Patent Description:
This invention relates to beds, and more particularly, to beds with zippers.

People have traditionally used beds that come in many shapes, sizes, and styles. Such beds can range from extremely simple designs to rather complex designs that include a variety of features. For example, some beds include mattresses that include foam, inner-springs, air chambers, other materials, or combinations thereof.

Such mattresses may be supported by a structure such as a frame, box spring, adjustable foundation, or a non-adjustable foundation. For adjustable foundations, portions of the mattress can be raised and lowered, such as a head and foot of the mattress. For example, <CIT> relates to a type of adjustable bed having junctions with equipped back support board, calf board support, front part bridge piece, back board support, rear bridge piece, thigh board support, back board support end and underframe crosstie woggle joint. The back board support has another end and is connected to the bedboard's back board woggle joint. A mattress core has a top cover and a bottom sheet, and the bottom sheet has a foot pocket having a foot pocket opening and a head pocket having a head pocket opening. The head pocket fits over an end of the back board. The foot pocket fits over an end of the calf board. <CIT> describes a box spring having a box spring base (<NUM>) that is connected to a bed mattress (<NUM>) which is arranged on box spring, by a detachable connection unit (<NUM>) provided along edge regions (<NUM>,<NUM>) of the box spring base and mattress. The detachable connection unit is comprised with slide fasteners along the edge regions. The connection unit is secured in the inner side of edge regions and disrupted in the region of upper and lower front ends of bed. <CIT> describes a magnetic coupler for attaching a mattress to a bed foundation including a magnet assembly, a target assembly, and a shunt. The magnet assembly includes a housing and a magnet, wherein the housing is configured to couple the magnet to the mattress. The target assembly is configured to couple a target to the foundation. The shunt is disposed within the housing of the magnet assembly or in the mattress. The magnet assembly and the target assembly are releasably attached when the magnet is magnetically coupled to the target.

Some embodiments of a bed system provided herein can include one or more of the features and functions disclosed herein, according to the definition of the invention in the appended claims. According to the invention, it is provided a bed system as claimed in claim <NUM> and a method for attaching a mattress to a foundation as claimed in claim <NUM>. In particular, the bed system includes an adjustable foundation, a mattress positioned on the adjustable foundation, wherein the mattress has a head end and a foot end, and a zipper that extends from the head end to the foot end of the mattress. The zipper can connect the mattress to the adjustable foundation. The zipper comprises a first zipper tape attached along a seam of an underside of the mattress and a second zipper tape attached along a seam of a top of the adjustable foundation. The first and second zipper tapes include first and second teeth, respectively, and the second teeth are configured to engage the first teeth. The zipper connecting the mattress to the adjustable foundation can be configured to retain the mattress to the adjustable foundation when the adjustable foundation is actuated to raise at least one of the head end and the foot end of the mattress. In some embodiments, the first zipper tape can be attached to the underside of the mattress by sewing the first zipper tape into the seam of the underside of the mattress. In addition, the second zipper tape can be attached to the top of the adjustable foundation by sewing the second zipper tape into the seam of the top of the adjustable foundation.

In yet other embodiments, the foundation can have a first perimeter and the mattress can have a second perimeter. The first zipper tape can be connected to a top of the foundation at a first zipper location that is interior of the first perimeter. The second zipper tape can be connected to an underside of the mattress at a second zipper location that is interior of the second perimeter. The first and second zipper locations can be substantially vertically aligned. The first zipper tape can be sewn into a seam interior to the first perimeter along the top of the foundation and the second zipper tape can be sewn into a seam interior to the second perimeter along the underside of the mattress.

In some embodiments, the adjustable foundation can also provide at least one articulation point, wherein the zipper extends across the at least one articulation point. The adjustable foundation can comprise a platform with at least a head panel, a middle panel, and a foot panel, wherein at least one panel is raised or lowered when the adjustable foundation is actuated. The articulation point can also be positioned between the head panel and the middle panel such that the zipper extends along a portion of the head panel, across the articulation point, and along a portion of the middle panel.

The bed system according to the invention further comprises an air chamber within the mattress, wherein a second zipper connects the air chamber to an interior portion of the mattress. In such embodiments, the zipper connecting the mattress to the adjustable foundation can be substantially vertically aligned with the second zipper connecting the air chamber to the interior portion of the mattress. Further, the second zipper is attached along a seam of a bottom of the air chamber. In another embodiment, the second zipper can be attached along a seam of at least one of a bottom of the air chamber and the interior portion of the mattress. In some embodiments, the second zipper can be attached at a corner of the air chamber. In yet other examples, a first zipper tape of the first zipper and a second zipper tape of the second zipper can be sewn to a common seam of a mattress cover. In some embodiments, the bed system can further comprise an upside down foam tub positioned above the air chamber.

The bed system can further comprise a mattress cover surrounding the mattress, wherein the zipper is attached to the mattress cover and configured to couple the mattress cover to the top of the adjustable foundation at a bottom of the mattress. The zipper can be attached along a seam of at least one of an exterior underside of the mattress cover and the top of the foundation.

In some embodiments, the adjustable foundation can further comprise an actuator and a controller. The controller can be operably connected to the actuator and configured to drive the actuator to actuate at least one portion of the adjustable foundation between a lower position and an upper position. The bed system described herein can further comprise an air controller having a pump fluidly connected to an air chamber within a core of the mattress, wherein the air controller can be configured to adjust a fluid pressure within the air chamber.

A method as defined in claim <NUM> is also discussed herein for attaching a mattress to a foundation.

A bed system includes a foundation, a mattress, and a zipper. The mattress can have a mattress core and a mattress cover covering the mattress core. The zipper can connect the mattress core to the foundation. The mattress core can be an air chamber. The mattress cover can define a zipper hole through which the zipper extends when connecting the mattress core to the foundation. The foundation is an adjustable foundation. The zipper includes a first tape attached to the mattress core and a second tape attached to a platform of the foundation. A second zipper can connect the mattress core to the foundation. The zipper can extend through the mattress cover.

The bed system with zippers can provide several advantages. Use of the zippers can ensure that the mattress remains in place on the foundation and does not fall off the foundation over time. Additionally, zippers positioned interior to a perimeter of the mattress and interior to the perimeter of the foundation can be hidden from sight. As a result, the mattress and foundation can appear to be seamlessly coupled to each other. Moreover, the zipper can extend from the head end of the mattress to the foot end of the mattress and over one or more articulation points. As a result, when the adjustable foundation is actuated, the mattress can bend and/or articulate accordingly while the zipper can retain the mattress to the foundation. In other words, as the adjustable foundation is actuated and the mattress bends accordingly, the mattress can remain coupled to the foundation and bend with the foundation without falling off or becoming undesirable misaligned with the foundation. Furthermore, the zipper can be sewn into and/or along the seam of the mattress and the seam of the foundation so that the zipper can take advantage of the strength of the seam. As a result, the zipper can be less likely to come undone or break while the mattress is attached to the foundation. The zipper can also take advantage of the strength of the seam when the adjustable foundation is actuated and a portion of the mattress is raised or lowered. Finally, the mattress having an air chamber within the mattress, a zipper is included for retaining the air chamber to the mattress cover and another zipper can retain the mattress cover to the foundation. Such an arrangement with a zipper inside the mattress cover and another zipper outside the mattress cover can help hold the air chamber (or another mattress core for embodiments without an air chamber) in place during articulation of an adjustable foundation. In some embodiments, internal and external zippers can be aligned adjacent to one another so as to further strengthen connections. This can be especially beneficial when the adjustable foundation is actuated and a portion of the mattress is raised or lowered.

These and other embodiments can each optionally include one or more of the features described below. Particular embodiments of the subject matter described in this specification can be implemented so as to realize none, one, or more of the advantages described herein.

Over time, a mattress can fall off or slide around on a foundation, such as an adjustable foundation. To overcome this concern, one or more zippers can be used to attach the mattress to the foundation. Accordingly, the mattress can be coupled (i.e., zippered) to the foundation. As a result, the mattress can remain in place on the foundation. The mattress can also be easily moved from or on the foundation by undoing the zipper. In embodiments of a bed system that has an adjustable foundation, the adjustable foundation can be used to selectively raise and lower a head and/or a foot of the mattress. In some embodiments, a mattress can be relatively heavy and/or flexible so as to naturally contour to the adjustable foundation's shape under force of gravity when one or more portions of the adjustable foundation are articulated. In other embodiments, a mattress can be relatively light weight and/or stiff so as to bend less under the force of gravity when one or more portions if the adjustable foundation are articulated. For either embodiment (and particularly for embodiments that have a mattress that is relatively light weight and/or stiff), a zipper attachment mechanism can be used to hold the mattress to the foundation during articulation such that the shape of the mattress can more closely follow the shape of the foundation.

<FIG> discloses a bed system <NUM> that includes a mattress <NUM> and a foundation <NUM>. The mattress <NUM> can have a mattress cover <NUM> that includes a fabric <NUM>, and the mattress cover <NUM> can enclose various internal parts (not shown) of the mattress <NUM>, such as foam, springs, air chambers, and or other components suitable for the application. The fabric <NUM> of the cover <NUM> can be hypoallergenic or any other type of material intended to protect the mattress <NUM> from spills, stains, bacteria, and other allergens. In some embodiments, the fabric of the mattress cover <NUM> can be water-resistant. The fabric of the cover <NUM> can also allow for airflow and breathability. The cover <NUM> can be configured to fit over the entire mattress <NUM>. In some embodiments, the cover <NUM> can be zippered around the mattress <NUM>. In other embodiments, the cover <NUM> can be held in place around the mattress <NUM> by any other mechanism including but not limited to velcro, buttons, snaps, and/or other fasteners. The cover <NUM> can further have one or more seams <NUM> that run along a length of the cover <NUM>, for example from a head end to a foot end of the cover <NUM>. The one or more seams <NUM> can also be positioned interior to a perimeter of the cover <NUM>. Moreover, the one or more seams can be positioned around corners of the cover <NUM> such that the cover <NUM> is fitted around the mattress <NUM> having a particular height, length, and width. In some embodiments, the cover <NUM> can be an optional addition to the bed system <NUM>. In other embodiments, the cover <NUM> can already come fitted to the mattress <NUM> in the bed system <NUM>. In some embodiments, the cover <NUM> can be removable.

The mattress <NUM> defines a mattress top <NUM>, a mattress bottom <NUM>, and a mattress perimeter <NUM>. In some embodiments, the seams <NUM> of the mattress <NUM> can be positioned on one, more, or all of the mattress top <NUM>, the mattress bottom <NUM>, and the mattress perimeter <NUM>. For example, in some embodiments the mattress <NUM> can have some of the seams <NUM> around the mattress perimeter <NUM>. Such seams <NUM> can connect one piece of fabric to another piece of fabric. In some embodiments, the seams <NUM> can be functional, aesthetic, or both. In some embodiments, the mattress <NUM> can have seams <NUM> on the mattress bottom <NUM>. Such seams can be hidden from view when the mattress <NUM> is positioned on the foundation <NUM>.

The foundation <NUM> has a foundation perimeter <NUM>. The foundation <NUM> can include a platform <NUM> and legs <NUM>. The platform <NUM> can define a foundation top <NUM>. In some embodiments, the platform <NUM> can be made from a wood material, including but not limited to wood (such as medium density fiberboard or plywood), or other materials suitable for the application. The platform <NUM> can be covered in fabric, batting, and/or other materials.

The platform <NUM> of the foundation <NUM> can have one or more panels (e.g. a head panel, a foot panel, and one or more middle panels). In some embodiments, the foundation <NUM> can be an adjustable foundation configured to raise and lower one or more panels of the platform <NUM>, which, in turn, raise or lower portions of the mattress <NUM>. The adjustable foundation can be actuated via a controller and/or manually actuated by a user.

The mattress <NUM> can be connected (i.e., coupled) to the foundation <NUM> by a zipper <NUM>. In some embodiments, the mattress <NUM> can be coupled to the foundation <NUM> by multiple zippers <NUM>. In the embodiment of <FIG>, the zipper <NUM> extends from a position proximate a head end of the mattress <NUM> to a position proximate a foot end of the mattress <NUM>. Thus, the zipper <NUM> extends substantially a full length of the mattress <NUM>. In some embodiments, the bed system <NUM> further includes a second zipper <NUM> (see <FIG>) that extends substantially a full length of the mattress <NUM> on the other side of the mattress <NUM>, substantially parallel to the zipper <NUM>. The zipper <NUM> includes zipper tapes 124A and 124B and zipper teeth 126A and 126B attached to the zipper tapes 124A and 124B, respectively. The zipper tape 124A can be attached to the mattress cover <NUM> at the mattress bottom <NUM> and the zipper tape 124B can be attached to the platform <NUM> of the foundation <NUM> at the foundation top <NUM>. For example, the zipper tape 124A can be sewn to an underside of the cover <NUM> and the zipper tape 124B can be sewn to a fabric on a top of the foundation <NUM>. In other embodiments, the zipper tape 124A can be attached to the mattress <NUM> by other suitable mechanisms. In addition or alternatively, the zipper <NUM> can be arranged at a head side and/or a foot side of the mattress <NUM>. For example, the zipper <NUM> can extend substantially a full length of the head side and/or the foot side of the mattress <NUM>.

In other embodiments, the zipper <NUM> extends at a length shorter than the full length of the mattress <NUM>. Further, in other embodiments, the mattress <NUM> can be coupled to the foundation <NUM> by a single, continuous zipper.

The zipper <NUM> can be configured to attach the mattress <NUM> to the foundation <NUM> and to hold the mattress <NUM> in place on the foundation <NUM>. In embodiments in which the foundation <NUM> is an adjustable foundation, the zipper <NUM> can retain the mattress <NUM> in place when the foundation <NUM> raises and/or lowers one or more panels of the platform <NUM>, which further raises and/or lowers one or more portions of the mattress <NUM>. Moreover, in such embodiments, the zipper <NUM> can extend substantially a full length, from a location near the head end of the mattress <NUM> to a location near the foot end of the mattress <NUM>, across one or more articulation points of the mattress <NUM> and the foundation <NUM>. Portions of the mattress <NUM> and the foundation <NUM> that bend during actuation can be considered articulation points. For example, in embodiments when the platform <NUM> of the foundation has multiple panels, a joint between two adjacent panels can be considered an articulation point. Therefore, the zipper <NUM> can be able to retain the mattress <NUM> to the foundation <NUM> when the foundation <NUM> is actuated and one or more portions of the mattress <NUM> are raised and/or lowered in response to one or more panels of the platform <NUM> being raised and/or lowered.

In some embodiments, the zipper <NUM> can be hidden from sight. As a result, additional covers and/or fabric may not be required to hide the zipper <NUM> from sight. The zipper <NUM> can be arranged and sewn into the seam <NUM> of the mattress <NUM> such that the zipper <NUM> is not visible. When the zipper <NUM> is sewn into the seam <NUM>, the zipper <NUM> can take advantage of strength already existing in the seam <NUM>. Therefore, the zipper <NUM> can be less likely to come undone or break when retaining the mattress <NUM> to the foundation <NUM>. This can be especially advantageous when the foundation <NUM> is adjustable and one or more panels of the platform <NUM> and one or more portions of the mattress <NUM> are raised and/or lowered.

<FIG> is a top view of the foundation <NUM>. As shown in <FIG>, the foundation <NUM> has the foundation platform <NUM> (which at least partially defines the foundation top <NUM>), and the zippers <NUM> that include zipper tapes 124B and 124D. Each zipper tape 124B and 124D have zipper teeth 126B and 126D, respectively. The teeth 126B and 126D are configured to couple with the zipper teeth of the zipper tapes attached to the bottom of the mattress <NUM> (e.g., as shown in <FIG>) and therefore retain the mattress <NUM> to the foundation <NUM>. The foundation <NUM> can further have a foundation cover <NUM> with one or more fabric portions at least partially covering the platform <NUM>. Fabric portions of the foundation cover <NUM> can meet at one or more seams <NUM>. The seams <NUM> can extend along an entire perimeter of the foundation top <NUM> (refer to <FIG>, foundation perimeter <NUM>). In some embodiments, the zipper tapes 124B and 124D can attach to the foundation top <NUM> at the seam <NUM>, interior to the perimeter of the foundation <NUM>. As a result, the zipper tapes 124B and 124D can take advantage of the strength of the existing seam <NUM> when the teeth 126B and 126D are coupled with the teeth of the zipper tapes attached to the mattress <NUM>. In addition, the zipper <NUM> can be hidden from sight when the mattress <NUM> is coupled to the foundation <NUM>. This is possible when the zipper tapes 124B and 124D are attached (i.e. sewn) interior to the perimeter of the foundation <NUM> and/or when the zipper tapes 124B and 124D are attached (i.e., sewn) into the seam <NUM>.

In other embodiments, the seams <NUM> can extend along a portion of the perimeter of the foundation top <NUM>. The zippers can attach to the foundation top <NUM> at the seams <NUM> as described above. In addition or alternatively, the zippers can extend along a portion of the foundation top <NUM> that has no seam.

In other embodiments, the zippers <NUM> need not be attached at seams. For example, in some embodiments the zippers <NUM> can be sewn to fabric at a location that does not include a seam. In other embodiments, the foundation cover <NUM> can be omitted and the zippers <NUM> can be attached to the foundation <NUM> via other suitable mechanisms, such as screws, bolts, rivets, or adhesive.

In some embodiments, the foundation <NUM> can define multiple passages 121A-B that extend through the foundation top <NUM>. The passages 121A-B can be configured to allow passage of one or more hoses (not shown) through the foundation <NUM> and into the mattress <NUM>. The passages 121A-B can be useful, for example, in embodiments where the mattress <NUM> is fluidically connected to an air source (not shown) in or under the foundation <NUM>.

In some embodiments, the foundation <NUM> can be an adjustable foundation and the platform <NUM> can include multiple panels 128A-128D, including a head panel 128A, a middle panel 128B, a leg panel 128C, and a foot panel 128D. Each of the panels 128A-D can be moved when the adjustable foundation is actuated. When each of the panels 128A-D are moved, one or more portions of the mattress <NUM> attached to the foundation <NUM> by the zipper <NUM> can also be moved accordingly. For example, if the head panel 128A of the platform <NUM> is raised, the mattress <NUM> is raised as well at a head portion of the mattress <NUM>, and the mattress <NUM> remains coupled to the foundation <NUM> by the zipper <NUM>.

The foundation <NUM> can include an actuator (not shown) operably connected to each of the panels 128A-D of the platform <NUM> so as to actuate one or more of the panels 128A-D between raised and lowered positions in response to actuation by the actuator and a controller <NUM> operably connected to the actuator and configured to electronically drive the actuator to actuate one or more of the panels 128A-D between raised and lowered positions. In some embodiments, the one or more panels 128A-D can be actuated manually by the user with or without the controller <NUM>. In other embodiments, the one or more panels 128A-D can be actuated automatically by the controller <NUM>. The controller <NUM> can be configured to raise and/or lower one or more of the panels 128A-D from a predetermined minimum height to a predetermined maximum height. For example, using the controller <NUM>, the user can raise the head panel 128A to a maximum height position while lowering the foot panel 128D to a minimum height position. Each of the panels 128A-D can be adjusted to a same height such that the user lays flat on top of the mattress <NUM>.

<FIG> is a bottom view of the mattress <NUM>. As shown in <FIG>, the mattress <NUM> includes the mattress bottom <NUM>, the mattress cover <NUM>, and the zippers <NUM>. The zippers <NUM> further includes zipper tapes 124A and 124C which connect to zipper teeth 126A and 126C, respectively. The zipper teeth 126A and 126C are configured to couple with corresponding zipper teeth of the zipper tapes attached to the foundation <NUM> (shown in <FIG>) and therefore retain the mattress <NUM> to the foundation <NUM>. In some embodiments, the zipper tapes 124A and 124C can attach to the mattress bottom <NUM> at one or more of the seams <NUM> interior to a perimeter of the mattress <NUM>. As a result, the zipper tapes 124A and 124C can take advantage of the strength of the existing seam <NUM> when the teeth 126A and 126D are coupled with the teeth and the zipper tapes attached to the foundation <NUM>. In addition, the zipper <NUM> can be hidden from sight when the mattress <NUM> is coupled to the foundation <NUM>. This is possible when the zipper tapes 124A and 124C are attached (i.e. sewn) interior to the perimeter of the mattress <NUM>, such as when the zipper tapes 124A and 124C are attached (i.e., sewn) into the seam <NUM>.

<FIG> is a side view of the foundation <NUM> and the mattress <NUM> when the foundation <NUM> is an adjustable foundation. The foundation <NUM> can be actuated manually, by the user, and/or automatically by the controller, as previously described (refer to <FIG>). The mattress <NUM> is enclosed in the mattress cover <NUM> and the platform <NUM> of the foundation <NUM> is enclosed (i.e., covered) in the foundation cover <NUM>, as previously described. The zipper <NUM> extends from a position near the head end of the mattress <NUM> to a position near the food end of the mattress <NUM> and couples and retains the mattress <NUM> to the platform <NUM> when the foundation <NUM> is actuated. As a result, the zipper <NUM> extends over one or more articulation points of the foundation <NUM> and the mattress <NUM>. In some embodiments, a zipper tape of the zipper <NUM> is attached to a bottom of the cover <NUM> and another zipper tape of the zipper <NUM> is attached to a top of the foundation cover <NUM>.

The mattress bottom <NUM> is raised when the head panel 128A of the platform <NUM> (refer to <FIG>) is actuated/raised by the controller <NUM>. As a result, the head portion of the mattress <NUM> is also raised. As previously discussed, when the foundation <NUM> is an adjustable foundation and it is actuated, the mattress <NUM> remains coupled to the foundation <NUM> as one or more panels 128A-D of the platform <NUM> of the foundation <NUM> are raised and/or lowered, thereby raising and/or lowering the associated portions of the mattress <NUM>.

In some embodiments, the zipper tape 124A can be attached directly to the mattress <NUM> (e.g. sewn to the mattress cover of the mattress <NUM>) and the zipper tape 124B can be attached directly to the foundation <NUM> (e.g. to a cover of the foundation <NUM>) without additional lengths of extension fabric in-between. In such embodiments, the zipper <NUM> can provide a relatively tight connection between the mattress and the foundation. For example, in embodiments where the zipper tapes 124A and 124B have a width of between about <NUM> and about <NUM> inches, then the zipper <NUM> can hold the mattress <NUM> to the foundation <NUM> with a gap of about <NUM> to about <NUM> inches. In other embodiments, the zipper tapes 124A and 124B can be narrower or wider for applications where tighter or looser connections are deemed desirable. In still other embodiments, one or more portions of fabric can be added as an extension where looser connections between the mattress <NUM> and the foundation <NUM> are deemed desirable.

In some embodiments, the zipper <NUM> can be spaced inward from a perimeter of the mattress <NUM> and the foundation <NUM> by an amount suitable to substantially conceal the zipper <NUM> from view and suitable to allow for sheets to be tucked in between the mattress <NUM> and the foundation <NUM>. For example, the zipper <NUM> can be spaced inward from a perimeter of the mattress <NUM> and the foundation <NUM> by between about <NUM> and about <NUM> inches.

In some embodiments, the bed system <NUM> can include exactly two zippers <NUM> that connect the mattress <NUM> to the foundation <NUM>. For example, a first zipper <NUM> can extend longitudinally along a left side of the bed system and a second zipper <NUM> can extend along a right side of the bed system.

In some embodiments, the bed system <NUM> can include exactly one zipper <NUM> that connects the mattress <NUM> to the foundation <NUM>. For example, the zipper <NUM> can follow a full (or nearly full) loop whereby the zipper <NUM> extends along a top portion, a left side, a bottom portion, and a right side of the bed system <NUM>. In one example, the zipper <NUM> can extend along a left side of the bed system <NUM>, turn and extend along a foot side of the bed system <NUM>, turn and extend along a right side of the bed system <NUM>, and turn and extend along a top side of the bed system <NUM>. In some embodiments with a single zipper <NUM> connecting the mattress <NUM> to the foundation <NUM>, the zipper <NUM> can be positioned under the mattress <NUM> at a location inward of the perimeter of the mattress so as to have a gap between the perimeter of the mattress <NUM> and the zipper <NUM>.

In some embodiments, the bed system <NUM> can have more than two zippers <NUM> that connect the mattress <NUM> to the foundation <NUM>.

<FIG> is a schematic view of the bed system <NUM> when viewed from the head end. As shown in <FIG>, the foundation <NUM> can include the legs <NUM> and the platform <NUM>. In some embodiments, the foundation <NUM> is an adjustable foundation (refer to <FIG>), wherein one or more panels 128A-D of the platform <NUM> can be adjusted to a raised or lowered height (refer to <FIG>). The platform <NUM> can be made from wood, such as medium density fiberboard or plywood, and covered in a fabric, as previously described throughout this disclosure.

The mattress <NUM> can be placed on top of the platform <NUM> of the foundation <NUM>.

The mattress <NUM> includes one or more air chambers <NUM> and one or more foam portions <NUM> covered in the mattress cover <NUM>. The air chamber <NUM> can be an inflatable air chamber filled with air to provide support to one or more portions of the mattress <NUM>. The amount of air in the air chamber can be adjusted by using an air controller having a pump or blower. As a result, fluid pressure in the air chamber <NUM> can be customized to change the firmness and/or support of the mattress <NUM>. In some embodiments, the air chamber <NUM> can extend a full length of the mattress <NUM>, from the head end to the foot end of the mattress <NUM>. In other embodiments, the air chamber <NUM> can be placed in a particular portion of the mattress <NUM> (i.e., only at the head end and/or only at the foot end of the mattress <NUM>). In yet other embodiments, multiple air chambers can be placed within the mattress <NUM> and each air chamber can be individually controlled/manipulated by the controller. In alternative embodiments, the air chamber <NUM> can be replaced with another type of mattress core suitable for the application.

The air chamber <NUM> can be surrounded on one or more sides by one or more foam members <NUM>. For example, in some embodiments the foam members <NUM> can include a top foam member <NUM> and a number of side foam members <NUM> that combine to form an upside down foam tub <NUM> that can be placed on top of the air chamber <NUM> within the mattress <NUM>. In other embodiments, the mattress <NUM> can have one or more foam members that are sized, shaped, and positioned differently than as illustrated in <FIG>, or can have no foam members. In some embodiments, the mattress <NUM> can include one or more foam members <NUM> without the air chamber <NUM>. For example, the air chamber <NUM> can be replaced with a mattress core that includes foam, springs, and/or other suitable materials.

The air chamber <NUM> can be formed of a layer of polymer material configured to substantially retain air and a layer of fabric configured to provide reinforcing strength. In some embodiments, such a combination of materials can be advantageous in making the air chamber <NUM> durable and substantially airtight. As a result, the combination of materials can substantially retain air within the air chamber <NUM> when weight is added on top of the mattress <NUM> and/or the mattress <NUM> is bent and/or articulated when the adjustable foundation is actuated.

Still referring to <FIG>, a bottom of the air chamber <NUM> can be attached to the mattress cover <NUM> by a zipper <NUM>. In some embodiments, the zipper 123can extend substantially a full length of the air chamber <NUM> and/or the mattress <NUM>. In other words, the zipper <NUM> can extend from a head end of the air chamber <NUM> to a foot end of the air chamber <NUM>. In such embodiments, the zipper <NUM> can be sewn into (i.e., along) a seam of the air chamber <NUM>. Therefore, the zipper <NUM> can take advantage of the existing strength in the seam of the air chamber <NUM> such that the zipper <NUM> does not become undone or break when the zipper <NUM> retains the air chamber <NUM> to the mattress <NUM>. In some embodiments, the zipper <NUM> can be attached at one or more corners of the air chamber <NUM> such that the zipper <NUM> can take advantage of the strength of an existing seam along the one or more corners of the air chamber <NUM>.

In addition to the zipper <NUM> connecting the air chamber <NUM> to the mattress cover <NUM>, the zipper <NUM> can further connect the mattress cover <NUM> to the foundation <NUM>. The zipper <NUM> can couple the mattress <NUM>, via the cover <NUM>, to the foundation <NUM>. The zipper <NUM> can be arranged adjacent the zipper <NUM> (i.e., vertically aligned) such that both zippers <NUM> and <NUM> act together to form a relatively strong connection between the air chamber <NUM> and the foundation <NUM>. Moreover, if the zippers <NUM> and <NUM> are aligned along seams of the air chamber <NUM>, the mattress cover <NUM>, and the foundation <NUM>, the zippers <NUM> and <NUM> can take advantage of the existing strength from the seams. As a result, the connection between the mattress <NUM> and the foundation <NUM> can be relatively strong, especially where the foundation <NUM> is an adjustable foundation and the foundation <NUM> is actuated.

In some examples which are not part of the present invention, the air chamber <NUM> can be omitted. For example, the mattress <NUM> can include a mattress core (that does not necessarily have any air chambers) inside the mattress cover <NUM>. One or more zippers <NUM> can connect the mattress core to the mattress cover <NUM> and one or more zippers <NUM> can connect the mattress cover <NUM> to the foundation <NUM>. Accordingly, a combination of one or more zippers <NUM> inside the mattress <NUM> and one or more zippers <NUM> outside of the mattress <NUM> can function to retain a mattress core (with our without an air chamber) in position on an adjustable foundation.

<NUM> a schematic elevation view of a portion of the bed system <NUM> in one embodiment, showing a portion of the zippers <NUM> and <NUM>. The bed system <NUM> includes the foundation <NUM> and the mattress <NUM> (including the mattress cover <NUM> and the air chamber <NUM>). In this example, the first zipper <NUM> connects (i.e., couples) the mattress cover <NUM> to the top <NUM> of the foundation <NUM> at the platform <NUM>. The zipper tape 124A can connect the zipper teeth 126A to the mattress <NUM> (such as by being sewn along a seam, in some embodiments). The zipper tape 124B can connect the zipper teeth 126B to the top <NUM> of the foundation <NUM> at the platform <NUM> (such as by being sewn along a seam, in some embodiments). When the zipper <NUM> is zipped, the zipper teeth 126A can be connected to the zipper teeth 126B such that the zipper <NUM> can connect the mattress <NUM>, via the mattress cover <NUM>, to the top <NUM> of the foundation <NUM> at the platform <NUM>. In other words, when zipper teeth 126A and zipper teeth 126B are coupled, the zipper <NUM> can securely attach the mattress <NUM> to the foundation <NUM>.

According to the invention, a second zipper, the zipper <NUM>, connects the air chamber to an interior portion of the mattress. For example, the zipper <NUM> can connect an exterior underside (i.e., bottom) of the air chamber <NUM> to an interior portion of the mattress cover <NUM>. The zipper <NUM> can include zipper tapes 136A and 136B that connect to corresponding zipper teeth 138A and 138B. The zipper tape 136A can connect the zipper teeth 138A to the mattress air chamber <NUM> (such as by being sewn to a bottom portion of the air chamber <NUM>, in some embodiments). The zipper tape 136B can connect the zipper teeth 138B to the mattress cover <NUM> (such as by being sewn along a seam, in some embodiments). When the zipper <NUM> is zipped, the zipper teeth 138A can be connected to the zipper teeth 138B such that the zipper <NUM> can connect the air chamber <NUM> to the mattress cover <NUM>.

This configuration of the zippers <NUM> and <NUM> can be beneficial in embodiments where the foundation <NUM> is an adjustable foundation. When the foundation <NUM> is actuated and one or more panels 128A-D comprising the platform <NUM> of the foundation <NUM> are raised and/or lowered, the one or more portions of the mattress <NUM> and one or more corresponding portions of the air chamber <NUM> move accordingly. For example, if the head panel 128A of the platform <NUM> is raised, then the corresponding portion of the mattress <NUM> is raised, as well as any part of the air chamber <NUM> that is located in that corresponding portion.

<FIG> is a schematic view of the bed system <NUM>, which is not according to the invention, when viewed from the head end. The bed system <NUM> is similar to the bed system <NUM> (shown in <FIG>) except that the bed system <NUM> has a different zipper configuration. The bed system <NUM> includes zippers <NUM> extending from the air chamber <NUM> to the platform <NUM> of the foundation <NUM>. The zippers <NUM> can each include first and second zipper tapes <NUM> and <NUM>, with the zipper tape <NUM> connected to the air chamber <NUM> and the zipper tape <NUM> connected to the foundation <NUM>. The zipper tapes <NUM> and <NUM> can be zipped together in order to connect the air chamber <NUM> to the foundation <NUM> and hold the air chamber <NUM> in place on the foundation <NUM>, such as during actuation of the foundation <NUM>.

In some embodiments, the mattress cover <NUM> can define holes through which the zippers <NUM> extend between the air chamber <NUM> and the foundation <NUM>. This can allow the zippers <NUM> to connect the air chamber <NUM> directly to the foundation <NUM> without additional intervening zippers. For example, the zipper <NUM> can extend a full distance between the air chamber <NUM> and the foundation <NUM> as opposed to using two zippers to span the same distance, such as shown in <FIG> and <FIG>.

Claim 1:
A bed system comprising:
an adjustable foundation (<NUM>);
a mattress (<NUM>) positioned on the adjustable foundation, wherein the mattress has a head end and a foot end;
a zipper (<NUM>) that extends from the head end to the foot end of the mattress and connects the mattress to the adjustable foundation, wherein the zipper comprises a first zipper tape (124A) attached along a seam of an underside of the mattress and a second zipper tape (124B) attached along a seam of a top of the adjustable foundation, wherein the first and second zipper tapes include first and second teeth (126A, 126B), respectively, and the second teeth are configured to engage the first teeth; and
an air chamber (<NUM>) within the mattress, wherein a second zipper (<NUM>) connects the air chamber to an interior portion of the mattress, and wherein the second zipper is attached along a seam of a bottom of the air chamber.