Patent Publication Number: US-2023148761-A1

Title: Mattress assembly

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. 
     Infants and 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. In that young children are likely to wet the bed, such mattresses may include a waterproof cover to prevent urine from getting into the mattress. However, such waterproof covers prevent body heat from ventilating through the mattress and are hence uncomfortable to sleep on. Furthermore, conventional mattresses typically include a cover that is sewn onto an inner core of 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 is provided that includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The inner core includes opposite first and second portions. The first portion has a firmness that is different than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the spring pack and a second configuration in which the second portion directly engages the spring pack to alter a firmness of a sleep surface of the mattress. 
     In one embodiment, in accordance with the principles of the present disclosure, a mattress assembly is provided that includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The cover comprises a porous, non-waterproof material and a zipper. The spring pack comprises opposite first and second surfaces and a plurality of springs positioned between the first and second surfaces. The first surface defines a waterproof barrier. The inner core comprises a matrix of polyurethane fibers. The matrix comprises opposite first and second portions. The fibers that make up the first portion are more densely packed than the fibers that make up the second portion such that the first portion has a firmness that is greater than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the waterproof barrier and a second configuration in which the second portion directly engages the waterproof barrier to alter a firmness of a sleep surface of the mattress. 
     In one embodiment, in accordance with the principles of the present disclosure, a mattress assembly is provided that includes a cover, a spring pack positioned within the cover, and an inner core positioned within the cover. The cover comprises a porous, non-waterproof material and a zipper. The spring pack comprises opposite first and second surfaces and a plurality of springs positioned between the first and second surfaces. The first surface defines a waterproof barrier. The inner core comprises a mat of electrospun polyurethane fibers. The mat comprises opposite first and second portions. The fibers that make up the first portion are more densely packed than the fibers that make up the second portion such that the first portion has a firmness that is greater than a firmness of the second portion. The inner core is configured to be moved between a first configuration in which the first portion directly engages the waterproof barrier and a second configuration in which the second portion directly engages the waterproof barrier to alter a firmness of a sleep surface of the mattress. 
    
    
     
       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 of one embodiment of a mattress assembly in accordance with the present principles of the present disclosure; 
         FIG.  2    is a cross sectional view of the mattress assembly shown in  FIG.  1   ; 
         FIG.  3    is a perspective view of components of the mattress assembly shown in  FIG.  1   ; 
         FIG.  4    is a perspective view of components of the mattress assembly shown in  FIG.  1   ; 
         FIG.  5    is a perspective view of components of the mattress assembly shown in  FIG.  1   ; 
         FIG.  6    is a perspective view of a component of the mattress assembly shown in  FIG.  1   ; and 
         FIG.  7    is a perspective view of a component of the mattress assembly shown in  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     The exemplary embodiments are discussed in terms of mattresses, such as, for example, mattress assemblies that include a dual-side inner core 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” or “top” and “bottom” 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. Mattress assembly  10  may be made from materials such as, for example, one or more of cotton, kapok, flax, linen, jute, ramie, hemp, kenaf, bamboo, coir, sisal, silk, wool (sheep), alpaca, llama, goat (mohair, cashmere), rabbit (angora), camel, horse, yak, vicuna, qiviut, guanaco, rayon, azlon, lyocell, acetate, triacetate, rubber, polyester, olefin, nylon, acrylic, modacrylic, aramid, spandex. Mattress assembly  10  is made such that mattress assembly  10  is compliant with all U.S. Federal Mattress Regulations, such as, for example, 16 C.F.R. §§ 1632 and 1633. 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, and durability. 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. 
     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  16  to provide access to pocket  14 . In some embodiments, cover  12  comprises a porous material, such as, for example, a porous fabric that allows air to move in and out of pocket through cover  12 . In some embodiments, cover  12  comprises a breathable material, such as, for example, a breathable fabric that allows air to move in and out of pocket through cover  12 . In some embodiments, cover  12  is made entirely of a porous material and/or a breathable material. That is, no portion of cover  12  is waterproof. In some embodiments, cover  12  is washable. That is, cover  12  is configured to be washed in a standard washing machine. 
     One or a plurality of spring packs  18  is/are positioned within pocket  14 . Spring pack  18  comprises a plurality of springs  20  positioned within a pouch  22 . Springs  20  are enclosed within pouch  22 . Spring pack  18  comprises one or a plurality of rows of springs  20  and one or a plurality of columns of springs  20 . In some embodiments, spring pack  18  includes a plurality of rows of springs  20  and a plurality of columns of springs  20 . In some embodiments, spring pack  18  includes a plurality of strings of springs, as described in U.S. Patent Application No. 62/347,199 to the inventor of the current application, which is incorporated by reference herein, in its entirety. In some embodiments, springs  20  are each positioned within a pocket, such as, for example, a fabric pocket. The pockets may be coupled to one another to form a string of pockets that each include one of springs  20  therein. In some embodiments, the string of pockets includes one or more slits between adjacent pockets to allow springs  20  to move independently of one another. In some embodiments, the sting of pockets includes one or more slits that extend through a top surface of the string of pockets between adjacent pockets and/or one or more slits that extend through a bottom surface of the string of pockets between adjacent pockets. In some embodiments, spring pack  18  is permanently fixed to cover  12 . In some embodiments, spring pack  18  is removably disposed within pocket  14 . 
     Pouch  22  includes a bottom surface that directly engages cover  12  and an opposite top surface  24 . Springs  20  are positioned between the bottom surface of pouch  22  and surface  24 . In some embodiments, surface  24  comprises a waterproof material such that surface  24  defines a waterproof barrier of pouch  22  that prevents liquids from passing through surface  24  to prevent liquids or moisture from entering pouch  22  through surface  24 . In some embodiments, surface  24  is entirely waterproof. That is, the entire area of surface  24  that is defined by the perimeter of surface  24  is waterproof. In some embodiments, surface  24  is non-porous. In some embodiments, surface  24  comprises a waterproof fabric. In some embodiments, surface  24  comprises a waterproof polymer. In some embodiments, surface  24  comprises a thermoplastic polyurethane. In some embodiments, surface  24  comprises a thermoplastic polyurethane breathable waterproof fabric. In some embodiments, surface  24  comprises a porous fabric that is coated with a waterproof material. 
     In some embodiments, mattress assembly  10  does not include any springs, such as, for example, spring pack  18 . In some embodiments, mattress assembly  10  includes a material, such as, for example, a foam block in place of spring pack  18 . 
     An inner core  26  is removably positioned within pocket  14  such that core  26  directly engages surface  24  of spring pack  18 . Core  26  includes opposite first and second portions  28 ,  30  and a middle portion  32  between portions  28 ,  30 . Portion  28  has a firmness that is different than a firmness of portion  30  to provide two different comfort choices. For example, core  26  can include a firmer side for toddlers and a softer side for tweens. In some embodiments, portion  32  has a firmness that is less than a firmness of portion  28  and a firmness of portion  30 . Core  26  can be flipped as the child grows to prevent the need to buy another mattress as the child ages. 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. Core  26  is configured to be moved between a first configuration in which portion  28  directly engages surface  24  of spring pack  18  and a second configuration in which portion  30  directly engages surface  24  to alter a firmness of a sleep surface  34  of mattress assembly  10 . 
     In some embodiments, core  26  comprises a matrix of fibers. The fibers that make up portion  28  are more densely packed than the fibers that make up portion  30  such that portion  28  is firmer than portion  30 . In some embodiments, the fibers are made from a polymer, such as, for example, polyurethane. In some embodiments, core  26  consists of the fibers. That is, core  26  does not include any material or components other than the fibers. In some embodiments, core  26  comprises a mat of electrospun fibers. A first side of core  26  that defines portion  28  and a second side of core  26  that defines portion  30  are heat pressed to provide portions  28 ,  30  with selected firmnesses. In some embodiments, portion  28  is heat pressed for a longer duration of time and/or at a higher temperature than portion  30  to make portion  28  firmer than portion  30 . In some embodiments, core  26  is washable. That is, core  26  is configured to be washed using water to remove any urine or other material on the fibers that make up core  26 . In some embodiments, core  26  is free of any foam. 
     In operation and use, core  26  may be positioned within pocket  14  such that portion  30  directly engages surface  24  of spring pack  18  and portion  28  is positioned adjacent to sleep surface  34  of mattress assembly  10  to provide sleep surface  34  with a firmness sufficient to accommodate infants or toddlers. If the infant or toddler should wet the bed, the urine will move through cover  12  and core  26  and onto surface  24  of spring pack  18 . To clean mattress assembly  10 , zipper  16  of cover  12  can be moved from a closed configuration to an open configuration. Spring pack  18  and core  26  may be removed from pocket  14  when zipper  16  is in the open configuration. Cover  12  may be cleaned in a standard washing machine, for example. Spring pack  18  may be cleaned by wiping any urine off of surface  24 . A cleaning material, such as, for example, bleach or vinegar may be applied to surface  24  before surface  24  is wiped clean. Core  26  may be cleaned by rinsing core  26  with water, for example. After cover  12 , spring pack  18  and core  26  are cleaned, spring pack  18  may be repositioned within pocket  14 . Core  26  is then inserted into pocket  14  such that portion  30  directly engages surface  24  of spring pack  18  and portion  28  is positioned adjacent to sleep surface  34  of mattress assembly  10 . Zipper  16  is then moved from the open configuration to the closed configuration. 
     As the infant or toddler ages, he or she may desire that sleep surface  34  be less firm. To alter the firmness of sleep surface  34 , zipper  16  of cover  12  can be moved from the closed configuration to the open configuration. Core  26  is removed from pocket  14  when zipper  16  is in the open configuration. Core  26  is flipped and is repositioned within pocket such that portion  28  directly engages surface  24  of spring pack  18  and portion  30  is positioned adjacent to sleep surface  34  of mattress assembly  10  to provide sleep surface  34  with a firmness sufficient to accommodate older children. In some embodiments, spring pack  18  remains within pocket  14  while core  26  is being flipped. That is, cover  12  and spring pack  18  are not flipped to alter the firmness of sleep surface  34 . Rather, only core  26  is flipped, while cover  12  and spring pack  18  remain stationary. Should mattress assembly  10  become soiled, spring pack  18  and core  26  may be removed from pocket  14  and cover  12 , spring pack  18  and/or core  26  may be cleaned, as discussed herein. After cover  12 , spring pack  18  and/or core  26  is/are cleaned, spring pack  18  and core  26  may be repositioned within pocket  14 , as discussed herein. 
     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.