Patent Publication Number: US-2007094808-A1

Title: Mattress

Description:
STATEMENT OF RELATED APPLICATIONS  
      This patent application is based on and claims convention priority on German Patent Application No. 20 2005 016 203.5 having a filing date of 13 Oct. 2005, which is incorporated herein in its entirety by this reference.  
     BACKGROUND OF THE INVENTION  
      1. Technical Field  
      The invention relates to a mattress, a lounger, a chair or the like with a lower layer on which an upper layer is arranged.  
      2. Related Art  
      Mattresses are employed to enhance sleeping, sitting and lying comfort. As such, they serve as supports for sleeping or resting, but also as cushioning. Such mattresses are not only employed for sleeping, sitting and lying furniture, but also for seats, loungers or beds in vehicles. In addition, the mattresses addressed here can also be used for therapeutic and medicinal purposes in sick beds and reclining chairs.  
      It is already known that sleeping, lying and sitting comfort can be improved for various purposes by using solid or liquid substances, but also by heating elements, vibrators, light and/or acoustic means. These are usually placed on or under a mattress. It is difficult, however, to retain the substances or means at the intended position on or under the mattress. Furthermore, the substances or means result in elevated regions of the known mattress.  
      The object of the invention is to provide a mattress which results in a permanent enhancement of sleeping, lying and sitting comfort in a simple and effective matter.  
     BRIEF SUMMARY OF THE INVENTION  
      A mattress which achieves this object is a mattress for a bed, lounger or a chair, with a lower layer on which an upper layer is arranged, characterized in that the upper layer is formed by a plurality of filled cushions arranged in a grid-like pattern. Accordingly, the upper layer is formed by a plurality of filled cushions that are arranged in a grid-like pattern. Preferred are in each case a plurality of cushions which are arranged next to one another as well as one after another. The resulting arrangement is preferably one in which at least part of the upper layer&#39;s surface area, preferably its entire surface area, is formed by a plurality of cushions. Pursuant to the invention, the filled cushions are fitted in a tight arrangement to each other on all sides in the manner of paving stones, thus providing the upper layer with a continuous surface area.  
      The cushions may be provided with any kind of filling, it being possible to arrange special fillings exactly where they are desired. The arrangement of adjacent cushions in the style of paving stones effectively prevents any slipping or shifting of the cushions. Special fillings do not create any crevices in the top side of the upper layer, which therefore remains essentially smooth and flat. By virtue of the individual cushions, which exhibit a relatively small base area in relation to the overall surface area of the upper layer, the elastic or spring characteristics of the upper layer are not impaired but instead remain at least virtually unaffected by the cushions.  
      All adjacent cushions preferably have the same or approximately the same base area, in particular having a square shape. However, it is also conceivable to combine cushions having different geometric base areas and/or to have parts of the upper layer formed by larger cushions, while the other parts of the upper layer are composed of smaller cushions. In this manner it is possible to produce customized lying, sleeping and sitting comfort through the corresponding arrangement and combination of the plurality of cushions.  
      In a preferred embodiment of the invention, all cushions have an approximately cuboid-shaped configuration. Like the arrangement of paving stones in a pavement, this configuration makes it possible to form an upper layer having a smooth surface with the smallest possible gaps (joints).  
      The cushions may have a wide variety of fillings, it being also possible to combine cushions having different fillings. One type of preferred filling is that employing an organic material, such as straw, flowers, fruit or pips. It is also conceivable to use a filling made of inorganic materials, such as minerals. A mixture of organic and inorganic materials can also be used for the filing. The filling can also comprise a fluid material, for example either curative waters or gases. In this case the filling is accommodated in an additional fluid-tight wrapping. But the filling can also be formed from active means, such as heating elements, lights or vibrators. The filling can also consist of a tone generator for supplying acoustic signals or even music. The filling of the cushions comprising the aforementioned materials and means can extend across the entire surface of the upper layer. However, it is also possible to have the aforementioned fillings arranged in only some cushions. Cushions having different fillings can be distributed at various positions of the upper layer as desired. Inasmuch as some cushions have none of the aforementioned organic or inorganic materials, they can be filled merely with a padding of foam material, for example. It is also conceivable that the cushions having fillings made of the aforementioned organic and inorganic materials and means can be filled out with padding made of foam plastic, for example.  
      Each cushion has a cover which is made of a permeable material, in particular a woven textile. If appropriate, a person can lie directly on the cushions having such a cover. The cover of at least some cushions has one—or more if necessary—closeable openings. This makes it easy to fill the cushions. The covers are exchangeable and can be washed or dry-cleaned.  
      In a preferred embodiment of the mattress, the lower layer is made of a preferably single-piece lower mattress layer. This mattress layer can be made of foam plastic or some other known mattress design, such as a spring mattress core. The lower layer, which may vary in thickness, is preferably somewhat thicker than the height of the cushions. The lower layer thus forms an elastic base of support for the cushions, with the elastic or spring characteristics of the upper layer being maintained by the tight arrangement of the cushions in the longitudinal and transverse direction in the same manner as that of a paved surface. Such a mattress is essentially formed by two full-surface layers, specifically the lower layer and the upper layer comprising closely successive cushions arranged in a grid-like pattern and extending continuously across the entire surface of the lower layer. As an alternative, however, the mattress may also have additional layers, which can be elastic, but are essentially inelastic.  
      Pursuant to a preferred further development of the mattress, the cushions are attached to the lower layer, which is of a one-piece design, but which may also comprise several adjacent components. This attachment can, for example, be achieved by hook and loop fasteners arranged at the bottom side of each cushion and/or at the top of the lower layer. The lower layer has, at least on its top side, a cover layer made of a woven woolen material with which the micro-hooks of the hook and loop fasteners under the cushions can engage, with the result that the lower layer does not require any additional means for making a connection with the cushions. As an alternative, it is also conceivable for the cushions to be connected to each other only, or in addition, at their side surfaces by means of snap fasteners, hook and loop fasteners or the like. The cushions can also be bound together.  
      Further dependent claims relate to additional configurations of the mattress according to the invention. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
      Preferred exemplary embodiments of the mattress will be described in more detail according to the drawings, which show:  
       FIG. 1  is a top view of the mattress with a partial cutaway section of the outer cover.  
       FIG. 2  is an enlarged partial cross-section through the mattress of  FIG. 1 . 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
      The mattress shown in the figures is intended for a bed. The bed can be used for personal, commercial or even therapeutical purposes. The mattress lies on a suspension of the bed, for example a slatted frame. Such a mattress has a rectangular base area with an essentially flat top side  10  on which the person in bed lies, it also being possible for a bedspread (not shown in the figures) to be drawn over the mattress as necessary.  
      The shown mattress has a lower layer  11  and an upper layer  12 . Therefore, the shown mattress essentially has a two-layer configuration. But it is also conceivable for the mattress to have the one upper layer  12  only, or more than two layers, with at least one layer being configured in the matter of the upper layer  12 .  
      The lower layer  11  extends across the full surface of the entire mattress. As an alternative, the lower layer  11  can also be formed from two or three lower support components, each of which runs across the entire width of the mattress and which lie closely to one other in succession in the longitudinal direction of the mattress. The lower layer  11  forming the lower part of the mattress can be made of foam plastic or another material or combination of materials generally used for mattresses, such as a spring interior. In the exemplary embodiment shown, the lower layer  11  has a thickness that is somewhat greater than half the thickness or height of the mattress itself, meaning that the upper layer  12  is thinner than the lower layer  11 . The lower layer  11  shown here has a core  13  that forms part of the mattress and which is made of foam plastic or other material, which can be multi-layered if necessary, and an outer sheathing  14 . The sheathing  14  preferably encompasses the core  13  completely, but can also be configured to sheath the core  13  only partially. The sheathing  14  is provided with a usual lateral opening (not shown in the figures), which, for example, can be opened and closed by a zipper in order to remove the sheathing  14  from the core  13  for washing as necessary. The sheathing  14  is preferably completely made from the same material, specifically a woven fabric, it being possible for at least the top side  15  of the sheathing  14  facing the upper layer  12  to have a woolen surface structure that is suitable for making a clinging connection with the micro-hooks of a hook and loop fastener. But it is also conceivable that the sheathing  14 , including its top side  15 , is completely made of a smooth material. In this case, strips, points or the like are glued or otherwise attached to the top side  15  of the sheathing  14  in order to form part of the connection means.  
      The upper layer  12  according to the invention is configured in a special manner. It comprises a plurality of filled cushions  16  having a relatively small surface area. In the shown exemplary embodiment, each filled cushion  16  is of equal size and exhibits an approximately square base area  17 . Each of the identically configured cushions has an approximately cuboid shape whose thickness is smaller than the width or length of the respective filled cushion  16 . The filled cushions  16  are arranged over the lower layer  11  in a grid-like pattern, specifically such that a plurality of cushions  16  lie closely adjacent to one another in the longitudinal and transverse direction of the mattress. As a result, there is no, or no appreciable, crevice space between adjacent filled cushions  16 . By virtue of their close succession, the filled cushions  16  form a continuous upper layer  12  across the entire surface of the mattress. The upper layer  12  thus exhibits a structure on its top side  18  which corresponds to a pattern of laid paving stones.  
      In the shown exemplary embodiment, six filled cushions  16  lie next to one another in the transverse direction of the mattress, while eleven filled cushions  16  follow one another closely in the longitudinal direction of the mattress. Depending on the side of the mattress as well as the size of the filled cushions  16 , the number of successive cushions  16  in the longitudinal and transverse direction may vary. Since the filled cushions  16  in the shown exemplary embodiment have a square base area and lie next to each other in rows and columns, the corners of any four adjacent cushions  16  always abut each other. As a result, there is no bonded, or lapping, arrangement of the filled cushions  16  similar to that common in brick walls, i.e. the joints between the cushions run continuously from one end or one side of the upper layer to the other. If such a bonded system is desired, cushions  16  of different sizes can be used to form the upper layer  12 , in particular square and rectangular-shaped cushions that are grouped with respect to each other so that a bonded arrangement is achieved between adjacent filled cushions  16 . As a result, few if any corners of four filled cushions  16  will meet as in the case shown in the exemplary embodiment of  FIG. 1 .  
      Each filled cushion  16  has a filling  18  and a cover  19  which preferably encloses the cushion  16  completely. In the shown exemplary embodiment, the cover  19  of each cushion is provided with a closeable opening  20 . The closeable opening  20  is located in the region of a bottom side  21  of each cushion  16 . But the opening  20  can also be located in the region of a side surface. The opening can be closed by a zipper  22  or other closing means, such as hook and loop fasteners, snap fasteners, or hook fasteners.  
      Each filled cushion  16  is detachably connected to the lower layer  11 . To this end the bottom side  21  of each filled cushion  16  is assigned at least one connecting means  23 . The connecting means  23  can be a hook and loop fastener, for example. Such a fastener has a micro-hook part and a loop part. One of these two parts is assigned to the bottom side  21  of the respective filled cushion  16 , while the other part is located on the top side  15  of the lower layer&#39;s  11  sheathing  14 . The parts of the connection means  23  are appropriately attached to the cover  19  of the respective cushion  16  and to the sheathing  14  of the lower layer  11 , for example by sewing or adhesive bonding. If the sheathing  14  of the lower layer  11  is made of a textile material, in particular one with a woolen surface, no loop part of the connecting means needs to be attached to the top side  15  of the lower layer&#39;s  11  sheathing  14 . A satisfactory connection can be made if the bottom side  21  of each filled cushion  16  has a micro-hook part which can hook into the preferably woven textile material of the lower layer&#39;s  11  sheathing  14 . In this case, only micro-hooks need to be arranged under the filled cushions  16  in order to form a part of the connection means  23 .  
      The lower layer  11  and the upper layer  12 , the latter being formed by the cushions  16  arranged tightly adjacent to one another, are surrounded by an outer cover  24 . The outer cover thus forms the outer side of the mattress, providing additional support and a permanent stabilization of the filled cushions  16  on the lower layer  11 . Due to the presence of the outer cover  24 , under some circumstances it is then possible to omit the connecting means  23  for the detachable attachment of the filled cushions  16  to the lower layer  11 . The outer cover  24  of the mattress is provided, at least on the top side  10 , with a textile material that is comfortable for lying, sitting and/or sleeping. In order to provide access to the lower layer  11  and in particular to the upper layer  12  of the mattress formed by the filled cushions  16 , the outer cover  24  has at least one closeable opening  25 . In the shown exemplary embodiment, the opening  25  is located on an upright edge surrounding the mattress, with the opening  25  extending at least continuously across three upright side surfaces of the mattress. The opening  25  can be closed by a zipper  26 , it also being possible to provide other conventional closing means, such as hook and loop fasteners, snap fasteners or string fasteners.  
      The outer cover  24  of the mattress can be provided at least on its top side  10  with decoration and/or thin supplementary cushioning. This supplementary cushioning can be designed in the style of a quilt in order to improve the aesthetic effect of the top side  10  of the mattress.  
      In an alternative exemplary embodiment (not shown) of the mattress according to the invention the outer cover  24  is absent. The mattress then comprises only the lower layer  11  and the upper layer  12 , which is formed by filled cushions  16  positioned adjacent to one another in the manner of a stone pavement. In this exemplary embodiment, a particularly reliable connection of the filled cushions  16  to the lower layer  11  is required. Inasmuch as the connection means  23  shown in  FIG. 2  are not sufficient for this purpose, the invention provides the additional measure of connecting the filled cushions  16  with one another at their adjacent upright side surfaces, again by means of the appropriate connecting means, such as hook and loop fasteners, snap fasteners or even laces. The connection of the filled cushions  16  at the side surfaces can, as an alternative to the connection means  23 , also be considered for connecting the filled cushions  16  to the lower layer  11 , in particular in the exemplary embodiment shown in  FIGS. 1 and 2  with an outer cover. The connection of the cushions  16  to each other can then replace the connection means  23  for the purpose of attaching the cushions  16  onto the lower layer  11 . In the presence of an outer cover  24 , a connection of the filled cushions  16  to each other and/or to the lower layer  11  can, if necessary, be omitted completely.  
      Instead of using the closed outer cover  24  to encompass the lower layer  11  and the upper layer  12  formed by the filled cushions  16 , it is also conceivable to employ a net or a lattice. Such a net or lattice can be made of electroconductive material in order to provide the mattress with a shield against electromagnetic interference.  
      It is also conceivable to arrange the upper layer  12  comprising a grid of numerous, closely adjacent filled cushions  16  on a lower layer that is merely a flat textile web, that is, which itself is not designed to be resilient. This lower layer then only serves to provide a detachable connection to the bottom sides  21  of the filled cushions  16 . If the filled cushions  16  are connected to each other at their neighboring adjacent side surfaces, it is sufficient for the mattress to be formed by the upper layer  12  only, with a lower layer being omitted entirely. The mattress then consists of the filled cushions  16  lying adjacent to one another to form the upper layer and, if so required, of an outer cover  24 .  
      In all of the previously described exemplary embodiments of the mattress according to the invention, the fillings  18  of the cushions  16  can be constituted in a variety of ways:  
      For passive fillings  18  organic materials, such as straw, fruit, flowers, leaves and/or pips, can be used. Said materials are preferably dried. The respective filling  18  can also be made of blends of various organic materials, in particular of the aforementioned materials. The materials are arranged in the cover  19  of the cushion  16  such that the filling  18  essentially fills the cover  19  completely, thus giving the cushion  16  a firm yet elastic cuboid shape. If necessary, it may be sufficient to fill the cushion  16  only partially with organic materials of the aforementioned kind. In order that the shape of the cushion  16  is nevertheless as cuboid as possible, filler material can then be employed, such as foam plastic, in particular in the form of small particles. But inorganic materials can also be used as passive fillings  18 , in particular minerals. It is also possible to provide a mixture of inorganic and inorganic materials for the filling  18 .  
      Other types of fillings  18  can be formed from a fluid, that is, either a gas or a liquid. Preferred liquids include curative waters. A fluid-based filling is housed in an additional fluid-tight and permanently sealed wrapping, which in turn is surrounded by the cover  19 .  
      It is also possible to accommodate active fillings  18  in the cushions  16 . Such a filling may be a heating element, illuminants and/or vibrators, or other kinds of active movement generators. Finally, it is also conceivable to have an active filling  18  of means that emit acoustic tones.  
      The upper layer  12  of the exemplary embodiments of the mattress described above can be made of cushions  16  having the same fillings  18 . But as a rule, the upper layer  12  is composed of cushions  16  having different fillings  18 , with the fillings  18 , depending on their type, being deliberately arranged at certain positions under the top side  10  of the mattress so that the fillings  18  are able to express their intended characteristics in the vicinity of a specific part of the body of the person lying on the mattress that is meant to be targeted by these intended characteristics. Not all cushions  16  used in the formation of the upper layer  12  must have the aforementioned passive materials or active materials. It is conceivable that only a few specific fillings  18  have such characteristics. The other cushions  16  can then have a filling  18  made of a neutral material, such as foam plastic or other such constituent materials commonly used in mattresses.  
      The invention is not only suitable for the mattress described in connection with a bed, but also for mattresses of loungers for private and commercial use, as well as in vehicles. The mattress according to the invention can also be used as upholstery in sitting furniture.  
     LIST OF DESIGNATIONS  
     
         
           10  top side  
           11  lower layer  
           12  upper layer  
           13  core  
           14  sheathing  
           15  top side  
           16  filled cushion  
           17  base surface  
           18  filling  
           19  cover  
           20  opening  
           21  bottom side  
           22  zipper  
           23  connecting means  
           24  outer cover  
           25  opening  
           26  zipper