Abstract:
A modular mattress comprises a plurality of modules which can be arranged with respect to each other so as to form a mattress, and a fasteners for releasably holding the modules adjacent each other in a selected configuration.

Description:
FIELD AND BACKGROUND OF THE INVENTION 
       [0001]    This invention relates to mattresses. More particularly, the invention relates to mattresses which may comprise one or more components, and which may be more easily assembled and disassembled. Thus, the invention relates to a modular type mattress with a plurality of parts or sections, and which are able to be assembled in different configurations or orientations relative to each other. 
         [0002]    Mattresses are, of course, well known and commonly used by people throughout the world. They may be comprised of many different materials and have different structure. For example, some mattresses may be comprised of foam or similar such materials, while other mattresses have a system of springs and other frame members which are contained within a fabric or other envelope. More modern mattresses are constructed in a manner which absorbs movement without substantially spreading it over the entire area of the mattress. This enables a mattress upon which two people may be sleeping to be more comfortable for the users in that the movement of one person will not result in any considerable motion or bouncing of the mattress as a whole, thus making sleep easier for each user without disturbance from the other. 
         [0003]    A common feature of most mattresses is that they are heavy, cumbersome, and often difficult to move easily. Many mattresses may have handles or other structures by means of which they can be more easily moved, but these do not detract from the weight and the awkwardness which is often encountered when trying to move the mattress. This may be a particularly significant problem in establishments such as hotels where room servers have the duty to make many beds in the establishment and the sheer weight of the mattress makes the job that much more difficult. In this regard, it is to be noted that a mattress needs to be lifted not only for the purposes of tucking in sheets and blankets, but must also be moved to rotate it and for periodically taking it out for airing and cleaning and maintenance. 
         [0004]    A further common issue relating to mattresses is that they tend to sag or indent after a period of time due to the weight of the user who tends to occupy the same position on the mattress every time it is used. Under the weight of the user, the foam or springs of the mattress eventually start to lose their ability to return to their rest position, and the surface of the mattress thus becomes contoured or indented over time. This in turn can become uncomfortable for the user since it may roll or move the user into the furrow or indent which has been developed. This, of course, exacerbates the situation by causing the user to continue to sleep in the same spot on the mattress, thus making the indent even more marked. 
         [0005]    The furrowing of the mattress over time may create a situation where the user of the mattress is not properly supported thereon, and this may lead to back ache or other discomforts. It is well researched that proper mattress support is most important for the health of the spine, and many mattresses try to address this issue by ensuring that the user gets the proper support and that the spine is not unduly curved or bent when lying on the mattress. Therefore, the formation of the indents in the mattress may have health ramifications, and may result in the need to replace the mattress more frequently than may be necessary. 
       SUMMARY OF THE INVENTION 
       [0006]    According to one aspect of the invention, there is provided a modular mattress comprising a plurality of modules which can be arranged with respect to each other so as to form a mattress, and fastening means for releasably holding the modules adjacent each other in a selected configuration. Preferably, there are three modules in one embodiment of the invention. In one form of the invention, each of the modules is of substantially the same size, shape and dimension. 
         [0007]    Preferably, at least one module is comprised of springs located within an outer covering or envelope. The fastening means may comprise a plurality of Velcro strips formed on corresponding and abutting edges of the modules. In one embodiment, the fastening means comprises a strip of Velcro attachable to an upper surface and a side surface of adjacent modules. 
         [0008]    In one form of the invention, a top cover, also known in the industry as a topper when attached to the mattress and referred to by both names or other names in this specification, extends over at least a part of an upper surface of the modules when attached to each other. Further, the invention may comprise a base member having a size and shape corresponding to the plurality of modules when configured to form a mattress, the base member having an upper surface upon which the modules are located. 
         [0009]    In other forms of the invention, the fastening means may be comprised of at least one of: belt, tab, press stud. Further, the fastening means may comprise a plurality of Velcro patches formed on corresponding adjacent and abutting surfaces of each of the modules. 
         [0010]    According to a another aspect of the invention, there is provided a method of making a mattress comprising the steps of arranging a plurality of mattress modules adjacent to each other in a desired configuration, and releasably securing the mattress modules to each other to substantially prevent relative movement of the modules under normal use conditions. Preferably, the mattress modules are releasably secured to each other using a plurality of Velcro strips or patches, and one of the plurality mattress modules can be removed and replaced. 
         [0011]    In one embodiment, the number of mattress modules is selected based on the size of the mattress which is to be configured. Further, the position of a mattress module in the mattress may be swapped relative to other mattress modules in order to facilitate an even wear of the mattress and to prevent undue sagging or cratering through normal usage. 
         [0012]    The present invention, in one aspect, is thus designed and constructed in order to address some of the conventional problems as outlined above by providing a mattress which can be configured in different arrangements so as to make the mattress easier to work with in terms of its weight, and also to prevent the sagging or furrowing of the mattress as a result of the constant weight being concentrated at a particular point or area over a period of time. The mattress of the present invention is therefore constructed in a manner which attempts to reduce or at least delay the amount of sagging, and to expose different portions of the mattress to the weight of the user so that no one area will be constantly under the weight of the user while others are not. This in turn results in the more even wear off the mattress, prolonging its life and making it more comfortable over its useful life. 
         [0013]    The mattress in accordance with one aspect of the invention is comprised of modules or components, each of which may be of a different size and dimension, and all of which fit together in different configurations so as to ensure and facilitate the even wear of the mattress. 
         [0014]    According to one aspect of the invention, there is provided a modular mattress comprising a plurality of modules or sections, the modules or sections being connectable to each other in different configurations by a fastening mechanism. 
         [0015]    In a preferred form of the invention, there are three modules or sections, and these modules or sections may be, but are not necessarily, of substantially the same size. Further, in one embodiment of the invention, the mattress comprises three similarly sized and dimensioned modules which can be interchanged with each other and arranged with respect to each other so as to form a mattress of conventional size. In this regard, a conventional size mattress may comprise what is generally referred to as twin, double, queen and king. These are terms commonly used in the trade, and a mattress in accordance with the invention would typically have one of these conventional sizes. However, the invention is not limited to a modular mattress of conventional size, and any size and dimension may be utilized. 
         [0016]    The fastening mechanism in accordance with the invention which is used for the purpose of maintaining the modular components of the mattress adjacent each other so as not to separate under normal usage may take many different forms and styles. Thus, in various aspects of the invention, the fastening means may comprise correspondingly located Velcro strips along the side edge of mating or abutting surfaces of the mattress modules. The fastening means may also comprise rigid T-shaped structures which are located between sections or modules of the mattress and which engage adjacent modules in a manner which keeps them from separating under normal usage. Further, the fastening means may comprise belts or strips or similar such structures which releasably fasten to the mattress by means of Velcro, tabs, appropriately located recesses, or similar such devices. In this regard, it is to be appreciated that the scope of the invention is not to be limited to any one particular mechanism for fastening adjacent mattress modular components to each other in a temporary manner so that they can be disconnected for easier manipulation, cleaning and maintenance of any one mattress component. 
         [0017]    It is to be noted that the present invention allows for just one or some, but not all, of the mattress modules to be replaced when worn or otherwise considered unusable. This feature of the invention will certainly contribute to the money-saving potential of the mattress on the invention by allowing partial replacement of the most worn or unusable components. However, the other components may continue to be used until such time as they need replacement. Thus, it is possible to replace, in accordance with the invention, just a part of the mattress as a whole, without having to replace the entire mattress as is the case in conventional mattress structure. This feature may be particularly useful in establishments such as hotels where damage, overuse, stains, tears or other features would otherwise render an entire mattress unusable, but where the mattress of the present invention allows that at least a part of the mattress be retained without the need for replacement when a section thereof has been damaged or worn. 
         [0018]    In one form of the invention, the mattress of the invention may further comprise a topper or covering, which may be made of a foam or other suitable material. The topper may have any desired thickness, but a convenient thickness for many purposes may be approximately 2 to 3 inches. The object of the topper or cover member would be to provide additional comfort to the user. Additionally, the topper may provide a comfort area between the user and the join lines which extend between adjacent modules of the mattress, and thus shield the user and operate as a barrier so that the user will not feel or be aware of the line along the mattress where adjacent modules meet. The topper may be placed on top of the various modules, and have a size and dimension which is substantially the same as the mattress when comprised of the modules so that the topper covers the entire mattress. Preferably, the topper may be easily removable, with a suitable mechanism, if necessary, provided to ensure that the topper remains in place during use, and does not slide relative to the mattress when the bed is being used or maintained. 
         [0019]    Preferably, the mattress of the invention may be placed and located upon a conventional style box spring or base member of the type which is used in many beds. The box spring provides additional height and supports the mattress. In a preferred embodiment, the box spring portion of the bed would have a size and configuration which corresponds substantially to that of the assembled modules of the mattress in accordance with the present invention. 
         [0020]    The mattress on the invention has a number of benefits and advantages over conventional style mattresses. As already mentioned, the modular construction and the ability to replace one mattress module with another helps to prevent or entirely avoid the cratering or sagging effect which normally occurs in mattresses from use over a period of time. The absence of the cratering will of itself facilitate a more comfortable sleep, and may well prevent backaches which may be a normal consequence of sleeping on a cratered mattress where inadequate or incorrect spinal support is provided. 
         [0021]    The mattress of the invention also facilitates ease of rotation, when necessary. Since each module would be of considerably less weight than the total weight of the mattress which is comprised of the modules, the mattress is less cumbersome, easier to grip, and also easier to simply flip over when turning the mattress. 
         [0022]    Additionally, since the mattress is comprised of three separate components or modules, it is much easier not only to store, but also easier to move and deliver, and this can often be achieved fairly readily by one person. The lighter weight of each module relative to a conventional mattress, and its easier handling, make it more likely that a delivery person will not sustain any injury as a result of carrying and locating the mattress. There may also be benefits and advantages in terms of cost of production, since these smaller mattresses may be easier to manufacture due to their reduced size and weight. It has already been mentioned above that cost-effectiveness may already be present in that it may often be unnecessary to replace an entire mattress since, in accordance with the invention, a single worn component or module may be replaced while others which may be less used can be retained. 
         [0023]    Furthermore, since each module of the mattress may be alternated in its position in configuring the mattress as a whole, it may last longer in that it will not always be in the position where it is getting maximum wear. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    In the drawings: 
           [0025]      FIG. 1  is a perspective view of a modular mattress in accordance with one aspect of the invention; 
           [0026]      FIG. 2  is a side view of the mattress shown in FIG.  1  of the drawings, also showing a top cover or topper thereon; 
           [0027]      FIG. 3  is a detailed view of fastening means which is formed on a module of the mattress illustrating one embodiment of the invention used for securing modules with respect to each other; and 
           [0028]      FIG. 4  is a top perspective view of a modular mattress in accordance with the present invention showing Velcro strips and other fastening mechanisms for keeping modules of the mattress secured to each other in use. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    Reference is now made to the accompanying drawings which show various embodiments and features of a modular mattress in accordance with the present invention. With reference to  FIG. 1  of the drawings, there is shown a modular mattress  10  mounted on a box spring or base  12 . The base  12  is typically a single and integral unit providing an upper surface on which the modules of the mattress in accordance with the invention may be located.  FIG. 1  of the drawings shows modules  14 ,  16  and  18 . 
         [0030]    Each module has a first surface  20 , a second surface  22 , both of which are for sleeping on, longitudinal edges  24  and  26 , and side edges  28  and  30 . In the embodiment shown in  FIG. 1  of the drawings, as well as the other drawings, each of the modules  14 ,  16  and  18  are all of substantially the same size and dimension. However, it will be appreciated that in other embodiments of the invention these modules may be of different sizes and shapes, as may be desired. 
         [0031]    The modules  14 ,  16  and  18  are placed alongside each other on the base  12  so that the longitudinal edge  24  of one module is directly against the longitudinal edge  26  of an adjacent module. The three modules  14 ,  16  and  18  together are sized so as to substantially cover the upper surface of the base  12 , and together act in effect like a conventional mattress. The difference, of course, between the use of the three modules and a conventional mattress comprised of a single piece only is that: the modules may be reconfigured with respect to each other to provide more even wear of the mattress; only one of the modules need be replaced when worn; and handling and relocation of a particular module is much easier and less cumbersome than trying to maneuver a conventional one piece mattress. 
         [0032]    It will be seen in  FIG. 2  of the drawings that a top piece or topper  34  is provided which covers all of the modules  14 ,  16  and  18 . The top piece or topper  34  isolates the user from the upper surface of the modules and provides a barrier for additional comfort, and lessening the possibility that a user may be able to feel any of the lines which joined one module of the mattress to another module. 
         [0033]    In  FIG. 3  of the drawings, it will be seen that the longitudinal edges  24  and  26  of adjacent modules, such as modules  14  and  16  or modules  16  and  18 , have corresponding Velcro strips  38  and  40  which engage with one another when such adjacent modules are brought into contact with each other along their respective longitudinal edges. The Velcro strips  38  or  40  may be of a continuous nature, or they may be a plurality of strips or patches placed along the longitudinal edges. In any event, it will of course be appreciated that Velcro strips having sufficient adhesive force and power with respect to each other are used to ensure that the connected modules do not easily detach from each other in normal use. Furthermore, the strength of the Velcro strip fastening should not be so great so that undue force needs to be applied to separate the modules when such separation is appropriate and desired. 
         [0034]      FIG. 4  of the drawings shows a modular mattress  10  in accordance with an embodiment of the invention wherein the fastening means in the form of Velcro strips or other appropriate means is placed on top of and along the side edges of adjacent modules.  FIG. 4  shows a top Velcro strip  50  between modules  16  and  18 , and a second top Velcro strip  52  between modules  14  and  16 , the Velcro strips  50  and  52  extending most the way across the join or line between adjacent modules. The adjacent strips  50  and  52  attach to corresponding surfaces on the modules  14 ,  16 ,  18 , which enable them to adequately attach thereto in order to hold the modules together. 
         [0035]      FIG. 4  also shows side edge strips  54 , preferably also of Velcro, which holds together adjacent modules  14  and  16  or  16  and  18  along the side edges. Once more, the modules will have appropriate surfaces with the necessary texture in order to allow the proper adhesion of the Velcro strips to thereby maintain adjacent modules connected to each other during normal use. It will be appreciated that the combination of the top Velcro strips  50  and  52 , together with the side strips  54  together provide a good mechanism for holding modules adjacent each other. Furthermore, these strips  50 ,  52  and  54  can be easily accessed peeled off when it becomes necessary to reconfigure the modules, or to replace one or more of the modules. These strips may be easily disposable and replaced with new strips after a few uses, if this should become necessary. 
         [0036]    The top and side strips shown in  FIG. 4  of the drawings may be an alternative to, or in addition to, the Velcro strips  38  and  40  which all formed on longitudinal edges of the modules comprising the mattress. The size, shape and extent of the strips for fastening modules to each other so as to be sufficiently strong to hold modules together but also allow reasonably easy separation may be varied in a wide scope of different forms in a manner which may be best suited to a particular mattress and the shape and form of the modules of which it is comprised. 
         [0037]    It will also be appreciated that the modules which comprise the mattress of the invention may be connected to each other and releasably fastened in many other manners than described above with respect to the use of Velcro strips. Thus, each of the modules may have short belts, long belts, clasps, tabs, press studs or the like in place of or in addition to Velcro strips or any other fastening mechanism. 
         [0038]    In use, the modules of the mattress are placed on a base  12  and the modules are fastened together using the Velcro strips, belts, tabs or such other connecting devices. At appropriate time intervals, any one or more of the modules may be rotated, flipped, or repositioned entirely within the mattress. Such flexibility in the possible adjustments of the modules make the mattress of the invention eminently suitable for reconfiguration so as to minimize wear and cratering at any one point, and to spread the wear of the mattress as a whole. If one modules become damaged, stained, wet or otherwise unusable, whether this is temporary or permanent, it can simply be removed and replaced with another module. Further, a damaged module can be easily moved and repaired, such as the repair of a tear or rip, without replacing an entire mattress. 
         [0039]    While only several embodiments of the invention have been described herein, the invention may take many different forms. In this regard, any suitable number of modules and the shapes thereof may be provided. A larger bed may of course have more modules than a smaller bed. Some modules may be larger than others. Different modules may be comprised of different materials, such as a spring mattress versus a foam based mattress. 
         [0040]    Furthermore, a wide variety of different types of fastening mechanisms may be provided, and only a few have been described herein. However, it should be understood that the nature of the invention is not limited by or to the specific types of fastening mechanisms described herein. 
         [0041]    Top covers or toppers of different depth and size may be provided and may be configured so that they can easily attached to and be released from the modules themselves. Further, they may also be forms of connection between the modules and the base member to prevent sliding of the modules thereon. A top cover, or topper, when provided, may also be attachable to the base member. 
         [0042]    The modules comprising the mattress of the invention may also have appropriately formed handles which makes it easier to lift and maneuver the modules. The handles may be located typically on the side edges or longitudinal edges, but the invention is not limited to this arrangement.