells135from each of the layers176,177, and178. The fourth side124of the firm foam mattress foundation145includes a second vertical wall155, which conforms to a shape of each of the foam ‘M’ shaped elongate cells135from each of the layers176,177, and178.

The configurable foam mattress comfort system can further include one or more rectangular foam top layers120disposed atop the foam ‘M’ shaped elongate cells135. The one or more rectangular foam top layers120include a planar upper surface and a planar lower surface. The planar lower surface can be in contact with an apex185of each of the foam ‘M’ shaped elongate cells135, for example, of the upper layer178. The one or more rectangular foam top layers120can include a first foam top layer and a second foam top layer disposed atop the first foam top layer. At least one of the first foam top layer or the second foam top layer can include memory foam.

The configurable foam mattress comfort system can further include a foam body support section130disposed atop a subset of foam ‘M’ shaped elongate cells135and under the one or more rectangular foam top layers120. The foam body support section130can include a raised arcuate upper surface section194. The foam ‘M’ shaped elongate cells (e.g., from layer178) collectively form an upper surface having a plurality of triangular grooves151. The foam body support section130can include a lower section196having a plurality of triangular grooves153configured to fit together with the plurality of triangular grooves151of the upper surface of the layer of plurality of foam ‘M’ shaped elongate cells178.

A combination of the first layer176, the second layer177, and the third layer178of foam ‘M’ shaped elongate cells135is rearrangeable to create a customized comfort level and shape. One or more foam ‘M’ shaped elongate cells135from among the first layer176, the second layer177, and the third layer178of foam ‘M’ shaped elongate cells can include a first firmness characteristic, such as firm. One or more foam ‘M’ shaped elongate cells135from among the first layer176, the second layer177, and the third layer178of foam ‘M’ shaped elongate cells can include a second firmness characteristic, such as medium firm. One or more foam ‘M’ shaped elongate cells135from among the first layer176, the second layer177, and the third layer178of foam ‘M’ shaped elongate cells can include a third firmness characteristic, such as soft. The firm characteristic can indicate a firmness greater than the firmness of medium firm. The soft characteristic can indicate a softness greater than the softness of medium firm.

In some embodiments, the foam cells (e.g.,100and/or135) can include an internal air bladder. The pressure of the internal air bladder can be adjusted by the user. An outer material of the foam cells can be impermeable to air. In some embodiments, the user can adjust their comfort without having to get on the mattress. In some embodiments, the user can adjust their comfort level while on the mattress.

Embodiments are described herein, and illustrated in the drawings, in terms of functional blocks, units, and/or modules of a configurable foam comfort system. Having described and illustrated the principles of the inventive concept with reference to illustrated embodiments, it will be recognized that the illustrated embodiments can be modified in arrangement and detail without departing from such principles, and can be combined in any desired manner. And although the foregoing discussion has focused on particular embodiments, other configurations are contemplated. In particular, even though expressions such as “according to an embodiment of the invention” or the like are used herein, these phrases are meant to generally reference embodiment possibilities, and are not intended to limit the inventive concept to particular embodiment configurations. As used herein, these terms can reference the same or different embodiments that are combinable into other embodiments.