Patent Publication Number: US-10327564-B1

Title: Modular mattress renewal system

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates generally to beds and, more specifically, to a mattress enhancement that allows the user to compensate for the sags or indentations in the mattress that occur over a period of use. Even more specifically, it relates to a mattress enhancement that is modular and that additionally allows its use on various sized mattresses and on the portions thereof that require additional support for the comfort of the user. Even more specifically it relates to a modular mattress support that has varying degrees of compressibility in each of the support modules and that has fully modifiable connectors between the support modules for the varying ranges of support that are required in each specific case. 
     Description of the Prior Art 
     There are other support device designed for cushioning. Typical of these is U.S. Pat. No. 4,070,719 issued to Morgan on Jan. 31, 1978. 
     Another patent was issued to Fogel on Feb. 27, 2001 as U.S. Pat. No. 6,192,538. Yet another U.S. Pat. No. 6,401,282 was issued to Shum on Jun. 11, 2002 and still yet another was issued on Apr. 1, 2003 to Landvik et al. as U.S. Pat. No. 6,541,094. 
     Another patent was issued to Visser et al. on Oct. 11, 2005 as U.S. Pat. No. 6,952,850. Yet another U.S. Pat. No. 7,805,791 was issued to Malzl on Oct. 5, 2010. Another was issued to Gladney on Aug. 28, 2012 as U.S. Pat. No. 8,250,689 and still yet another was issued on Jan. 22, 2013 to Howard as U.S. Pat. No. 8,356,371. 
     Another patent was issued to Fukano on Feb. 12, 2013 as U.S. Pat. No. 8,370,979. Yet another U.S. Pat. No. 8,418,297 was issued to Mikkelsen et al. on Apr. 16, 2013. Another was issued to Witherell et al. on Oct. 22, 2013 as U.S. Pat. No. 8,613,120 and still yet another was issued on Dec. 24, 2013 to Hawkins as U.S. Pat. No. 8,613,120. 
     U.S. Pat. No. 4,070,719 
     Inventor: Charles W. Morgan 
     Issued: 31 Jan. 1978 
     An improved cushioning element is provided which is prepared from a synthetic resinous cellular resilient body. A plurality of intersecting grooves are formed in the surface of the cushioning element thereby providing a bodysupporting surface of a plurality of spaced-apart bosses generally independently deflectable and recoverable. 
     U.S. Pat. No. 6,192,538 
     Inventor: Isaac Fogel 
     Issued: 27 Feb. 2001 
     A mattress system offering combinations of comfort and support comprising at least two modules, positioned side-by-side along their longest dimension to define at least two recumbent user areas, and a comfort cushion receivable atop each of the at least two modules. At least one of the modules includes a depression in its upper surface, adapted to removably retain a support insert comprised of an envelope containing a plurality of liquid filled bladders. The mattress system provides an immense array of combinations of firmness and support, allowing each user to adjust, to a very wide degree, the comfort, firmness and support beneath their upper body, lumbar area, and lower body. The adaptable structure of the mattress system also allows the individual user to customize his/her side of the bed and easily change his/her side of the bed as his/her preferences change. Additionally, the construction increases the longevity of the bed, because components may be replaced one at a time as deemed necessary. Further, the various components of the modular mattress system enable the manufacturer to ship the bed at reduced cost to the customer, because the mattress system may be shipped in smaller freight components. 
     U.S. Pat. No. 6,401,282 
     Inventor: Hai S hum 
     Issued: 11 Jun. 2002 
     A mattress system, sofa, cushioned seat, and the like, having top surface made from rigid material which is divided into plurality of polygonal columns or spherical shapes and configured into a geometrical pattern in various size and shape which has the transversal width and the longitudinal length adding or reducing according to the user&#39;s preference. The top surface elements are correspondingly supported by plurality of resilient elements, which are pneumatic in general, adjustable to provide the preferable comfort, desirous top surface contour and prescriptive pressure at particular spots. The top surface elements and resilient elements are individually replaceable and exchangeable. The mattress, sofa, cushioned seat and the like can be retrofit or modified three dimensionally. 
     U.S. Pat. No. 6,541,094 
     Inventor: Dag Landvik et al 
     Issued: 1 Apr. 2003 
     A laminated support for pressure-relief comprising an upper layer of visco-elastic foam, a middle layer of visco-elastic foam having a greater hardness, and a bottom layer of highly resilient polyurethane foam. These layers are sandwiched between two layers of reticulated filter polyurethane foam. 
     U.S. Pat. No. 6,952,850 
     Inventor: Barnet D. Visser et al 
     Issued: 11 Oct. 2005 
     A no-flip mattress is constructed of a mattress core, a first padding layer positioned on top of the core, wherein the first padding layer has a density in the range from about 0.5 pounds per cubic foot to about 3 pounds per cubic foot and a firmness in the range from about 8 IFD to about 45 IFD. A second padding layer is adjacent to the first padding layer, wherein the second padding layer has a density in the range from about 0.5 pounds to about 1.9 pounds, and an IFD in the range from about 5 to about 23. A bottom support layer is beneath the core, and comprises a relatively dense and firm material. 
     U.S. Pat. No. 7,805,791 
     Inventor: Hans L. Malzl 
     Issued: 5 Oct. 2010 
     The invention relates to a sectional element mat (2), the support properties of which may be individually tailored, whereby exchangeable sectional elements (E) are arranged tightly together or above each other. The above is characterized in that the individual sectional elements (E) may be easily removed and exchanged with other sectional elements. The individual sectional elements are either connected to each other by means of a separable material bridge or perforation (5, 6), connected to each other by means of a plug connector (27, 31), plugged onto or into a common base mat (40) or lying loose on the same. Individual sectional elements can be removed or separated from the combination where necessary and replaced by softer or stiffer sectional elements. In certain situations the resulting free space is left empty. The sectional element mat (2) is either part of a combination with other sectional element mats or contiguous or separate layers (1, 3), or itself forms the mattress core. 
     U.S. Pat. No. 8,250,689 
     Inventor: Richard F. Gladney 
     Issued: 28 Aug. 2012 
     The support characteristics within a foam mattress body may be varied by inserting reinforcements into channels cut or otherwise formed within the foam. 
     U.S. Pat. No. 8,356,371 
     Inventor: John H. Howard 
     Issued: 22 Jan. 2013 
     A mattress system and method according to which a custom mattress is built according to customer-specific parameters. In several exemplary embodiments, the custom mattress includes one or more removable core cartridges and/or one or more removable topper cartridges . . . . 
     U.S. Pat. No. 8,370,979 
     Inventor: Michihiro Fukano 
     Issued: 12 Feb. 2013 
     Provided is a mattress wherein the elastic characteristics of each portion can be changed simply and inexpensively depending on the user&#39;s preference. A mattress (10) has a plurality of spring units (60, 70, 80, 90) respectively constituted by holding a plurality of vertically stretchable pocket coils integrally, a lower elastic body (40) in which a housing space (44) capable of housing and holding the spring units (60, 70, 80, 90) is formed, and an upper enclosure (21) and a lower enclosure (30) for covering the outer periphery of the lower elastic body (40), wherein the lower elastic body (40) is provided with a partitioning elastic body (50) for dividing the housing space (44) into a plurality of spaces, and the spring units (60, 70, 80, 90) are formed in such a shape that each of the spring units can be housed in the divided housing spaces (44), and are housed and held in the respective divided housing spaces (44). 
     U.S. Pat. No. 8,418,297 
     Inventor: Tom D. Mikkelsen 
     Issued: 16 Apr. 2013 
     A support cushion including a top surface, a bottom surface opposite top surface, a layer of flexible foam having plurality of cells defining a reticulated cellular structure, the reticulated cellular structure cells comprising a skeletal plurality of supports through which substantially open cell walls establish fluid communication between interior of the cell and interiors of adjacent cells, the layer of flexible foam having density no less than about 30 kg/m.sup.3 and no greater than about 175 kg/m.sup.3, and hardness of no less than about 20 N and no greater than about 150 N at 40% indentation force deflection measured at about 22 degrees Celsius, the layer of flexible foam comprising visco-elastic foam having at least one material property responsive to temperature change in range of 10-30.degree. C., and layer of polyurethane foam located beneath layer of flexible foam, the layer of polyurethane foam having hardness of at least about 50 N. 
     U.S. Pat. No. 8,561,236 
     Inventor: Timothy M. Witherell et al 
     Issued: 22 Oct. 2013 
     Stepped-edge and side-support members, systems, assemblies, and related methods for an innerspring assembly or other core are disclosed. In one embodiment, an innerspring assembly or core is provided having an interior area of a first height surrounded by one or more exterior, perimeter area(s) of shorter height(s) to provide a stepped-edge innerspring assembly or core. At least a portion of side-support members are placed onto at least a portion of the top surface of the perimeter area to provide edge-support for the innerspring assembly or core. In this manner, a greater portion of the side-support members can be disposed in the sleeping area of the innerspring assembly or core since the underlying perimeter area provides spring support to the side-support members. Further, this support can assist in retention and/or recovery of the shape of the side-support members to further prevent or reduce compression set of the side-support members. 
     U.S. Pat. No. 8,613,120 
     Inventor: Steven D. Hawkins 
     Issued: 24 Dec. 2013 
     A cushioning device with an upper foam layer and a lower positioned foam layer, with the upper foam layer having multiple thickness zones defined by different height projections from one zone to another as to provide a thickness variation pattern, one side of the upper foam layer is less contoured when not yet assembled in the cushioning device and a second side is comprised of the multiple thickness zones such that, upon connection of the multiple thickness zones to the lower positioned foam layer, the height differential along a length of the upper foam layer is transmitted as to form a non-planar, crown configuration in the upper surface of the upper foam layer. A method includes roller contouring different height and shaped projection zones including zones with different ratios of peak height to overall zone height. 
     While these various devices may be suitable for the purposes for which they where designed, they would not be as suitable for the purposes of the present invention as heretofore described. It is thus desirable to provide a modular mattress support that is fully customizable by the user. It is further desirable to provide a modular mattress support where the connectors between the support units are flexible, or semi-flexible to allow for various configurations of the support units to be placed as needed between the mattress and the box spring or other base support. 
     SUMMARY OF THE PRESENT INVENTION 
     A primary object of the present invention is to provide a modular renewal system for an existing mattress. 
     Another object of the present invention is to provide a modular renewal system for an existing mattress where the interlocking support system is variously configurable to allow the system to be used on a variety of mattress sizes. 
     Yet another object of the present invention is to provide a modular renewal system for a mattress where the nodal blocks of the system may be made up of a variety of layers with varying compressibility, depending on the degree of support that needs to be added to the mattress. 
     Still yet another object of the present invention is to provide a modular renewal system for a mattress where the layering of the nodal blocks may be a single layer with an increasing density to provide a support gradient between the box spring and the mattress itself. 
     Another object of the present invention is to provide a modular renewal system for a mattress where the nodal block connectors extending between the necessary blocks are flexible to allow for user customization. 
     Yet another object of the present invention is to provide a modular renewal system where the layers or gradients in the nodal blocks provide a shock absorbing means. 
     Still yet another object of the present invention is to provide a modular renewal system for a mattress where the system itself is not detectable by the user once it has been put in place. 
     Still yet another object of the present invention is to provide a modular renewal system for mattresses or the like where the varying degrees of compressibility in the nodal blocks are color coded for ease in customization. 
     Additional objects of the present invention will appear as the description proceeds. 
     The present invention overcomes the shortcomings of the prior art by providing a fully customizable modular mattress renewal system that allows the user to compensate for the sleep indentations in the mattress that appear over time. 
     The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying drawing, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawing, like reference characters designate the same or similar parts throughout the several views. 
     The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims. 
     DESCRIPTION OF THE REFERENCED NUMERALS 
     Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the use of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures.
       10  present invention     12  nodal foam blocks     14  nodal block connectors     16  nodal block contoured guide apertures     18  single compressive layer nodal block     20  double compressive layer nodal block     22  triple compressive layer nodal block     24  adhesive base layer     26  mattress     28  box spring     30  mattress sleep indentations     32  sofa     34  bed     36  easy chair     38  block connector engagement ends     40  single foam layer     42 ,  42 A double foam layer     44 ,  44 A,  44 B triple foam layer     46  support arrows     48  king-size box spring     50  king-size mattress     52  compressed nodal foam block     54  star guide aperture     56  square guide aperture     58  star guide connector end     60  square guide connector end     62  diamond-shaped connector end     64  diamond guide aperture     66  cross-shaped connector end     68  cross-shaped aperture     70  round connector end     72  round receiving aperture     74  hexagonal connector end     76  hexagonal receiving aperture   

    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawing in which: 
         FIG. 1  is an illustrative view of the prior art. 
         FIG. 2  is an illustrative view of the present invention and its uses. 
         FIG. 3A  is an illustrative view of a single density nodal foam block. 
         FIG. 3B  is a cross sectional view of the single density nodal foam block, taken from  FIG. 3A  as indicated. 
         FIG. 3C  is an illustrative view of a multi layered nodal foam block having differing densities. 
         FIG. 3D  is a cross sectional view of the multi layered nodal foam block, taken from  FIG. 3C  as indicated. 
         FIG. 3E  is an illustrative view of a nodal foam block having a plurality of layers having differing densities. 
         FIG. 3F  is a cross sectional view of the plural layered nodal foam block, taken from  FIG. 3E  as indicated. 
         FIG. 4  is an illustrative view of the nodal foam blocks and the block connectors. 
         FIG. 5  is a perspective view of one embodiment of the present invention with the block connectors latched to form a support between a box spring and the mattress. 
         FIG. 6  is an exploded view of an embodiment of the present invention in use between a box spring and a mattress. 
         FIG. 7  is a view showing an embodiment of the present invention assembled in place between the box spring and the mattress. 
         FIG. 8  is an exploded view of an embodiment of the present invention being used on a king-sized mattress with two sleep indentations. 
         FIG. 9  is an assembled view of the present invention in a king-sized mattress, related to that seen in  FIG. 8 . 
         FIG. 10  is an illustrative view of the present invention in use. 
         FIG. 11  is another assembled view of the present invention in use. 
         FIG. 12  is a perspective view of one of the nodal foam blocks under pressure. 
         FIG. 13  is an illustrative view of various configurations and contoured shapes for attachment of the nodal blocks and the various block connectors. 
         FIG. 14A  is an illustrative view of the nodal blocks and the corresponding block connectors in a hexagonal configuration. 
         FIG. 14B  is an illustrative view of the nodal blocks and the corresponding block connectors in a square configuration. 
         FIG. 14C  is an illustrative view of the nodal blocks and the corresponding block connectors in a triangular configuration. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The following discussion describes in detail one embodiment of the invention (and several variations of that embodiment). This discussion should not be construed, however, as limiting the invention to those particular embodiments, practitioners skilled in the art will recognize numerous other embodiments as well. For definition of the complete scope of the invention, the reader is directed to appended claims. 
     Turning first to  FIG. 1 , a view of the prior art is seen. Over the course of time a user U sleeping in a regular position on a mattress  26  causes a sleep indentation as indicated at  30 . These sleep indentations  30  are annoying in that they may cause back problems as they become more pronounced and that they can lead to disturbed sleep. In many cases, makeshift solutions, such as boards or folded blankets located under the mattress are used, but these types of solutions are ineffective, difficult to fit, and can be felt by the user. Additionally, these makeshift solutions may cause more problems than they solve, by making portions of the mattress unaffected by the sleep indentations  30  too firm for the user&#39;s comfort. 
       FIG. 2  shows the present invention, indicated at  10 . The invention  10  includes a plurality of nodal foam blocks  12  attached one to the other by a plurality of nodal block connectors  14 . As can be seen and as will be discussed further below, each of the nodal foam blocks includes contoured guide apertures  16  which are selectively engageable with nodal block connector engagement ends indicated at  38 . The present invention  10  relieves the sagging that occurs over time in cushions, mattresses, and the like and as is seen in the Figure, the present invention  10  may be used to increase the comfort of an easy chair  36 , a bed  34 , or a sofa  32 . Other types of furniture with cushions, could of course, also be addressed. 
     Turning now to  FIGS. 3A to 3F , various types of foam construction involved in the nodal blocks  12  will be discussed. First in  FIG. 3A  a single layer of foam construction is shown and is indicated at  18 . In  FIG. 3B  this single layer is indicated at  40 . This layer  40  could include a density gradient from the bottom of the block proximate the adhesive base layer  24  to the top, or it could be consistent all the way through. In  FIG. 3C  a double layer of foam having different compressibility and densities is indicated generally at  20  and these layers are pointed out in  FIG. 3D  at  42  and  42 A. Likewise the adhesive base layer  24  is also seen. In  FIG. 3E  a triple layer of foam having different compressibility and densities is generally indicated at  22  and these layers are more specifically indicated in  FIG. 3F  at  44 ,  44 A, and  44 B. The various nodal foam blocks  12  (and the variations seen in this Figure at  18 ,  20 , and  22 ) can be chosen by the user to provide the amount of support that is desired. It is contemplated that the varying compressibility combinations of these blocks  12  could be color coded to aid in the in-place assembly of the invention. Another aspect of the present invention is that either the density gradient of the blocks  12  as seen in the Figures or the layers of the blocks as indicated at  18 ,  20 , and  22  allows for lateral or torsional movement of the upper portion of the blocks  12  (proximate the mattress) to prevent detection and sliding or the like, which provides additional comfort for the user once the present invention  10  is in place. 
     Turning now to  FIG. 4  the details of the connectors  14  will be discussed. As can be seen in the Figure, the blocks  12  are provided with a plurality of contoured guide apertures as indicated at  16 . In this Figure these are seen as half-moon shaped slots extending substantially through the nodal foam blocks  12 . The connectors  14  themselves are contemplated as being made of a flexible and compressible material, similar to that of the compressed nodal blocks  12  themselves. The flexibility of the block connectors  14  allow for even greater customization of the invention  10  as it is being installed. Also as discussed above, the flexibility and compressibility of the connectors  14  additionally add to the comfort of the device during use in that the user will be unaware of the present invention&#39;s presence below the mattress. It should be noted here that various types of mattresses will benefit from the application of the present invention such as inner spring mattresses, pillowtop mattresses, and the like. 
       FIG. 5  shows an assembled lattice array of the present invention  10  with the nodal foam blocks  12  and the block connectors  14  attached to one another to form an array that is to be placed under the sagging or weakened portion of the mattress, cushion, or the like. 
     The exploded view seen in  FIG. 6  shows the present invention  10  ready to be placed as shown between the box spring  28  and the mattress  26  to solve the problem of the mattress sleep indentation indicated at  30 . The present invention may be easily assembled and placed as needed. 
     In  FIG. 7  the present invention  10  is shown in place between the mattress  26  and the box spring  28 . The present invention eliminates the sleep indentation  30  as is indicated by the support arrows  46 . One of the advantages of the present invention  10  is that no further adjustment is necessary once it is in place such as is needed with inflatable air bladders or the like. 
     Referring to  FIG. 8  the present invention is shown being installed under a king-size mattress  50  and above the king-size box spring  48 . The invention  10  is located beneath each of the mattress sleep indentations  30 . 
       FIG. 9  shows the present invention  10  in place between the king-size box spring  48  and the king-size mattress  50  and supporting the two mattress sleeping indentations as indicated at  30 . 
       FIG. 10  shows the present invention  10  assembled and placed between the mattress  26  and box spring  28  with the nodal foam blocks  12  and the connectors  14  spread in an array that is designed to support the mattress sleep indentation  30 . 
     In  FIG. 11  the present invention  10  is seen in place between the mattress  26  and the box spring  28  with the nodal foam blocks  12  and the corresponding connectors  14  forming a support lattice underneath the mattress sleep indentation  30 . 
       FIG. 12  shows first the uncompressed nodal foam block  12  as is seen in the other Figures discussed above. Additionally, the Figure shows the compressed nodal foam block as indicated at  52  and the contoured guide apertures  16  adapted to receive the block connector engagement ends  38  of the block connectors  14  (neither seen in this Figure) as the compressed nodal block  52  stabilizes the mattress. 
     Turning to  FIG. 13  various ends are disclosed for the block connectors indicated throughout the Figure at  14 . First we see a star-shaped connector end at  58  with the corresponding star guide aperture  54 . A square shaped connector end  60  has a square guide aperture  56 . The diamond-shaped connector end  62  is fitted to a diamond-shaped receiving aperture  64 , a cross-shaped connector end  66  is fitted to a cross-shaped receiving aperture  68 , a round connector end  70  fits into a round receiving aperture  72  and, likewise, a hexagonal connector end  74  fits a hexagonal receiving aperture  76 . It should be understood that any shape of connector ends and corresponding receiving apertures could be utilized in the performance of the present invention and these connector ends and receiving apertures are in no way limited to those seen in the Figures. As long as the present invention  10  is supported and stable in creating the lattice needed under the mattress the connecting shapes do not signify except that they provide a secure stable structure. 
     Turning now to  FIG. 14A through 14C  various lattice configurations of the present invention are seen. In  FIG. 14A  a hexagonal lattice is made up of the nodal foam blocks  12  and the connectors  14 . In  FIG. 14B , the lattice created between the nodal foam blocks  12  and the connectors  14  is a square lattice. Lastly, in  FIG. 14C  the lattice structure created between the nodal blocks  12  and the connectors  14  is comprised of triangles. 
     Thus the present invention  10  in use is adapted to restore a mattress, cushion, or like portion of a piece of furniture that has developed a sag or indentation through a combination of time and usage by providing a modular support that may be placed underneath the sagging portion. The varying degrees of compressibility provided by the novel nodal foam blocks indicated at  12  in the Figures and the compressible and flexible connector portions indicated at  14  in the Figures allows the user to custom fit the invention to a bed, chair, sofa, or the like that has a sag or sleep indentation therein. The construction of the nodal foam blocks with the varying degrees of compressibility attendant to them allows for small amounts of movement while the invention is in use without sliding. This feature is further enhanced by the adhesive pads located under the blocks  12 . These adhesive pads or base layers indicated at  24  in  FIGS. 3A, 3C , and  3 E may be of a light enough tackiness that the nodal blocks  12  and the connectors  14  may be fixed and then moved as needed or desired. 
     It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. 
     While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. 
     Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.