Mattress assembly

A mattress assembly includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The inner core includes opposite first and second portions. The first portion has a firmness that is different than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the spring pack and a second configuration in which the second portion directly engages the spring pack to alter a firmness of a sleep surface of the mattress. Methods of use are disclosed.

TECHNICAL FIELD

The present disclosure generally relates to mattresses, and more particularly to mattress assemblies that include a dual-side mattress having two different comfort choices.

BACKGROUND

Sleep is critical for people to feel and perform their best, in every aspect of their lives. Sleep is an essential path to better health and reaching personal goals. Indeed, sleep affects everything from the ability to commit new information to memory to weight gain. It is therefore essential for people to use bedding that suit both their personal sleep preference and body type in order to achieve comfortable, restful sleep.

Infants and toddlers often require firmer mattresses than older children. In order to prevent having to purchase a new mattress when children become older, some mattresses include a first side having a firmness that is suited for toddlers and a second side having a firmness that is suited for older children. In that young children are likely to wet the bed, such mattresses may include a waterproof cover to prevent urine from getting into the mattress. However, such waterproof covers prevent body heat from ventilating through the mattress and are hence uncomfortable to sleep on. Furthermore, conventional mattresses typically include a cover that is sewn onto an inner core of the mattress, thus requiring that the cover be flipped when the mattress is flipped. This disclosure describes an improvement over these prior art technologies.

SUMMARY

In one embodiment, in accordance with the principles of the present disclosure, a mattress assembly is provided that includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The inner core includes opposite first and second portions. The first portion has a firmness that is different than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the spring pack and a second configuration in which the second portion directly engages the spring pack to alter a firmness of a sleep surface of the mattress.

In one embodiment, in accordance with the principles of the present disclosure, a mattress assembly is provided that includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The cover comprises a porous, non-waterproof material and a zipper. The spring pack comprises opposite first and second surfaces and a plurality of springs positioned between the first and second surfaces. The first surface defines a waterproof barrier. The inner core comprises a matrix of polyurethane fibers. The matrix comprises opposite first and second portions. The fibers that make up the first portion are more densely packed than the fibers that make up the second portion such that the first portion has a firmness that is greater than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the waterproof barrier and a second configuration in which the second portion directly engages the waterproof barrier to alter a firmness of a sleep surface of the mattress.

In one embodiment, in accordance with the principles of the present disclosure, a mattress assembly is provided that includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The cover comprises a porous, non-waterproof material and a zipper. The spring pack comprises opposite first and second surfaces and a plurality of springs positioned between the first and second surfaces. The first surface defines a waterproof barrier. The inner core comprises a mat of electrospun polyurethane fibers. The mat comprises opposite first and second portions. The fibers that make up the first portion are more densely packed than the fibers that make up the second portion such that the first portion has a firmness that is greater than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the waterproof barrier and a second configuration in which the second portion directly engages the waterproof barrier to alter a firmness of a sleep surface of the mattress.

DETAILED DESCRIPTION

The exemplary embodiments are discussed in terms of mattresses, such as, for example, mattress assemblies that include a dual-side inner core having two different comfort choices. The present disclosure may be understood more readily by reference to the following detailed description of the disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure.

Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. For example, the references “upper” and “lower” or “top” and “bottom” are relative and used only in the context to the other, and are not necessarily “superior” and “inferior”.

The following discussion includes a description of a mattress assembly10. Alternate embodiments are also disclosed. Reference will now be made in detail to the exemplary embodiments of the present disclosure.

Mattress assembly10includes a cover12that defines a pocket14. In some embodiments, cover12includes only one pocket, such as, for example, pocket14. In some embodiments, cover12includes a plurality of discrete pockets. In some embodiments, cover12includes a fastener, such as, for example, a zipper16to provide access to pocket14. In some embodiments, cover12comprises a porous material, such as, for example, a porous fabric that allows air to move in and out of pocket through cover12. In some embodiments, cover12comprises a breathable material, such as, for example, a breathable fabric that allows air to move in and out of pocket through cover12. In some embodiments, cover12is made entirely of a porous material and/or a breathable material. That is, no portion of cover12is waterproof. In some embodiments, cover12is washable. That is, cover12is configured to be washed in a standard washing machine.

One or a plurality of spring packs18is/are positioned within pocket14. Spring pack18comprises a plurality of springs20positioned within a pouch22. Springs20are enclosed within pouch22. Spring pack18comprises one or a plurality of rows of springs20and one or a plurality of columns of springs20. In some embodiments, spring pack18includes a plurality of rows of springs20and a plurality of columns of springs20. In some embodiments, spring pack18includes a plurality of strings of springs, as described in U.S. Patent Application No. 62/347,199 to the inventor of the current application, which is incorporated by reference herein, in its entirety. In some embodiments, springs20are each positioned within a pocket, such as, for example, a fabric pocket. The pockets may be coupled to one another to form a string of pockets that each include one of springs20therein. In some embodiments, the string of pockets includes one or more slits between adjacent pockets to allow springs20to move independently of one another. In some embodiments, the sting of pockets includes one or more slits that extend through a top surface of the string of pockets between adjacent pockets and/or one or more slits that extend through a bottom surface of the string of pockets between adjacent pockets. In some embodiments, spring pack18is permanently fixed to cover12. In some embodiments, spring pack18is removably disposed within pocket14.

Pouch22includes a bottom surface that directly engages cover12and an opposite top surface24. Springs20are positioned between the bottom surface of pouch22and surface24. In some embodiments, surface24comprises a waterproof material such that surface24defines a waterproof barrier of pouch22that prevents liquids from passing through surface24to prevent liquids or moisture from entering pouch22through surface24. In some embodiments, surface24is entirely waterproof. That is, the entire area of surface24that is defined by the perimeter of surface24is waterproof. In some embodiments, surface24is non-porous. In some embodiments, surface24comprises a waterproof fabric. In some embodiments, surface24comprises a waterproof polymer. In some embodiments, surface24comprises a thermoplastic polyurethane. In some embodiments, surface24comprises a thermoplastic polyurethane breathable waterproof fabric. In some embodiments, surface24comprises a porous fabric that is coated with a waterproof material.

In some embodiments, mattress assembly10does not include any springs, such as, for example, spring pack18. In some embodiments, mattress assembly10includes a material, such as, for example, a foam block in place of spring pack18.

An inner core26is removably positioned within pocket14such that core26directly engages surface24of spring pack18. Core26includes opposite first and second portions28,30and a middle portion32between portions28,30. Portion28has a firmness that is different than a firmness of portion30to provide two different comfort choices. For example, core26can include a firmer side for toddlers and a softer side for tweens. In some embodiments, portion32has a firmness that is less than a firmness of portion28and a firmness of portion30. Core26can be flipped as the child grows to prevent the need to buy another mattress as the child ages. For example, the same mattress can be used from when the child is 2 or 3 years old until the child is 12 or 13 years old. Core26is configured to be moved between a first configuration in which portion28directly engages surface24of spring pack18and a second configuration in which portion30directly engages surface24to alter a firmness of a sleep surface34of mattress assembly10.

In some embodiments, core26comprises a matrix of fibers. The fibers that make up portion28are more densely packed than the fibers that make up portion30such that portion28is firmer than portion30. In some embodiments, the fibers are made from a polymer, such as, for example, polyurethane. In some embodiments, core26consists of the fibers. That is, core26does not include any material or components other than the fibers. In some embodiments, core26comprises a mat of electrospun fibers. A first side of core26that defines portion28and a second side of core26that defines portion30are heat pressed to provide portions28,30with selected firmnesses. In some embodiments, portion28is heat pressed for a longer duration of time and/or at a higher temperature than portion30to make portion28firmer than portion30. In some embodiments, core26is washable. That is, core26is configured to be washed using water to remove any urine or other material on the fibers that make up core26. In some embodiments, core26is free of any foam.

In operation and use, core26may be positioned within pocket14such that portion30directly engages surface24of spring pack18and portion28is positioned adjacent to sleep surface34of mattress assembly10to provide sleep surface34with a firmness sufficient to accommodate infants or toddlers. If the infant or toddler should wet the bed, the urine will move through cover12and core26and onto surface24of spring pack18. To clean mattress assembly10, zipper16of cover12can be moved from a closed configuration to an open configuration. Spring pack18and core26may be removed from pocket14when zipper16is in the open configuration. Cover12may be cleaned in a standard washing machine, for example. Spring pack18may be cleaned by wiping any urine off of surface24. A cleaning material, such as, for example, bleach or vinegar may be applied to surface24before surface24is wiped clean. Core26may be cleaned by rinsing core26with water, for example. After cover12, spring pack18and core26are cleaned, spring pack18may be repositioned within pocket14. Core26is then inserted into pocket14such that portion30directly engages surface24of spring pack18and portion28is positioned adjacent to sleep surface34of mattress assembly10. Zipper16is then moved from the open configuration to the closed configuration.

As the infant or toddler ages, he or she may desire that sleep surface34be less firm. To alter the firmness of sleep surface34, zipper16of cover12can be moved from the closed configuration to the open configuration. Core26is removed from pocket14when zipper16is in the open configuration. Core26is flipped and is repositioned within pocket such that portion28directly engages surface24of spring pack18and portion30is positioned adjacent to sleep surface34of mattress assembly10to provide sleep surface34with a firmness sufficient to accommodate older children. In some embodiments, spring pack18remains within pocket14while core26is being flipped. That is, cover12and spring pack18are not flipped to alter the firmness of sleep surface34. Rather, only core26is flipped, while cover12and spring pack18remain stationary. Should mattress assembly10become soiled, spring pack18and core26may be removed from pocket14and cover12, spring pack18and/or core26may be cleaned, as discussed herein. After cover12, spring pack18and/or core26is/are cleaned, spring pack18and core26may be repositioned within pocket14, as discussed herein.

It will be understood that various modifications may be made to the embodiments disclosed herein. For example, features of any one embodiment can be combined with features of any other embodiment. Therefore, the above description should not be construed as limiting, but merely as exemplification of the various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.