Patent Publication Number: US-2021177161-A1

Title: Mattress with rails and method of use

Description:
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. 
     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. However, such mattresses lack any structure, such as, for example, rails that can help prevent younger children from rolling out of bed. Furthermore, such mattresses typically include a cover that is sewn onto 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 comprises a cover including a pocket. A mattress is positioned within the pocket. The mattress comprises opposite first and second sides, the first side comprising a cavity. An insert is positioned within the cavity. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure will become more readily apparent from the specific description accompanied by the following drawings, in which: 
         FIG. 1  is a perspective view, in part phantom, of one embodiment of a mattress assembly in accordance with the present principles of the present disclosure; 
         FIG. 2  is a side view, in part phantom, of the mattress assembly shown in  FIG. 1 ; 
         FIG. 3  is a top view of a component of the mattress assembly shown in  FIG. 1 ; 
         FIG. 4  is a top view of a component of the mattress assembly shown in  FIG. 1 ; 
         FIG. 5  is a side, cross sectional view of one embodiment of components of the mattress assembly shown in  FIG. 1 , in accordance with the present principles of the present disclosure; 
         FIG. 6  is a side, cross sectional view of one embodiment of components of the mattress assembly shown in  FIG. 1 , in accordance with the present principles of the present disclosure; 
         FIG. 7  is a side, cross sectional view of one embodiment of components of the mattress assembly shown in  FIG. 1 , in accordance with the present principles of the present disclosure; 
         FIG. 8  is a side, cross sectional view of one embodiment of components of the mattress assembly shown in  FIG. 1 , in accordance with the present principles of the present disclosure; 
         FIG. 9  is a side, cross sectional view of one embodiment of a component of the mattress assembly shown in  FIG. 1 , in accordance with the present principles of the present disclosure; 
         FIG. 10  is a cross section view of one embodiment of a component of the mattress assembly shown in  FIG. 1 , in accordance with the present principles of the present disclosure; and 
         FIG. 11  is a cross section view of the mattress assembly shown in  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION 
     The exemplary embodiments are discussed in terms of mattresses, such as, for example, mattress assemblies that include a dual-side mattress 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” 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 assembly  10 . Alternate embodiments are also disclosed. Reference will now be made in detail to the exemplary embodiments of the present disclosure. 
     The components of mattress assembly  10  can be fabricated from materials including metals, synthetic polymers, ceramics and/or their composites, depending on the particular application and/or preference. For example, the components of mattress assembly  10 , individually or collectively, can be fabricated from materials such as stainless steel alloys, aluminum, commercially pure titanium, titanium alloys, Grade 5 titanium, super-elastic titanium alloys, cobalt-chrome alloys, stainless steel alloys, superelastic metallic alloys (e.g., Nitinol, super elasto-plastic metals, such as GUM METAL® manufactured by Toyota Material Incorporated of Japan), ceramics, thermoplastics such as polyaryletherketone (PAEK) including polyetheretherketone (PEEK), polyetherketoneketone (PEKK) and polyetherketone (PEK), carbon-PEEK composites, PEEK-BaSO 4  polymeric rubbers, polyethylene terephthalate (PET), fabric, silicone, polyurethane, silicone-polyurethane copolymers, polymeric rubbers, polyolefin rubbers, hydrogels, semi-rigid and rigid materials, elastomers, rubbers, thermoplastic elastomers, thermoset elastomers, elastomeric composites, rigid polymers including polyphenylene, polyamide, polyimide, polyetherimide, polyethylene, and epoxy. Various components of mattress assembly  10  may have material composites, including the above materials, to achieve various desired characteristics such as strength, rigidity, elasticity, compliance, mechanical performance, durability and radiolucency or imaging preference. The components of mattress assembly  10 , individually or collectively, may also be fabricated from a heterogeneous material such as a combination of two or more of the above-described materials. The components of mattress assembly  10  may be monolithically formed, integrally connected or include fastening elements and/or instruments, as described herein. 
     In some embodiments, mattress assembly  10  includes a dual-side mattress of two different comfort choices. For example, the mattress can include a firmer side for toddlers and a softer side for tweens. The mattress can be flipped as the child grows to prevent the need to buy another bed for approximately 10-11 years. 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. 
     In some embodiments, one side of the mattress, such as, for example, the firmer side of the mattress includes pockets in the underlying fabric surface which hold removable foam rails, which when in use, keep the child from rolling off the bed at night. That is, the foam rails are like bolsters often used to keep a child from rolling off the bed. As the child grows, the rails are removed, and the stretch pockets in the mattress just return to a substantially flat configuration thereby making a relatively flat surface of the mattress. 
     In some embodiments, the mattress assembly includes a zip-off surface, such as, for example, a cover that can be removed to expose the pockets. The rails can be inserted into the pockets when the pockets are exposed. The mattress can then be inserted into the cover to maintain the rails within the pockets. Likewise, the mattress can be removed from the cover to remove the rails from the pockets. The mattress can then be inserted into the cover without the rails being positioned within the pockets. This configuration allows the mattress to be flipped after the mattress is removed from the cover and for the mattress to be reinserted into the cover after the mattress is flipped. 
     Mattress assembly  10  includes a cover  12  that defines a pocket  14 . In some embodiments, cover  12  includes only one pocket, such as, for example, pocket  14 . In some embodiments, cover  12  includes a plurality of discrete pockets. In some embodiments, cover  12  includes a fastener, such as, for example, a zipper to provide access to pocket  14 . 
     Mattress assembly  10  includes a mattress  16  that is configured to be positioned within pocket  14 . Mattress  16  includes opposite top and bottom surfaces  18 ,  20  and opposite left and right surfaces  22 ,  24  that each extend from top surface  18  to bottom surface  20 . Mattress  16  has a maximum height defined by the distance from top surface  18  to bottom surface  20  and a maximum width defined by the distance from left surface  22  to right surface  24 . Mattress  16  includes opposite first and second sides  26 ,  28  that each include surfaces  18 ,  20 ,  22 ,  24 . First side  26  has a first firmness and second side  28  has a second firmness. In some embodiments, the second firmness is different than the first firmness. In some embodiments, the second firmness is less than the first firmness. In some embodiments, the second firmness greater than the first firmness. In some embodiments, first side  26  comprises a first material to impart first side  26  with the first firmness and second side  28  comprises a second material to impart second side  28  with the second firmness. In some embodiments, the first material is the same as the second material. In some embodiments, the first material is different than the second material. First side  26  has a thickness t 1  and second side  28  has a thickness t 2 . In some embodiments, thickness t 1  is the same as thickness t 2 . In some embodiments, thickness t 1  is different than thickness t 2 . In some embodiments, thickness t 1  is less than thickness t 2 . In some embodiments, thickness t 1  is greater than thickness t 2 . 
     First side of the mattress  26  includes a first cavity  30  adjacent to left surface  22  and a second cavity  32  adjacent to right surface  24 . Cavities  30 ,  32  each extend into an upper surface  26   a  of first side  26 . First cavity  30  is spaced apart from second cavity  32 . First cavity  30  is positioned inwardly of left surface  22  and second cavity  32  is positioned inwardly of right surface  24  such that cavities  30 ,  32  are each positioned between left surface  22  and right surface  24 . However, it is envisioned that first cavity  30  may extend into and/or through left surface  22  and second cavity  32  may extend into and/or through right surface  24 . 
     In some embodiments, cavities  30 ,  32  each have a uniform diameter along the entire length of cavities  30 ,  32 . In some embodiments, first cavity  30  extends parallel to second cavity  32 . In some embodiments, cavities  30 ,  32  are each positioned inwardly of top surface  18  and bottom surface  20  such that cavities  30 ,  32  are each positioned between top surface  18  and bottom surface  20 . In some embodiments, cavities  30 ,  32  each extend through top surface  18  and/or bottom surface  20 . In some embodiments, cavity  30  and/or cavity  32  may have various cross section configurations, such as, for example, oval, oblong, triangular, rectangular, square, polygonal, irregular, uniform, non-uniform, variable, tubular and/or tapered. In some embodiments, cavity  30  may be disposed at alternate orientations, relative to cavity  32 , such as, for example, transverse and/or other angular orientations such as acute or obtuse and/or may be offset or staggered. 
     Mattress  16  is movable between an unstretched configuration in which first side  26  includes cavities  30 ,  32  ( FIG. 3 ) and a stretched configuration in which first side  26  is completely flat ( FIG. 4 ). That is, cavities  30 ,  32  are visible when mattress  16  is in the unstretched configuration and are not visible when mattress  16  is in the stretched configuration. When mattress  16  is in the stretched configuration, first side  26  is completely planar from top surface  18  to bottom surface  20  and from left surface  22  to right surface  24 . As such, first side  26  is free of any indents, recesses or cavities when mattress  16  is in the stretched configuration. 
     Cavity  30  is configured for disposal of a rail, such as, for example, a first insert  34  and cavity  32  is configured for disposal of a rail, such as, for example, a second insert  36 . First insert  34  is removably positioned within cavity  30  and second insert  36  is removably positioned within cavity  32 . When mattress  16  is positioned in pocket  14 , cover  12  maintains inserts  34 ,  36  in cavities  30 ,  32  such that inserts  34 ,  36  are fixed relative to mattress  16 , as discussed herein. 
     In some embodiments, inserts  34 ,  36  may each have a configuration that prevents inserts  34 ,  36  from moving relative to mattress  16 . For example, in one embodiment, shown in  FIGS. 5 and 6 , first insert  34  includes a planar bottom surface  34   a  that extends between planar side surfaces  34   b ,  34   c . Side surfaces  34   b ,  34   c  extend transverse to bottom surface  34   a . In some embodiments, side surfaces  34   b ,  34   c  extend perpendicular to bottom surface  34   a . First insert  34  includes an arcuate top surface  34   d . Top surface  34   d  is convexly curved. In some embodiments, top surface  34   d  is continuously curved from side surface  34   b  to side surface  34   c . In some embodiments, top surface  34   d  has a continuous radius of curvature from side surface  34   b  to side surface  34   c . When first insert  34  is positioned within first cavity  30 , bottom surface  34   a  directly engages a surface  30   a  of mattress  16  and side surfaces  34   b ,  34   c  directly engage surfaces  30   b ,  30   c  of mattress  16  to prevent first insert  34  from moving relative to mattress  16 . Second insert  36  includes a planar bottom surface  36   a  that extends between planar side surfaces  36   b ,  36   c . Side surfaces  36   b ,  36   c  extend transverse to bottom surface  36   a . In some embodiments, side surfaces  36   b ,  36   c  extend perpendicular to bottom surface  36   a . First insert  36  includes an arcuate top surface  36   d . Top surface  36   d  is convexly curved. In some embodiments, top surface  36   d  is continuously curved from side surface  36   b  to side surface  36   c . In some embodiments, top surface  36   d  has a continuous radius of curvature from side surface  36   b  to side surface  36   c . When first insert  36  is positioned within first cavity  32 , bottom surface  36   a  directly engages a surface  32   a  of mattress  16  and side surfaces  36   b ,  36   c  directly engage surfaces  32   b ,  32   c  of mattress  16  to prevent first insert  36  from moving relative to mattress  16 . 
     In one embodiment, shown in  FIG. 6 , inserts  34 ,  36  may be coupled to mattress  16  using a fastener, such as, for example, a hook and loop fastener (Velcro®). A first portion  38   a  of the hook and loop fastener may be applied to bottom surface  34   a  of first insert  34  and a second portion  38   b  of the hook and loop fastener may be applied to surface  30   a  of mattress  16  such that first portion  38   a  directly engages second portion  38   b  when first insert  34  is positioned within first cavity  30  to maintain first insert  34  within first cavity  30 . Likewise, first portion  38   a  of the hook and loop fastener may be applied to bottom surface  36   a  of first insert  36  and second portion  38   b  of the hook and loop fastener may be applied to surface  32   a  of mattress  16  such that first portion  38   a  directly engages second portion  38   b  when first insert  36  is positioned within second cavity  32  to maintain second insert  36  within second cavity  32 . 
     It is envisioned that inserts  34 ,  36  and cavities  30 ,  32  may be variously configured to maintain inserts  34 ,  36  within cavities  30 ,  32 . For example, in one embodiment, shown in  FIG. 7 , bottom surfaces  34   a ,  36   a  of inserts  34 ,  36  each have a polygonal configuration that is configured to mate with a polygonal configuration of surfaces  30   a ,  32   a  to prevent inserts  34 ,  36  from moving within cavities  30 ,  32 . In one embodiment, shown in  FIG. 8 , bottom surfaces  34   a ,  36   a  of inserts  34 ,  36  each have an arcuate configuration that is configured to mate with an arcuate configuration of surfaces  30   a ,  32   a  to prevent inserts  34 ,  36  from moving within cavities  30 ,  32 . In such embodiments, bottom surface  34   a  is continuously curved from side surface  34   b  to side surface  34   c . In some embodiments, bottom surface  34   a  has a continuous radius of curvature from side surface  34   b  to side surface  34   c . Surface  30   a  is continuously curved from surface  30   b  to surface  30   c . In some embodiments, surface  30   a  has a continuous radius of curvature from surface  30   b  to surface  30   c . Likewise, bottom surface  36   a  is continuously curved from side surface  36   b  to side surface  36   c . In some embodiments, bottom surface  36   a  has a continuous radius of curvature from side surface  36   b  to side surface  36   c . Surface  32   a  is continuously curved from surface  32   b  to surface  32   c . In some embodiments, surface  32   a  has a continuous radius of curvature from surface  32   b  to surface  32   c.    
     When inserts  34 ,  36  are positioned within cavities  30 ,  32 , top surfaces  34   d ,  36   d  of inserts  34 ,  36  extends above upper surface  26   a  of first side  26  such that top surfaces  34   d ,  36   d  are superior to upper surface  26   a . Cover  12  conforms to the portions of inserts  34  and  36  that extend above the surface of the mattress resulting in the rails. This configuration allows inserts  34 ,  36  to act as rails that may prevent a sleeper from unintentionally rolling off mattress assembly  10 . That is, inserts  34 ,  36  project outwardly from upper surface  26   a  such that the sleeper would have to roll over at least one of inserts  34 ,  36  in order to roll off of mattress assembly  10 . 
     In operation and use, insert  34  is positioned within cavity  30  and insert  36  is positioned within cavity  32 , as discussed herein. Mattress  16  is then positioned within pocket  14  of cover  12  with first side  26  facing upward such that cover  12  directly engages upper surface  26   a  of first side  26  and top surfaces  34   d ,  36   d  of inserts  34 ,  36  to maintain inserts  34 ,  36  within cavities  30 ,  32 . A sleeper may then lay on first side  26  between inserts  34 ,  36  such that inserts  34 ,  36  prevent the sleeper from unintentionally rolling off mattress  16 . Should the sleeper desire a firmness that is different than the firmness of first side  26 , mattress  16  may be removed from cover  12  and flipped such that second side  28  faces upward. Mattress  16  is then positioned within pocket  14  of cover  12 . The sleeper may then lay on second side  28 . In some embodiments, mattress  16  may be removed from cover  12  without flipping mattress  16  such that first side  26  still faces upward. Inserts  34 ,  36  may then be removed from cavities  30 ,  32  and mattress  16  positioned within pocket  14  of cover  12 . 
     In some embodiments, first side  26  of the mattress is completely planar when mattress  26  is in both the unstretched and stretched configurations. That is, first side  26  does not include any recesses or cavities, such as, for example, cavities  30 ,  32 . In such embodiments, the mattress is encased by cover  12  that has at least two pockets  44 ,  46  attached to and/or directly sewn into the surface of cover  12 . The pockets are configured to receive inserts  34 ,  36 . Once inserts  34  and  36  are positioned within pockets  44  and  46 , two rails are created on the surface of the mattress  26  thereby preventing a child lying on the mattress from rolling off the mattress, as discussed above. In the alternative, inserts  34 ,  36  may be removably attached directly to the surface of cover  12  using a fastening system such as, for example, a hook and loop fastener (Velcro®), a zipper or snaps. When mattress  16  is positioned within pocket  14  of cover  12 , cover  12  directly engages inserts  34  and  36  to prevent inserts  34 ,  36  from moving relative to mattress  16 . 
     In some embodiments, cover  12  includes spaced apart members  40 ,  42  that are configured for disposal in cavities  30 ,  32  when inserts  34 ,  36  are not positioned within cavities  30 ,  32 , as shown in  FIG. 9 . That is, members  40 ,  42  completely fill cavities  30 ,  32  when inserts  34 ,  36  are not positioned within cavities  30 ,  32 . As such, mattress assembly  10  is completely planar from left surface  22  to right surface  24  along an entire length of mattress assembly  10  to allow a sleeper to lay upon first side  26  even when inserts  34 ,  36  are not positioned within cavities  30 ,  32 . 
     In some embodiments, first side  26  is completely planar when mattress  16  is in both the unstretched and stretched configurations and cover  12  includes spaced apart pockets  44 ,  46 , as shown in  FIGS. 10 and 11 . Pockets  44 ,  46  are each configured for disposal of one of inserts  34 ,  36 . It is envisioned that cover  12  may be used with or without inserts  34 ,  36  positioned within pockets  44 ,  46 . For example, cover  12  can be positioned on mattress  18  such that pockets  44 ,  46  engage first side  26  without inserts  34 ,  36  positioned within pockets  44 ,  46 . Cover  12  can be made of a stretchable material, such as, for example, spandex, to allow cover  12  to be stretched over mattress  18  such that first side  26  and the portion of cover  12  that engages first side  26  are completely planar, as shown in  FIG. 10 . Where rails are desired to prevent a child from falling out of bed, for example, inserts  34 ,  36  may be positioned within pockets  44 ,  46  and cover  12  can be positioned on mattress  18  such that pockets  44 ,  46  engage first side  26 , as shown in  FIG. 11 . 
     In some embodiments, cover  12  comprises an elastic material. In some embodiments, pockets  44 ,  46  are positioned on an inner surface of cover  12  such that pockets  44 ,  46  directly engage first side  26  when cover  12  is positioned over mattress  18 . In some embodiments, pockets  44 ,  46  are positioned on an outer surface of cover  12  such that pockets  44 ,  46  are spaced apart from first side  26  when cover  12  is positioned over mattress  18 . In some embodiments, at least one of pockets  44 ,  46  includes a zipper to allow inserts  34 ,  36  to be removed and/or inserted from/into pockets  44 ,  46 . In some embodiments, pockets  44 ,  46  extend an entire length of cover  12 . 
     In some embodiments, pockets  44 ,  46  are positioned between opposite top and bottom surfaces of cover  12  such that pockets  44 ,  46  do not extend the entire length of cover  12 . In some embodiments, mattress  16  includes cavities  30 ,  32 . In some embodiments, mattress  16  is a standard mattress that does not include cavities  30 ,  32 . 
     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.