Abstract:
A mattress with built-in massage capabilities that is arranged so the mattress can be used as a standard sleep surface when the massage function is idle. In standard sleep mode a user will not notice the massage aspects of the mattress. Massage is performed by air pumps and air bags controlled to simulate various massage protocols such as wave, stretching, kneading, and percussion.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/525,832 filed Aug. 21, 2011 the disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to a mattress, and more particularly to a mattress with multiple massage units concealed within, so that the one mattress is functional to massage users only when needed. When not being used for massage, the mattress functions as a regular mattress for sleeping. 
         [0003]    In today&#39;s modern, sedentary life style, people are spending more time sitting in their offices, or at desks, working on computers or performing other tedious work. Hours of sitting can cause sore, stiff limbs and back pain. Massage is a helpful remedy to relieve such maladies. However, as work days lengthen and budgets tighten, the time and resources required for receiving a massage have become increasingly scarce, leading a general reduction in feelings of health and well-being. 
         [0004]    The need for massage to relieve muscle tension and soreness is increasing. Many types of massage devices have been developed and are marketed to enable general consumers to more conveniently treat their sore, stiff limbs and back pain at home. Among these devices, there are large-sized massage lounges and small-sized massage rods. 
         [0005]    Some massage mattresses and mats have been constructed by offering a conventional mattress configured with one or more massage units that are fixedly mounted. In one configuration, compression bags attached to the exterior top surface of a pad inflate and protrude into the air around a user&#39;s limbs. Such compression bags may offer massage benefits but are not conducive to normal sleep. For example, for such a pad to function, the pad has to be above the mattress surface and cannot be covered with a standard mattress sheet. These pads are not conducive to the long term comfort required for restful hours of sleep. 
         [0006]    Another type of mattress and pad has been constructed of hard rollers that run under the mattress or pad covering. While perhaps useful for short periods, the hard, protruding rollers do not offer a long term solution to massage that can performed while one is asleep. Some users have reported bruising and inability to sleep due to the intrusive design of the rollers. 
         [0007]    A third type of mattress has been configured by combining one or more vibrating massage units to the mattress or bed frame. This solution does little to provide actual massage relief. In addition to the ineffectiveness of the massage, the constant buzzing and vibration can hinder restful sleep. 
         [0008]    A massage mattress, as described herein, may be the most desirable since a user needs only to lie on the mattress to have the whole body well massaged. Additional time traveling to and receiving a massage is not needed when a person can merge that treatment with the time spent sleeping in his own bed. The massage mattress described is also well suited for the aged and sick since the massage movements disclosed can help reduce the probability of bedsores by automatically moving pressure points and increasing circulation. 
       SUMMARY 
       [0009]    In one exemplary embodiment, a massage mattress is disclosed with a standard sleep function which is capable of selectively offering a variety of massage protocols. 
         [0010]    In another exemplary embodiment, a combination of massage components disclosed is combined to modify existing mattress to add massage capabilities. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. 
           [0012]      FIG. 1  is a front isometric view of the massage mattress according to an exemplary embodiment. 
           [0013]      FIG. 2  is a front isometric view of the massage mattress according to an exemplary embodiment with several layers partially cut away. 
           [0014]      FIG. 3  is a longitudinal cross-sectional view of a component of the massage mattress according to an exemplary embodiment. 
           [0015]      FIG. 4  is a top view of a massage engine for the massage mattress according to an exemplary embodiment. 
           [0016]      FIG. 5  is a top view of a massage engine for the massage mattress according to an exemplary embodiment. 
           [0017]      FIG. 6  is a top view of a massage engine for the massage mattress according to an exemplary embodiment. 
           [0018]      FIG. 7  is a top view of a massage engine for the massage mattress according to an exemplary embodiment. 
           [0019]      FIG. 8  is a top view of a massage engine for the massage mattress according to an exemplary embodiment. 
           [0020]      FIG. 9  is a side view of the massage mattress according to an exemplary embodiment with a cover partially cut away. 
           [0021]      FIG. 10  is a front isometric view of the massage mattress according to an exemplary embodiment with a cover partially cut away. 
           [0022]      FIG. 11  is a front isometric view of the massage mattress according to an exemplary embodiment with a cover partially cut away. 
           [0023]      FIGS. 12   a  through  12   c  are side views of a massage effector according to an exemplary embodiment. 
           [0024]      FIG. 13   a  is a top view of a massage effector according to an exemplary embodiment. 
           [0025]      FIGS. 13   b  and  13   c  are side views of a massage effector according to an exemplary embodiment. 
           [0026]      FIG. 14   a  is a top view of a massage effector according to an exemplary embodiment. 
           [0027]      FIGS. 14   b  and  14   c  are side views of a massage effector according to an exemplary embodiment. 
           [0028]      FIG. 15  is a top view of a massage effector according to an exemplary embodiment. 
           [0029]      FIG. 16  is a top view of a massage effector according to an exemplary embodiment. 
           [0030]      FIG. 17  is a top view of the massage mattress according to an exemplary embodiment. 
           [0031]      FIG. 18  is a cross-sectional view of the massage mattress taken along line  18 - 18  in  FIG. 17 . 
           [0032]      FIG. 19  is an exemplary embodiment of the configuration in  FIG. 18 . 
           [0033]      FIG. 20  is a top view of the massage mattress according to an exemplary embodiment with several layers partially cut away. 
           [0034]      FIG. 21  is an exploded side view of the massage mattress in  FIG. 20 . 
           [0035]      FIG. 22  is a cross-sectional view of the massage mattress taken along line  22 - 22  in  FIG. 20 . 
           [0036]      FIG. 23  is a cross-sectional view of the massage mattress taken along line  22 - 22  in  FIG. 20 . 
       
    
    
     DETAILED DESCRIPTION 
       [0037]    This disclosure describes a novel mattress design which incorporates concealed massage units. The novel mattress design has strategically placed, and specifically shaped air bags that are inflated and deflated to achieve a desired massage effect. The novel mattress design allows for a standard mattress that is used for sleeping to simultaneously be used to obtain one or more therapeutic massage protocols. The novel mattress design has a massage engine that includes a controller that operates one or more massage effectors. The controller operates pumps and various valves connected to pneumatic tubing or other motorized parts. In a pneumatic embodiment, tubing connects to inflatable bags which are situated to simulate various massage protocols. In a mechanical embodiment, inflatable bags are used to situate a mechanical massage effector to carry out massage protocols. In particular, the massage engine can create a slow wave effect to variously stretch large body parts. Specific body parts can be moved by raising and lowering, or inflating and deflating, certain bags. A percussion massage protocol can be achieved by the massage engine, targeted for specific body parts. Additionally, a kneading type of massage protocol is obtained by using certain air bag configurations. 
         [0038]    Referring to  FIG. 1 , a massage mattress  100  is shown according to an exemplary embodiment in a front isometric view. In this exemplary embodiment the massage mattress would take the place of a user&#39;s standard sleeping mattress. When the massage engine is off, the massage components would not be detectable by the user. 
         [0039]    Referring now to  FIG. 2 , a front isometric view of massage mattress  100  according to an exemplary embodiment is shown with several layers partially cut away. Mattress  100  is generally enclosed in a fabric mattress cover  102 . Inside the cover  102  are enclosed a control system  104  which is in operable communication with massage effectors  106 . The control system  104  and massage effectors  106  generally reside in a cavity  108 , and are jointly referred to as a massage engine  124 , shown in  FIG. 4 . Communication between the control system  104  and massage effectors includes pneumatic and hydraulic tubing  132 . Cavity  108  is created by removal of material from a core layer  110 . The cover  102  is preferably comprised of an upper cover  112  and lower cover  114 . The upper and lower covers are removable connected with a zipper, hook and loop fastener tape, or other methods know in the art. Removal of the upper cover  112  may facilitate construction of the mattress and maintenance, as needed. A resilient layer  116  covers the massage engine  124  and may be attached to core  110  with attachment pad  120 . Attachment pads  120  are used as needed to maintain the position of the layer  116  with respect to core  110 , and more particularly, with respect to the massage effectors  106 . An additional layer of stretchable fabric  118  may be adhered to the bottom of resilient layer  116  to increase the wear resistance and reduce the friction between layer  116  and the effectors  106 . Layer  116  and core  110  are both preferably constructed of a resilient foam material, such as memory foam, but may be comprised of other open or closed cell foam or padding. The layer  116  and core  110  may be constructed from dissimilar materials as well. 
         [0040]    Referring now to  FIG. 3 , a longitudinal cross-sectional view of the core  110  is shown. The cavity  108  is created to accommodate the massage engine  124 , shown in  FIG. 4 . In the embodiment shown in  FIG. 2 , core  110  is manufactured from a single piece of foam. In another embodiment, core  110  may be assembled from various pieces of foam to obtain specific properties and to modify the manufacturing process. 
         [0041]    Referring now to  FIG. 4 , a top view of massage engine  124  for massage mattress  100  is shown. Massage engine  124  is generally comprised of a control system  104  operably connected to massage effectors  106  using connections  132 . Connections  132  may be hoses, tubes, or control wires. Control system  104  is generally comprised of a controller  136  which is connected to one or more pumps  140 , valves  134 , and power source  138 . The pumps are preferably air pumps but hydraulic pumps may also be used by adding additional components, such as a reservoir, as needed. In some embodiments, the motive force for the massage effectors may be distributed throughout massage engine  124 . As shown in  FIG. 4 , various types of massage effectors may be connected to the control system, including square air bags  126 , rectangular air bags  128 , and small asymmetrical air bags  130 . The inflatable bags, whether filled with air or another fluid, are preferably constructed from fluid tight, flexible materials, such as, but not limited to, thermoplastic polyurethane, polyurethane, urethane, polyvinyl chloride, rubber, silicon, polyethylene, nylon, nylon 6-6, TEFLON, polyester, or polyamide. Although representative massage effectors are shown, additional shapes and configuration may be used and are contemplated. 
         [0042]    Referring now to  FIG. 5 , a top view of a massage engine is shown with massage effectors  106  comprised of lateral, narrow inflatable bags  142 , which are generally cylindrical in shape and reach between the sides of the massage engine. The arrangement using bags  142  can be used to simulate a massage protocol that feels like a travelling wave. 
         [0043]    Referring now to  FIG. 6 , a top view of a massage engine is shown with massage effectors  106  comprised of lateral, wide inflatable bags  144 , which are generally cylindrical in shape and reach between the sides of the massage engine. The arrangement using bags  144  can be used to simulate a massage protocol that feels like a bobbing wave. 
         [0044]    Referring now to  FIG. 7 , a top view of a massage engine is shown with massage effectors  106  comprised of small inflatable bags  126 , which are generally square in shape and are arranged to provide a percussive massage protocol to various user body parts. 
         [0045]    Referring now to  FIG. 8 , a top view of a massage engine is shown with massage effectors  106  comprised of a plurality of circular inflatable bags  146 . Circular bags  146  may be considered air springs as they are generally circular in shape and extend upwards to form a cylinder shape when extended. This arrangement of bags  146  may be used to provide a percussive massage and may be used to change the firmness and height of the entire mattress or of various individual points or regions. In one embodiment the air springs  146  are encased in a layer of foam through which holes have been created to accommodate and restrain lateral movement of the springs as they are inflated. 
         [0046]    Referring now to  FIG. 9 , a side view of the massage mattress  200  according to an exemplary embodiment is shown with a cover  202  partially cut away. In between the cover  202  and the mattress base  204  are located two large air bags  152  and  154 . Lateral leg air bag  152  and asymmetrical, pleated air bag  154  are arranged to provide a user with adjustable support and massage when inflated. When bags  152  and  154  are deflated, massage mattress  200  is usable a standard mattress without any discomfort to the user created by the air bags  152  and  154 . 
         [0047]    Referring now to  FIG. 10 , a front isometric of a massage mattress  400  is shown with a cover partially cut away. Mattress topper  402  contains air bags  152  and  156  which may be removed from mattress base  404  for sleeping. Lateral leg air bag  152  and lateral torso-support air bag  156  may have cross-sectional shapes other than those shown. Other cross-sectional shapes may include circular, oval, triangular, square, and the like. Mattress topper  402  may provide a user with adjustable, removable support and massage when inflated. 
         [0048]    Referring now to  FIG. 11 , a front isometric of a massage mattress  300  is shown with a cover partially cut away. In this configuration, the massage mattress  300  is configured by placing an existing foam mattress  302  over the top of air bags  152  and  156 . 
         [0049]    Referring now to  FIGS. 12   a  through  12   c,  inflatable bags, or air springs, as described in  FIG. 8 , are shown in various stages of inflation. In  FIG. 12   a , air spring  146  is shown completely deflated, making it essentially flat. As air is pumped into the air spring  146 , it expands as shown in  FIG. 12   b . When fully extended, air spring  146  may appear as shown in  FIG. 12   c . Pleats  158  allow the air spring  146  to expand to many times its deflated height. The material used to construct the air springs  146  is generally non-elastic, such that the expansion of the air bag is provided for by the pleats  158  rather than by stretching and deformation of the air bag material. 
         [0050]    Referring now to  FIGS. 13   a  through  16 , various inflatable massage effectors are shown.  FIG. 13   a  shows the top of an air bag  160  which is arranged as a double, asymmetrical pleated bag. The two sides of air bag  160  rotate upward about central seam  162 .  FIG. 13   b  is a side view of the air bag  160  in a deflated state.  FIG. 13   c  is a side view of the air bag  160  in an inflated state. Pleats  164  allow the two halves of the air bag to open while being constrained in the center by seem  162 . Pressure surfaces  166  come upwards and towards each other allowing this air bag to create a massage feeling of compression.  FIGS. 14   a ,  14   b , and  14   c  show a single asymmetrical pleated bag from the top, from the side, deflated, and from the side, inflated, respectively.  FIGS. 15 and 16  show two additional embodiments of asymmetrically expanding air bags that can be used to create massage pressure around a body part or region. 
         [0051]    Referring now to  FIG. 17 , a top view of the massage mattress according to an exemplary embodiment is shown. The massage effectors  106  are comprised of a plurality of cylindrical air bladders  148 . The material used to construct the air bladders  148  is generally elastic, such that the expansion of the air bladders is not provided for by the inclusion of pleats but rather by stretching and deformation of the air bladder material. The air bladders are generally elongated circular balloon shapes with a length at least several times greater than a maximum diameter. Although the air bladders  148  may extend upwards somewhat when inflated, a primary function is to selectively increase and decrease the overall firmness of the mattress. A piece of foam  172  may be created with multiple holes to allow insertion of multiple air bladders  148 . Air foam  172  can then achieve changes in overall firmness, height adjustment, point and regional firmness variation by selective inflation of the air bladders  148 . 
         [0052]    Referring now to  FIGS. 18 and 19 ,  FIG. 18  is a partial cross-sectional view of foam  172  taken along line  18 - 18  in  FIG. 17  and  FIG. 19  shows an alternative embodiment to the embodiment shown in  FIG. 18 . As shown in  FIG. 18 , air foam  172  is created with through-holes  174  which accommodate air bladders  148 . Air bladders  148  may be filled using connecting hoses  176 . Alternatively, some of the through-holes  174  can be left empty to provide air movement through the air foam  172 . In one embodiment, one or more of the air bladders  148  may be partially encased in a fabric sleeve  150  to modify the lateral stretching and change the air foam properties.  FIG. 19  shows and embodiment for air foam  172  where partial-depth holes  178  are created to accommodate the air bladders  148 , which may provide a more homogeneous sleep surface. 
         [0053]    Referring now to  FIG. 20 , a top view of the massage mattress  460  according to an exemplary embodiment is shown with several layers partially cut away. Massage mattress  460  incorporates a novel combination of inflatable bags and mechanical massage effectors to provide a standard sleeping surface that can also provide massage characteristics. The mattress  460  has a top layer of foam  462  which covers a large upper inflatable air chamber  468  which covers the entire mattress. A mattress frame  464  provides an enclosure for various mattress components and frame  464  has an inner edge  466 . From the bottom of the frame  464 , the first layer of interest is an inflatable lower air chamber  482  that fills the frame  464  up to the inner edge  466 . On top of the lower air chamber  482  is a rigid panel  480 , shown in  FIG. 21 , which supports idler wheel massage units  476  and  478 , shown in  FIG. 21 . Unit  476  is optionally placed to provide rolling massage of a user&#39;s back, while unit  478  is optionally placed to provide rolling massage of a user&#39;s lower body and legs. A semi-rigid foam board  472  covers the massage units but has wheel slots  474  which permit the idler massage wheels free passage along their tracks. A layer of wear resistant material  470 , such as leather, rubber, pleather, or the like, is located between the wheels of units  476  and  478  and the upper air chamber  468  to prevent premature wear and damage to the components and layers above the wheels. 
         [0054]    Referring now to  FIG. 21 , an exploded side view of the massage mattress  460  is shown. In this view, rigid panel  480  is shown, in addition to the layers and components described in  FIG. 22 . 
         [0055]    Referring now to  FIGS. 22 and 23 , cross-sectional side views of the massage mattress  460  taken along line  22 - 22  in  FIG. 20  are shown.  FIG. 22  shows the mattress  460  in normal sleep mode. In sleep mode, upper air bag  468  is inflated. Lower air bag  482  is deflated, thereby lowering the massage unit wheels so they are not felt by a user.  FIG. 23  shows the mattress  460  in massage mode, with lower air bag  482  inflated. When bag  482  is inflated, the wheels on the massage units protrude up through the slots  474  in foam panel  472 . In order for a user to feel the massage action of the wheels, however, upper air bag  468  is deflated, allowing the foam layer  462  to press against the rolling wheels. Estimated pressure curves  484  are shown to approximate the massage compression provided by the massage wheels. 
         [0056]    Although embodiments of the present disclosure have been described in detail, those skilled in the art should understand that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure. Accordingly, all such changes, substitutions and alterations are intended to be included within the scope of the present disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.