Abstract:
A mattress is provided having three layers of differing properties stacked on top of each other which together have the effect of letting the user sleep in a simulated Zero G position without the aid of an articulating base. Two layers are contoured within the mattress let specific areas of the user&#39;s body sink further into the mattress than others. A cover with removable inserts is also provided for the mattress.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority to U.S. Provisional Application Ser. No. 62/262,579, filed Dec. 3, 2015 and U.S. Provisional Application Ser. No. 62/410,584, filed Oct. 20, 2016, both of which are incorporated by reference herein in their entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention provides a mattress capable of letting a user sleep in a simulated zero G position. 
       BACKGROUND 
       [0003]    In recent years, many new mattress types have come to market to address various deficiencies in the industry. For example, memory foam mattresses have become very popular. However, these mattresses can often be uncomfortable because the memory foam is not very breathable and can create hot spots. Further, memory foam mattresses do not provide any capability for a user to adjust the softness or firmness of the mattress, leading to further user discomfort. The mattress of the present invention has been designed to address these and other various deficiencies. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  depicts a view a side cutaway view of a first view of the mattress. 
           [0005]      FIG. 2  depicts a perspective view of the mattress without a cover. 
           [0006]      FIG. 3  depicts a user on their back laying on the mattress. 
           [0007]      FIG. 4  depicts a user on their side laying on the mattress. 
           [0008]      FIG. 5  depicts a view of the mattress with a cover. 
           [0009]      FIG. 6  depicts a view of the mattress with the cover partially removed. 
           [0010]      FIG. 7  depicts a view of the mattress with inserts added. 
           [0011]      FIG. 8  depicts a top view of the mattress with two inserts attached. 
           [0012]      FIG. 9  depicts a cutaway view of the inserts showing the inner construction. 
           [0013]      FIG. 10  depicts a full cutaway view of the mattress. 
           [0014]      FIGS. 11-13  show a view of the mattress being packaged for transport with the inserts attached. 
       
    
    
     SUMMARY 
       [0015]    Disclosed herein is a mattress comprised of different layers of material stacked on top of each other which together have the effect of letting the user sleep in a “simulated Zero G” position without the aid of an articulating base. Contoured layers within the mattress let specific areas of the user&#39;s body sink further into the mattress than others which create the Zero G effect when sleeping on the back ( FIG. 3 ), and contour to the user&#39;s body when sleeping on the side ( FIG. 4 ). Specifically, when sleeping on the back, the user&#39;s head, upper back and feet are supported at mattress level, while the torso and hips sink into the mattress on an even slope. This position is more natural to the human body than laying on flat surface with a consistent amount of give &amp; support throughout. Additionally, there is a top layer of material specifically designed to retain minimum heat and to dissipate body heat over time, keeping the user cooler while sleeping and to retain the feeling of “bounce” or “springiness” in the mattress. 
       DETAILED DESCRIPTION 
       [0016]      FIG. 1  shows a side view of mattress  100  with internal layers A-C visible. Layer A is a breathable, springy and bouncy structural mesh layer (polymer material or other materials) between one inch and three inches thick which does not retain heat and serves to add spring and comfort for the user. For example, Layer A may be a material such as Airstring offered by Spec Tex® or any other similar material. Layer B is formed from a visco-elastic polyurethane foam (memory foam) which has a horizontal top surface and has a contoured bottom surface so that it is not a uniform thickness. The purposes of the “zones” formed by the various contours of the bottom surface of layer B will be explained later. In a preferred embodiment, the visco-elastic polyurethane foam of Layer B has a density in the range of 3-8 lb/ft̂3, preferably 4 lb/ft̂3. 
         [0017]    Layer C is a High Density polyurethane foam (HD foam) which has a horizontal bottom surface and is cut on a contour on its top surface so that it perfectly matches and fits together with the bottom contour of layer B. Preferably, the high density polyurethane foam has a density range of 1-3 lb/ft̂3, but preferably 2.8 lb/ft̂3. When fully assembled, the mattress  100  is flat on both top and bottom, appearing similar in shape and size to a traditional mattress. 
         [0018]    Preferably, layers B-C are permanently bonded to each other while layer A is removable as will be described later. However, it should be apparent that layers A-C can all be permanently bonded or attached to each other using known methods in the art. 
         [0019]    The mattress is divided laterally by five “zones” which are defined by the contour line ( FIG. 1 ) (or contact area between the bottom of layer B and the top of layer C). Zone  1  is a fully horizontal section starting at the head of the bed and extending from one inch in length to 18 inches along a length of mattress  100 . Zone  2  is a transition area between Zone  1  and Zone  3 , and extends from the end of Zone  1  from 1 inch to 20 inches along a length of mattress  100 . As previously explained, the top surface of layer  2  is flat while the bottom surface of layer  2  extends downward toward a bottom of mattress  100  at an angle which can vary from 5 degrees to 85 degrees from horizontal. The transition of layer B in zone  2  from flat to sloped can either be a sharp transition, as shown in  FIG. 1 , or a smooth transition with a convex surface into zone  1  and a concave surface into zone  3 . 
         [0020]    Zone  3  is a horizontal section symmetrical about the centerline of the bed connecting zone  2  and zone  4  in which layers A-C have a constant thickness. In zone  3 , layer B is the thickest layer. Zone  4  is a mirror image of zone  2  and zone  5  is a mirror image of zone  1  about the centerline of the mattress  100 . Because mattress  100  is symmetrical, a user can lie lengthwise in either direction. Table 1 below summarizes the thicknesses of the various layers in the various zones: 
         [0000]    
       
         
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Zones 1 &amp; 5 
                 Zones 2 &amp; 4 
                 Zone 3 
               
               
                   
               
             
             
               
                 Layer A 
                 1-4″ 
                 1-4″ 
                 1-4″ 
               
               
                 Layer B 
                 1-4″ 
                 Start—1-4″ 
                 2-10″ 
               
               
                   
                   
                 End—2-10″ 
                   
               
               
                 Layer C 
                 3-16″ 
                 Start—3-16″ 
                 1-10″ 
               
               
                   
                   
                 End—1-10″ 
               
               
                   
               
             
          
         
       
     
         [0021]    Layers B and C work together to create a support system for the body that allow for the “simulated Zero G positon.” The HD foam of layer C provides support which will give less under the user&#39;s weight, thus defining the user&#39;s sleeping position. The memory foam of layer B provides comfort and “give”, letting the user sink into the mattress  100 . Areas where the memory foam is thicker in layer B, such as zone  3 , provide a deeper sink and a more customized contour for the user&#39;s body. Areas with thicker HD foam in layer C, such as zones  1 ,  2 ,  4 , and  5 , provide more support and definition. 
         [0022]    Layer A has a number of distinct roles. Its first function is to be breathable, retain as little heat as possible and dissipate body heat over time, keeping the user cool while sleeping and separating the user from the memory foam of layer B which otherwise would retain much of the user&#39;s body heat. Secondly, layer A functions to distribute the weight of the user onto layer B. Memory foam deflects at highly local levels which can create a “sunk in” feeling, which prevents the user from easily moving/changing-position during sleep and also does not provide the ideal amount of support for all areas of the body. Layer A deflects in a very broad way, conforming to the body contour while distributing the weight of the user evenly over the memory foam&#39;s surface. In this way the memory foam will still offer the benefit of its “give” or vertical deflection, but layer A will prevent the “sunk in” feeling. Layer A also offers a desirable level of spring or bounce, common to an innerspring mattress, which foam alone cannot provide. 
       Zone Roles for Back Sleeping (FIG.  3 ) 
       [0023]    As shown in  FIG. 3 , when a user lays on their back on mattress  100 , zone  1  supports the user&#39;s head, keeping it raised above the mattress. Zone  2  supports the user&#39;s shoulders and upper back and defines the angle from horizontal that the user will sleep at. Zone  3  has a deeper area of memory foam in layer B that lets the user&#39;s hips and lower back sink into the mattress. Zones  4  and  5  support the user&#39;s legs but the contour underneath does not affect leg resting position as the legs are not heavy enough to sink into the mattress. Zone&#39;s  4  and  5  exist in order to keep the mattress  100  symmetrical, in this way the user can not set up the mattress in an incorrect orientation. 
         [0024]    If the user sets up the mattress  100  in reverse (head resting on Zone  5 ), zones  5  and  4  will function identically to zones  1  and  2  respectively. Together, these zones create the “simulated Zero G” position where the back/spine is in alignment in a downward slope (head rests higher than the hips) and the legs are elevated in a semi bent position. 
       Zone Roles for Side Sleeping (FIG.  4 ) 
       [0025]    As shown in  FIG. 4 , when a user lays on their side on mattress  100 , zone  1  supports the user&#39;s head, keeping it raised above the mattress. Zone  2  offers a thicker section of memory foam to allow the user&#39;s shoulders to sink in further by following the neck, shoulder and arm and body profile. Zone  3  offers the thickest section of memory foam to allow the heaviest areas of the body, the hips and torso, to sink in. Sections  4  and  5  offer less memory foam which still provide adequate support for the legs. This setup for side sleeping keeps the head supported and keeps the spine relaxed and naturally straight and in a parallel alignment with the floor. 
       Cover Construction (FIG.  5 ) 
       [0026]    In some embodiments, mattress  100  is further provided with a cover  500  which comprises top cover  502 , inner cover,  504 , and lower portion  506 . Top cover  502  is joined to lower portion  506  through exterior zipper  508  which can be used to completely separate top cover  502  from lower portion  506 . Piping  510  can be used to conceal the path of zipper  508  so the user never feels the metal or plastic zipper around the edge of the mattress cover  500  ( FIG. 5 ,  FIG. 6 ). The zipper  508  and piping  510  follow the same path around the perimeter of the mattress  100 . On the short ends of the mattress  100 , the zipper  508  and piping  510  are on a straight line near the top of mattress  100 . On the long sides of mattress  100 , the zipper  508  and piping  510  dip downward in a consistent convex arc ranging anywhere from 3″ to 10″ deep ( FIG. 5 ). The other side of mattress  100  not shown in  FIG. 5  is a mirror image of that shown in  FIGS. 5-6 . 
         [0027]    The cover  500  is constructed so that the user can unzip the top layer  502  as shown in  FIG. 6  ( FIG. 6 ). This is primarily so the user can access inner cover  504  located beneath top layer  502  ( FIG. 7 ). The top layer  502  can be removed for spot washing, washing in a washing machine, dry cleaning, or replacement. 
         [0028]    Top layer  502  generally comprises two distinct materials. The first material, ticking  512 , is a soft fabric which is quilted to an internal spacer fabric  1002  ( FIG. 10 ) in consistent width increments ( FIG. 5 ). As an example, ticking  512  may be 500 gram 100% polyester. A fire retardant fabric, such as Palidn FR fiber, may also be used. 
         [0029]    The internal spacer fabric enhances the breathability of the entire mattress and adds a plush-like topper to mattress  100 . Spacer fabrics are generally made up of two breathable pieces of fabric that have fine plastic threads oriented vertically between the two fabrics to create a defined space between the two pieces of fabric. The thickness of the spacer fabric located internal to ticking  512  can vary from 2 mm to 75 mm in thickness. 
       Inner Cover Construction (FIG.  7 ) 
       [0030]    In some embodiments, inner layer A of the mattress  100  shown in  FIGS. 1-4  may be inside one or more removable inserts  700  as depicted in  FIG. 7 . For full, queen, king and California king mattresses, layer A is made up of 2 inserts  700 . However, in some embodiments, layer A may be made up on a single insert  700  that is the full length and width of mattress  100 . Each insert  700  is preferably zippered to inner cover  504  using insert zippers  706 . However, other connection means, such as hook and loop fasteners, may also be used to attach inserts  700  to inner cover  504 . 
         [0031]    Inner cover  504  and lower portion  506  fully encase layers B and C so that the user is never exposed to those layers ( FIG. 7 ). In some embodiment, inner cover  504  is formed from a waterproof fabric to prevent any spills from traveling to parts of the mattress that are not washable. Inner cover  504  extends around the border of the mattress  100  and is attached to lower portion  506  along the same convex arc as top layer  502 . Preferably, inner cover  504  is sewn to lower portion  506  so it is not removable for holding the piping  510  and zipper  508  in place on mattress  100 . Inner cover  504  also prevents the user from smelling layers B and C of mattress  100  off-gassing, a natural property in foam. When the user removes top layer  502  to adjust inserts  700 , they only see a finished case. The user is never subjected to raw materials as in other foam mattresses ( FIG. 7 ). 
         [0032]    The bottom of lower portion  506  comprises a hidden zipper  1004  ( FIG. 10 ) which is used to attach lower portion  506  and inner cover  504  to mattress  100  during production. The construction of cover  500  allows the user to remove top layer to adjust the firmness using inserts  700  having varying densities while still maintaining the look and feel of a finished product ( FIG. 6 ). 
       Insert Construction (FIG.  9 ) 
       [0033]    In a preferred embodiment, layer A is contained within inserts  700  which are removable from mattress  100  as has been described. This allows users to select different densities of layer A to suit two users&#39; unique sleeping preferences. This can be due to heat, softness/firmness preferences, change in sleeping behavior, medical reasons, pregnancy, etc. 
         [0034]    As depicted in  FIG. 9 , Layer A is encased in fabric  902  using a folded fabric construction in which fabric  902  underneath layer A and is folded over the top of layer A. In the preferred embodiment, the fabric  902  is lightweight and breathable to optimize the breathability of layer A. The open edges of fabric  902  are then sewn shut. In the preferred embodiment, the open edges are sewn shut with bias tape  904 . Layer A is completely encased in the fabric  902  so the user never sees or touches the raw material. As shown in  FIG. 8 , the folded fabric construction allows for the two inserts  700  to sit side by side with no gap or crease between the two inserts  700  when users are laying on mattress  100 . 
         [0035]    At each end of insert  700  is a zipper  706  used to attach insert  700  to inner cover. In the preferred embodiment, zippers  706  are used to prevent the inserts from shifting while moving the mattress  100 . Other methods of securing the mattress include Velcro strips, strips of fabric, or strips of elastic on the corners of the mattress case which are pulled over layer A to keep inserts  700  in place. The zippers  706  on each end are designed so an insert can be zipped to either side of the mattress  100  by simply rotating the insert 180 degrees. 
       Roll Pack Packaging 
       [0036]    The mattress  100  is packaged for shipment with inserts  700  attached using a roll packing method in which the mattress  100  is first compressed and sealed in plastic. As shown in  FIG. 11 , the compressed mattress  100  is then folded in half along the centerline ( FIG. 1 ) so that both inserts  700  face outward. Mattress  100  is then rolled up as depicted in  FIGS. 12-13  and sealed with a plastic sheet. In the preferred embodiment, the mattress  100  is folded in the reverse along the center line. This prevents any permanent creasing or folding lines to layer A or the mattress case  500  during shipping.