SIMULATED ZERO "G" MATTRESS AND COVER

A mattress is provided having three layers of differing properties stacked on top of each other which together have the effect of letting the user sleep in a simulated Zero G position without the aid of an articulating base. Two layers are contoured within the mattress let specific areas of the user's body sink further into the mattress than others. A cover with removable inserts is also provided for the mattress.

FIELD OF THE INVENTION

The present invention provides a mattress capable of letting a user sleep in a simulated zero G position.

BACKGROUND

In recent years, many new mattress types have come to market to address various deficiencies in the industry. For example, memory foam mattresses have become very popular. However, these mattresses can often be uncomfortable because the memory foam is not very breathable and can create hot spots. Further, memory foam mattresses do not provide any capability for a user to adjust the softness or firmness of the mattress, leading to further user discomfort. The mattress of the present invention has been designed to address these and other various deficiencies.

SUMMARY

Disclosed herein is a mattress comprised of different layers of material stacked on top of each other which together have the effect of letting the user sleep in a “simulated Zero G” position without the aid of an articulating base. Contoured layers within the mattress let specific areas of the user's body sink further into the mattress than others which create the Zero G effect when sleeping on the back (FIG. 3), and contour to the user's body when sleeping on the side (FIG. 4). Specifically, when sleeping on the back, the user's head, upper back and feet are supported at mattress level, while the torso and hips sink into the mattress on an even slope. This position is more natural to the human body than laying on flat surface with a consistent amount of give & support throughout. Additionally, there is a top layer of material specifically designed to retain minimum heat and to dissipate body heat over time, keeping the user cooler while sleeping and to retain the feeling of “bounce” or “springiness” in the mattress.

DETAILED DESCRIPTION

FIG. 1shows a side view of mattress100with internal layers A-C visible. Layer A is a breathable, springy and bouncy structural mesh layer (polymer material or other materials) between one inch and three inches thick which does not retain heat and serves to add spring and comfort for the user. For example, Layer A may be a material such as Airstring offered by Spec Tex® or any other similar material. Layer B is formed from a visco-elastic polyurethane foam (memory foam) which has a horizontal top surface and has a contoured bottom surface so that it is not a uniform thickness. The purposes of the “zones” formed by the various contours of the bottom surface of layer B will be explained later. In a preferred embodiment, the visco-elastic polyurethane foam of Layer B has a density in the range of 3-8 lb/ft̂3, preferably 4 lb/ft̂3.

Layer C is a High Density polyurethane foam (HD foam) which has a horizontal bottom surface and is cut on a contour on its top surface so that it perfectly matches and fits together with the bottom contour of layer B. Preferably, the high density polyurethane foam has a density range of 1-3 lb/ft̂3, but preferably 2.8 lb/ft̂3. When fully assembled, the mattress100is flat on both top and bottom, appearing similar in shape and size to a traditional mattress.

Preferably, layers B-C are permanently bonded to each other while layer A is removable as will be described later. However, it should be apparent that layers A-C can all be permanently bonded or attached to each other using known methods in the art.

The mattress is divided laterally by five “zones” which are defined by the contour line (FIG. 1) (or contact area between the bottom of layer B and the top of layer C). Zone1is a fully horizontal section starting at the head of the bed and extending from one inch in length to 18 inches along a length of mattress100. Zone2is a transition area between Zone1and Zone3, and extends from the end of Zone1from 1 inch to 20 inches along a length of mattress100. As previously explained, the top surface of layer2is flat while the bottom surface of layer2extends downward toward a bottom of mattress100at an angle which can vary from 5 degrees to 85 degrees from horizontal. The transition of layer B in zone2from flat to sloped can either be a sharp transition, as shown inFIG. 1, or a smooth transition with a convex surface into zone1and a concave surface into zone3.

Zone3is a horizontal section symmetrical about the centerline of the bed connecting zone2and zone4in which layers A-C have a constant thickness. In zone3, layer B is the thickest layer. Zone4is a mirror image of zone2and zone5is a mirror image of zone1about the centerline of the mattress100. Because mattress100is symmetrical, a user can lie lengthwise in either direction. Table 1 below summarizes the thicknesses of the various layers in the various zones:

Layers B and C work together to create a support system for the body that allow for the “simulated Zero G positon.” The HD foam of layer C provides support which will give less under the user's weight, thus defining the user's sleeping position. The memory foam of layer B provides comfort and “give”, letting the user sink into the mattress100. Areas where the memory foam is thicker in layer B, such as zone3, provide a deeper sink and a more customized contour for the user's body. Areas with thicker HD foam in layer C, such as zones1,2,4, and5, provide more support and definition.

Layer A has a number of distinct roles. Its first function is to be breathable, retain as little heat as possible and dissipate body heat over time, keeping the user cool while sleeping and separating the user from the memory foam of layer B which otherwise would retain much of the user's body heat. Secondly, layer A functions to distribute the weight of the user onto layer B. Memory foam deflects at highly local levels which can create a “sunk in” feeling, which prevents the user from easily moving/changing-position during sleep and also does not provide the ideal amount of support for all areas of the body. Layer A deflects in a very broad way, conforming to the body contour while distributing the weight of the user evenly over the memory foam's surface. In this way the memory foam will still offer the benefit of its “give” or vertical deflection, but layer A will prevent the “sunk in” feeling. Layer A also offers a desirable level of spring or bounce, common to an innerspring mattress, which foam alone cannot provide.

Zone Roles for Back Sleeping (FIG.3)

As shown inFIG. 3, when a user lays on their back on mattress100, zone1supports the user's head, keeping it raised above the mattress. Zone2supports the user's shoulders and upper back and defines the angle from horizontal that the user will sleep at. Zone3has a deeper area of memory foam in layer B that lets the user's hips and lower back sink into the mattress. Zones4and5support the user's legs but the contour underneath does not affect leg resting position as the legs are not heavy enough to sink into the mattress. Zone's4and5exist in order to keep the mattress100symmetrical, in this way the user can not set up the mattress in an incorrect orientation.

If the user sets up the mattress100in reverse (head resting on Zone5), zones5and4will function identically to zones1and2respectively. Together, these zones create the “simulated Zero G” position where the back/spine is in alignment in a downward slope (head rests higher than the hips) and the legs are elevated in a semi bent position.

Zone Roles for Side Sleeping (FIG.4)

As shown inFIG. 4, when a user lays on their side on mattress100, zone1supports the user's head, keeping it raised above the mattress. Zone2offers a thicker section of memory foam to allow the user's shoulders to sink in further by following the neck, shoulder and arm and body profile. Zone3offers the thickest section of memory foam to allow the heaviest areas of the body, the hips and torso, to sink in. Sections4and5offer less memory foam which still provide adequate support for the legs. This setup for side sleeping keeps the head supported and keeps the spine relaxed and naturally straight and in a parallel alignment with the floor.

Cover Construction (FIG.5)

In some embodiments, mattress100is further provided with a cover500which comprises top cover502, inner cover,504, and lower portion506. Top cover502is joined to lower portion506through exterior zipper508which can be used to completely separate top cover502from lower portion506. Piping510can be used to conceal the path of zipper508so the user never feels the metal or plastic zipper around the edge of the mattress cover500(FIG. 5,FIG. 6). The zipper508and piping510follow the same path around the perimeter of the mattress100. On the short ends of the mattress100, the zipper508and piping510are on a straight line near the top of mattress100. On the long sides of mattress100, the zipper508and piping510dip downward in a consistent convex arc ranging anywhere from 3″ to 10″ deep (FIG. 5). The other side of mattress100not shown inFIG. 5is a mirror image of that shown inFIGS. 5-6.

The cover500is constructed so that the user can unzip the top layer502as shown inFIG. 6(FIG. 6). This is primarily so the user can access inner cover504located beneath top layer502(FIG. 7). The top layer502can be removed for spot washing, washing in a washing machine, dry cleaning, or replacement.

Top layer502generally comprises two distinct materials. The first material, ticking512, is a soft fabric which is quilted to an internal spacer fabric1002(FIG. 10) in consistent width increments (FIG. 5). As an example, ticking512may be 500 gram 100% polyester. A fire retardant fabric, such as Palidn FR fiber, may also be used.

The internal spacer fabric enhances the breathability of the entire mattress and adds a plush-like topper to mattress100. Spacer fabrics are generally made up of two breathable pieces of fabric that have fine plastic threads oriented vertically between the two fabrics to create a defined space between the two pieces of fabric. The thickness of the spacer fabric located internal to ticking512can vary from 2 mm to 75 mm in thickness.

Inner Cover Construction (FIG.7)

In some embodiments, inner layer A of the mattress100shown inFIGS. 1-4may be inside one or more removable inserts700as depicted inFIG. 7. For full, queen, king and California king mattresses, layer A is made up of 2 inserts700. However, in some embodiments, layer A may be made up on a single insert700that is the full length and width of mattress100. Each insert700is preferably zippered to inner cover504using insert zippers706. However, other connection means, such as hook and loop fasteners, may also be used to attach inserts700to inner cover504.

Inner cover504and lower portion506fully encase layers B and C so that the user is never exposed to those layers (FIG. 7). In some embodiment, inner cover504is formed from a waterproof fabric to prevent any spills from traveling to parts of the mattress that are not washable. Inner cover504extends around the border of the mattress100and is attached to lower portion506along the same convex arc as top layer502. Preferably, inner cover504is sewn to lower portion506so it is not removable for holding the piping510and zipper508in place on mattress100. Inner cover504also prevents the user from smelling layers B and C of mattress100off-gassing, a natural property in foam. When the user removes top layer502to adjust inserts700, they only see a finished case. The user is never subjected to raw materials as in other foam mattresses (FIG. 7).

The bottom of lower portion506comprises a hidden zipper1004(FIG. 10) which is used to attach lower portion506and inner cover504to mattress100during production. The construction of cover500allows the user to remove top layer to adjust the firmness using inserts700having varying densities while still maintaining the look and feel of a finished product (FIG. 6).

Insert Construction (FIG.9)

In a preferred embodiment, layer A is contained within inserts700which are removable from mattress100as has been described. This allows users to select different densities of layer A to suit two users' unique sleeping preferences. This can be due to heat, softness/firmness preferences, change in sleeping behavior, medical reasons, pregnancy, etc.

As depicted inFIG. 9, Layer A is encased in fabric902using a folded fabric construction in which fabric902underneath layer A and is folded over the top of layer A. In the preferred embodiment, the fabric902is lightweight and breathable to optimize the breathability of layer A. The open edges of fabric902are then sewn shut. In the preferred embodiment, the open edges are sewn shut with bias tape904. Layer A is completely encased in the fabric902so the user never sees or touches the raw material. As shown inFIG. 8, the folded fabric construction allows for the two inserts700to sit side by side with no gap or crease between the two inserts700when users are laying on mattress100.

At each end of insert700is a zipper706used to attach insert700to inner cover. In the preferred embodiment, zippers706are used to prevent the inserts from shifting while moving the mattress100. Other methods of securing the mattress include Velcro strips, strips of fabric, or strips of elastic on the corners of the mattress case which are pulled over layer A to keep inserts700in place. The zippers706on each end are designed so an insert can be zipped to either side of the mattress100by simply rotating the insert 180 degrees.

Roll Pack Packaging

The mattress100is packaged for shipment with inserts700attached using a roll packing method in which the mattress100is first compressed and sealed in plastic. As shown inFIG. 11, the compressed mattress100is then folded in half along the centerline (FIG. 1) so that both inserts700face outward. Mattress100is then rolled up as depicted inFIGS. 12-13and sealed with a plastic sheet. In the preferred embodiment, the mattress100is folded in the reverse along the center line. This prevents any permanent creasing or folding lines to layer A or the mattress case500during shipping.