Patent ID: 12256845

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of this disclosure. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for this disclosure.

The present disclosure relates to an adjustable firmness mattress system. For example, the system may include multiple rotatable assemblies that have an orientation-specific firmness. An individual may adjust the firmness of regions of the mattress by rotating one or more of the rotatable assemblies. As an example, a rotatable assembly may include multiple disk-like compressible elements that are mounted on a central axle. The rotatable assembly can rotate about the central axle. In some implementations, the central axle is oriented widthwise. The disk-like compressible elements of adjacent rotatable assemblies may be interleaved with one another to reduce gaps. A bridge assembly may be disposed above the rotatable assemblies to distribute force from a reclining body onto the top portions of the rotatable assemblies. A support assembly may be disposed beneath the rotatable assemblies to support the axles of the rotatable assemblies and minimize the amount of force from a reclining body that causes compression of the lower portions of the rotatable assemblies. In this manner, the material properties of the top portions of the compressible elements significantly impact the firmness of the mattress, while the material properties of the bottom portions minimally impact the firmness. In some implementations, the axles include a central rotatable pivot that allows for each side of the mattress to be independently adjusted to accommodate differing firmness preferences of two individuals. In some implementations, the rotatable assemblies span approximately half of the width of the mattress to allow for individual adjustment of each side of the mattress. In at least some of these implementations, a foam panel may run lengthwise through the middle of the mattress to separate the two sides.

FIG.1is a schematic diagram of an adjustable firmness mattress100according to embodiments described herein. The adjustable firmness mattress100is a rectangular pad that is configured to provide support to a reclining body.

The adjustable firmness mattress100includes a comfort layer102, a transition layer104, and an adjustable firmness support layer106. The adjustable firmness mattress100may also include a fabric covering (not shown inFIG.1) that encloses the comfort layer102, the transition layer104, and the adjustable firmness support layer106.

The adjustable firmness mattress100extends lengthwise (L) from a head end108to a foot end110and widthwise (W) from a first side112to a second side114. The adjustable firmness mattress100extends depth-wise (D) from a top side116to a bottom side118.

The comfort layer102, transition layer104, and adjustable firmness support layer106are rectangular and stacked depth-wise, with the comfort layer102nearest the top side116and the adjustable firmness support layer106nearest the bottom side118. Although shown as separate components inFIG.1, in at least some embodiments the comfort layer102and the transition layer104are combined as a single layer.

The comfort layer102is a soft, flexible layer that provides comfort and cushioning to a reclining body on the adjustable firmness mattress100. For example, the comfort layer102may be softer than the transition layer104and the adjustable firmness support layer106. The comfort layer102may include one or more layers of padding. The layers of padding may include polyurethane foam, viscoelastic foam, latex or synthetic latex foam, felt, polyester fiber, cotton fiber, wool fiber, down or imitation down, and non-woven fiber pads.

In some implementations, the comfort layer102may also include an active temperature control system, and various sensors, including temperature and pressure sensors. The sensors may be used to determine pressure points and suggest adjustments to the firmness of the mattress. The sensors may also be used to determine a heart rate, heart rate variability, or breathing rate of a person lying in the bed. The measurements made from the sensors may be used to infer whether the person lying in the bed is sleeping.

The transition layer104may be firmer and more rigid than the comfort layer102. The transition layer104may be configured to separate the comfort layer102from the adjustable firmness support layer106and prevent the softer more flexible materials of the comfort layer102from deforming into any softer (or less supported) regions of the adjustable firmness support layer106. The transition layer104may include one or more layers of padding. The layers of padding may include polyurethane foam, viscoelastic foam, latex or synthetic latex foam, felt, polyester fiber, cotton fiber, wool fiber, down or imitation down, and non-woven fiber pads. In some implementations, the comfort layer102is made from a first foam and the transition layer104is made from a second foam that has a higher Indentation Load Deflection (ILD) than the first foam. ILD is a measurement that refers to the pressure required to indent a piece of compressible material (e.g., a foam material) by a specific amount. For example, an ILD measurement may refer to the amount of pressure required to indent a 4-inch-thick piece of material by 1 inch. The ILD measurement can be used to compare different materials. A higher density foam will generally have a higher ILD than a lower density foam made of the same material. In some implementations, the first foam may be a lower density foam than the second foam.

The adjustable firmness support layer106includes rotatable components that allow for adjustment of the firmness of the adjustable firmness mattress100. Embodiments of the adjustable firmness support layer106are illustrated and discussed throughout this disclosure.

In some implementations, the adjustable firmness mattress100may include a spring layer that includes springs such as innersprings. The spring layer may be disposed beneath the adjustable firmness layer, within the transition layer, or elsewhere.

FIGS.2A and2Bare schematic diagrams of an example adjustable firmness support layer206according to embodiments described herein. The adjustable firmness support layer206is an example of the adjustable firmness support layer106. In this example, the adjustable firmness support layer206includes an enclosure structure220and an internal adjustable firmness structure230. InFIG.2A, the enclosure structure220obscures viewing the internal adjustable firmness structure230. InFIG.2Bportions of the enclosure structure220are not shown so as to permit viewing of the internal adjustable firmness structure230.

The enclosure structure220encloses at least a portion of the internal adjustable firmness structure230. For example, the enclosure structure220includes side panels222A,222B,222C, and222D (referred to collectively as side panels222). Here, the side panels222A and222C extend widthwise along the head end108and the foot end110, respectively; and the side panels222B and222D extend lengthwise along the first side112and the second side114, respectively.

The side panels222may be formed from a foam material. The foam material may have a firmness that is similar to the maximum firmness of the internal adjustable firmness structure230to provide a rigid structure along the edges of the adjustable firmness support layer206. The side panels222may be rectangular shaped and may include interlocking cut-outs (or teeth) on adjacent edges so as to fit together and support each other.

Referring now toFIGS.3A and3B, the internal adjustable firmness structure230is illustrated.FIG.3Ais a side view of the internal adjustable firmness structure230, andFIG.3Bis an orthographic projection of the internal adjustable firmness structure230. In this example, the internal adjustable firmness structure230includes a support assembly232, rotatable assemblies234A,234B,234C,234D,234E,234F,234G,234H,234I,234J, and234K (referred to collectively as the rotatable assemblies234), and bridge assembly236. Some implementations may include more or fewer of the rotatable assemblies depending, for example, on the size of the internal adjustable firmness structure230and the size of the rotatable assemblies234.

In some implementations, the rotatable assemblies234are structures made from compressible materials that are configured to be rotated to alter which portions of the rotatable assemblies face upwards (toward the top of the internal adjustable firmness structure230). In this example, the rotatable assemblies234have a cylindrical shape. Each of the rotatable assemblies234may be configured to rotate about its own central axis. In some implementations of the internal adjustable firmness structure230, the rotatable assemblies234are arranged such that the central axes are parallel with each other and oriented along the widthwise (W) dimension of the support assembly232.

Properties of the compressible materials may vary such that the firmness of the internal adjustable firmness structure230varies based on the orientations of the rotatable assemblies234. For example, a first portion of the rotatable assemblies234may have a first ILD and a second portion of the rotatable assemblies234may have a second ILD. Depending on the portions of the rotatable assemblies234that are oriented towards the top side of the mattress, the firmness of the mattress will vary. The rotatable assemblies234ofFIG.3Aare rotated by 90 degrees with respect toFIG.3B.

FIG.4is a schematic diagram of an example rotatable assembly334. The rotatable assembly334is an example of the rotatable assemblies234. The rotatable assembly334includes an axle340and compressible elements342A,342B,342C,342D,342E, and342F (referred to collectively as compressible elements342). In this example, the axle340is an elongate cylindrical structure with a long axis oriented widthwise (W).

The compressible elements342have an orientation-specific firmness. For example, the firmness (with respect to an object placed on top of the compressible elements342) of the compressible elements342may change based on the orientation of the compressible elements342. For example, the compressible elements342may be formed from multiple materials that have different compression properties. Additionally or alternatively, the compressible elements342may be formed from a single material that includes one or more cutouts that alter the compression properties of the compressible elements342. Examples of compressible elements having an orientation-specific firmness are illustrated and discussed with respect to at leastFIGS.9-11.

The compressible elements342share a central axis that is aligned with the long axis of the axle340. The compressible elements342are coupled to the axle340such that the axle340passes through the centers of the compressible elements342. The axle340is coupled to the compressible elements342such that if the axle340is rotated, the compressible elements342will also be rotated. In this manner, rotating the axle340will cause the compressible elements342to rotate and will, in turn, alter their firmness.

In this example, the compressible elements342are cylindrical structures made of a compressible material. Cylindrical compressible elements may also be referred to as compressible disks. The compressible elements342can be described in terms of a thickness (T) and a radius (R). The radius of the compressible elements342refers to the distance from the centers of the compressible elements342to their edges. Although the term radius is used herein, it should be understood that the compressible elements342are not circular in some embodiments. The thickness of the compressible elements342refers to the length of the compressible elements342along their central axes (i.e., in the widthwise (W) dimension). In this example, the compressible elements342are spaced apart from each other along the axle340by a distance equal to (or approximately equal to) the thickness of the compressible elements342. This spacing allows the compressible elements of two adjacent rotatable assemblies to be interleaved, which is illustrated and described further with respect to at leastFIGS.5A and5B.

In some implementations, the spacing between the compressible elements342is slightly larger than the thickness of the compressible elements342to allow a small gap between interleaved disks to reduce or eliminate friction between surfaces of the compressible elements. In some implementations, a thin layer of low-friction material may be coupled to the surfaces of the compressible elements342to reduce friction between the compressible elements342and adjacent compressible elements, the support assembly, or the bridge assembly. The low-friction material may be a sheet of polyethene, polytetrafluoroethylene, or flashspun high-density polyethylene fibers. In some implementations, the compressible elements may be enclosed or partially enclosed in an enclosure formed from a low-friction fabric formed from one or more of nylon, elastane, polyester, silk or artificial silk, viscose fabric or films such as rayon, or combinations thereof. In some implementations, the compressible elements may be dipped or otherwise coated with a low-friction compound. In some implementations, the axle may include air holes to allow passage of air in and out of the compressible elements if the coating is airtight. The compressible elements may also pass through a reservoir of a wet or dry lubricating material.

In some implementations, the axle340is formed from materials having properties that allow the axle340to be torqueable. As used herein, the axle340is torqueable if a rotational force around the long axis applied to an end of the axle340causes the axle340(and the coupled compressible elements342) to rotate by substantially the same magnitude along the length of the axis. In other words, the axle340is formed from materials that substantially resist deformation when a rotational force is applied to an end of the axle340. The axle340may be formed from a rigid material such as a rigid plastic (e.g., polyvinyl chloride (PVC)), wood, metal, or combinations thereof. Beneficially, the torqueable axle will cause the entire axle and the compressible elements342attached thereto to rotate substantially similarly, allowing control of the orientation of the compressible elements342.

In some embodiments, the axle340is both torqueable and compressible. As used herein, the axle340is compressible if it resiliently compresses under a load applied orthogonal to its long axis. In some implementations, the axle340is formed from a rigid foam material.FIG.4Aincludes an axle340A, which is an example of the axle340and includes a braided metal sleeve341A, which may be coated with plastic or another coating material. The braided metal sleeve341A may be hollow or may enclose an axle343A formed from another material such as a foam.

FIGS.5A and5Bare schematic diagrams of a portion of an example internal adjustable firmness structure430. The internal adjustable firmness structure430may be similar to the previously described internal adjustable firmness structure230.

As shown inFIG.5A, the portion of the internal adjustable firmness structure430includes rotatable assemblies434A and434B. As shown inFIG.5B, the portion of the internal adjustable firmness structure430includes rotatable assemblies434A,434B, and434C. The rotatable assemblies434A,434B, and434C may be similar to the rotatable assembly334. The internal adjustable firmness structure430may include additional rotatable assemblies that are not shown inFIGS.5A and5B.

Each of the rotatable assemblies434A,434B, and434C include compressible elements aligned along an axle of the rotatable assemblies. The compressible elements and axle are illustrated and described further with respect to at leastFIG.4. The long axes of the axles of the rotatable assemblies434A,434B, and434C are parallel to each other and spaced apart along the length of the internal adjustable firmness structure430. For example, the rotatable assemblies434may be separated in the lengthwise (L) direction by a space (S) that is approximately equal to the sum of the radius of compressible element (or compressible disk in this example) (RD) and the radius of the axle (RA).

In some implementations, this spacing is maintained by a rigid linkage, such as a thin plastic linkage structure, that spans between two adjacent rotatable assemblies and wraps at least partially around the axles. In some implementations, the spacing may be maintained by one or more cords that includes loops that fit over adjacent axles. The cords may prevent or limit the expansion of the spacing between the axles. An example linkage is illustrated and described further with respect to at leastFIG.17.

As can be seen, the compressible elements of the rotatable assembly434A are offset with respect to the compressible elements of the rotatable assembly434B along the long axis of the axle by approximately the thickness of one compressible disk. This offset allows the compressible elements of the rotatable assembly434A to be interleaved with the compressible elements of the rotatable assembly434B. Similarly, the compressible elements of the rotatable assembly434C are offset with respect to the compressible elements of the rotatable assembly434B along the long axis of the axle by approximately the thickness of one compressible disk. This offset allows the compressible elements of the rotatable assembly434B to be interleaved with the compressible elements of the rotatable assembly434C.

Referring back now toFIGS.3A and3B, the support assembly232is a structure that is configured to support the rotatable assemblies234. In this example, the support assembly232includes support wedges233A,233B,233C,233D, and233E (referred to collectively as support wedges233). Although the support wedges233are shown as separate components in this figure, in some embodiments, some or all of the support wedges are joined as a monolithic structure. For example, the support assembly232may also include a flat layer of foam that is joined to each of the support wedges.

The support wedges233may be formed from a relatively rigid compressible foam. For example, as compared to the rotatable assemblies234and the bridge assembly236, the support wedges233may be formed from a material having a higher ILD (i.e., a material that deflects/compresses less under the same force).

FIG.6Ais a schematic drawing of an example support wedge633. The support wedge633is an example of the support wedges233. The support wedge633includes axle support region650, compressible element support regions652A and652B, and bottom surface654. The axle support region650is configured to contact and support an axle of a rotatable assembly. By supporting the axle, the support wedge633reduces the amount of force that is transferred from a top portion of the compressible element to a bottom portion of the compressible element. In this manner, the material properties (e.g., the ILD) of the bottom portion of the compressible element have less impact on the overall firmness than the material properties of the top portion.

The compressible element support regions652A and652B are configured to contact and support the bottom portions of compressible elements of rotatable assemblies that are adjacent to the rotatable element being supported by the axle support region650. The shapes of the compressible element support regions652A and652B are negatives (or inverses) of the shape of a side of the bottom portion of a compressible element. In this example, the compressible element would be disk shaped and accordingly, the compressible element support regions652A and652B have an arch-shape corresponding to a quarter of a circle.

FIG.6Bis a schematic drawing that illustrates a compressible element642disposed on an axle640that is being supported by support wedges633A and633B. The axle640may be similar to the previously described axle340and the compressible element642may be similar to the previously described compressible elements342.

Forces that are applied to the top of the compressible element642will primarily either cause a compression of the top portion of the compressible element642(i.e., the portion of the compressible element642above the axle640) or be transferred to the axle640. The portion of the force transferred to the axle640will result in compression of the support wedges633A and633B. Depending on the amount of force transferred to the support wedges633A and633B and the consequent amount of compression experienced by the support wedges633A and633B, a portion of the force may also result in some compression of the bottom portion of the compressible element642(i.e., the portion below the axle640). In at least some embodiments, because the support wedges633A and633B are more rigid material than the compressible element642, a minority of the force transferred to the axle640results in compression of the bottom portion of the compressible element.

In some implementations, the support wedges are formed from a material that is no more rigid than the materials in the compressible elements. In some implementations, the support wedges are formed from a material that has similar compressibility as the most compressible material in the compressible elements. In these implementations, the support wedges may not divert force from the lower portions of the compressible elements. This arrangement may be beneficial when opposites sides of the compressible elements have similar properties (e.g., when the compressible element is formed with quadrants having different properties as discussed with respect to at leastFIGS.111and11J). Beneficially, in at least some of these embodiments, the axles of the rotatable assemblies are allowed to move and sink into the support assembly, reducing the likelihood that a reclining individual will feel the axles.

Referring back now toFIGS.3A and3B, the bridge assembly236is a structure that is configured to fit over the rotatable assemblies234. and conform to the shape of the rotatable assemblies234. The bridge assembly236may, for example, fill in the top surface of the rotatable assemblies234so as to form a substantially flat surface. In this example, the bridge assembly236includes bridge wedges237A,237B,237C,237D, and237E (referred to collectively as bridge wedges237). Although the bridge wedges237are shown as separate components in this figure, in some embodiments, some or all of the bridge wedges are joined as a monolithic structure. For example, the bridge assembly236may also include a flat layer of foam that is joined to each of the bridge wedges. In some implementations, the bridge assembly may be formed from a foam material that is more compressible (i.e., having a lower ILD) than the support assembly or the compressible element.

FIG.7Ais a schematic drawing of an example bridge wedge737A. The bridge wedge737A is an example of the bridge wedges237. The bridge wedge737A includes axle contact region760, compressible element contact regions762A and762B, and top surface764. The top surface764is a flat surface. In some embodiments, the top surface764is configured to contact the bottom side of the transition layer104or the comfort layer102.

The axle contact region760is configured to contact an axle of a rotatable assembly, and the compressible element contact regions762A and762B are configured to contact an upper surface of adjacent compressible elements. As force is applied to the top surface764that force, in part, compresses the bridge wedge737A and, in part, is transferred to the axle and the adjacent compressible elements via the axle contact region760and the compressible element contact regions762A and762B, respectively. In some implementations, because the compressible element contact regions762A and762B are larger than the axle contact region760, a majority of the transferred force is transferred to the adjacent compressible elements rather than to the axle. For example, the force may be transferred to the top portions of the adjacent compressible elements. Beneficially, this transfer of force to the compressible elements may allow the material properties (e.g., the ILD) of the top portions of the adjacent compressible elements to have a greater effect on the overall firmness of the adjustable firmness support layer than the axle.

FIG.7Bis a schematic drawing of an example bridge wedge737B. Also shown are an axle740and compressible elements742A and742B. The axle740may be similar to the previously described axle340and the compressible elements742A and742B may be similar to the previously described compressible elements342.

The bridge wedge737B is an example of the bridge wedges237. The bridge wedge737B includes a bottom surface766, compressible element contact regions768A and768B, and the top surface764. The bridge wedge737B may be similar to the bridge wedge737A except that the bridge wedge737B is not configured to contact the axle740. Instead, the bridge wedge737B includes a bottom surface766that is substantially flat. The bridge wedge737B is configured to be supported by the compressible elements742A and742B via the compressible element contact regions768A and768B, so as to provide a gap (G) between the bottom surface766and the axle740. The compressible element contact regions768A and768B may be similar to the compressible element contact regions762A and762B except that the compressible element contact regions768A and768B do not extend as far toward the axle740.

The gap provided by the bridge wedge737B may cause more of any force applied to the top surface764to be transferred to the adjacent compressible elements742A and742B than to the axle740. In fact, until the compressible elements742A and742B have compressed by an amount sufficient to close the gap between the bottom surface766and the axle740, no force will be transferred to the axle740by the bridge wedge737B.

FIG.8is a schematic diagram of an exploded view of a portion of an example adjustable firmness layer806. Also shown is an example transition layer804. The adjustable firmness layer806is an example of the adjustable firmness layer106and the transition layer804is an example of the transition layer104.

In this figure, the adjustable firmness layer106includes a support assembly832, a bridge assembly836, rotatable assemblies834A,834B,834C,834D, and834E (referred to collectively as the rotatable assemblies834), and side panels822A,822B,822C, and822D.

The rotatable assemblies834may be similar to the previously described rotatable assemblies434. Each of the rotatable assemblies834includes multiple compressible elements. The compressible elements of adjacent rotatable elements are offset from and interleaved with each other.

As can be seen, the support assembly832is a monolithic unit that includes multiple support wedges arranged in offset rows that are interleaved to support the axles of the rotatable assemblies834between the compressible elements. Similarly, the bridge assembly836includes multiple bridge wedges arranged in offset rows that are interleaved to fit against the compressible elements of the rotatable assemblies834.

The side panels822A,822B,822C, and822D may be similar to the previously described side panels222A,222B,222C, and222D, respectively. In this example, the side panels822B and822D and include apertures through which the axles of the rotatable assemblies834may pass. The apertures allow access through the side panels to the axles so that the rotatable assemblies may be rotated by applying a rotational force to the axles. Examples of the side panels and apertures are further described and illustrated with respect to at leastFIGS.12-15.

In some implementations, the axles of the rotatable assemblies are formed from two separate rods that are pivotably coupled at a midpoint widthwise, allowing each side of the axle to rotate about its long axis independently so as to allow independent adjustment of the firmness of each side of the rotatable assemblies (e.g., to accommodate two people with different firmness preferences).

In some implementations, the bridge assembly may include one or more of a gel layer or a microbead layer. These layers may fill gaps between the rotatable assemblies834to reduce any feeling of lumpiness that may be caused by the shapes of the rotatable assemblies834.

FIG.9is a schematic diagram of an example compressible element942. The compressible element942is an example of the compressible elements342. The compressible element942may be a component of a rotatable assembly.

In this example, the compressible element942has a cylindrical shape with a first portion970A and a second portion970B. The first portion970A may have different material properties than the second portion970B. For example, the first portion970A may be formed from a foam having a higher ILD than a foam that forms the second portion970B. The difference in ILD of the materials in the first portion970A and970B may allow for a different perceived firmness depending on the orientation of the compressible element.

The compressible element942also includes a mounting aperture972through which an axle of a rotatable assembly may pass and the compressible element942may be coupled to the axle. In some implementations, the compressible element942is coupled to the axle via adhesive, friction, or a combination thereof.

FIGS.10A and10Bare schematic diagrams of an example compressible element1042that includes a coupling element1074.FIG.10Ais an exploded view of the compressible element1042andFIG.10Bis a view of the compressible element1042coupled to an axle1040.

The compressible element1042is an example of the compressible elements342. The compressible element1042may be similar to the compressible element942except that the compressible element1042includes a coupling element1074that is configured to couple to an axle1040. The compressible element1042also includes the first portion970A and the second portion970B, which have been previously described.

The coupling element1074may be star shaped. In this example, the coupling element is shaped like a 6-point star. In other embodiments, the coupling element may have a star shape with more or fewer points. The star shape of the coupling element may fit into an aperture1076in the first portion970A and second portion970B of the compressible element1042that has a corresponding shape. The fit of the star shape into the aperture may serve to couple the coupling element1074to the first portion970A and second portion970B. Additionally, the surface area of the coupling element1074may provide a larger area upon which to apply adhesive to further couple the coupling element1074to the first portion970A and second portion970B.

In some embodiments, the coupling element1074is formed from a more rigid material than the rest of the compressible element1042. For example, the coupling element1074may be formed from a rubber material. The more rigid material of the coupling element1074may be more readily coupled to the axle1040than the more compressible material of the rest of the compressible element942. The coupling element1074may be coupled to the axle1040using one or more of adhesive, friction, or a mechanical fastener, such as a pin or a screw. In some embodiments, the coupling element1074may be formed from a material other than rubber, such as wood or foam.

Although the coupling element1074may be more rigid than the first portion970A and the second portion970B, the coupling element1074may also be flexible. For example, when made from rubber, the points of the star shape may remain flexible so as to not be felt by a body reclining on the mattress.

FIGS.11A-Hare schematic diagrams of example compressible elements. Although not shown in each of these figures, each of the illustrated compressible elements may include an aperture and may be combined with a coupling element similar to the previously described coupling element1074. In these examples, each of the compressible elements have a cylindrical shape. As these compressible elements are rotated, different portions of the underlying materials are oriented upward altering the firmness of the corresponding region of a mattress.

FIG.11Aillustrates a compressible element1142A that has a first portion having a crescent shape and a second portion corresponding to the remainder of the cylinder. The first portion and the second portion may be formed from different materials that have different properties, such as foams that have different ILD values.

FIG.11Billustrates a compressible element1142B that has a first portion having a tear-drop shape and a second portion having an opposite tear-drop shape. Together, the first portion and the second portion form a circle and the interface between the first portion and the second portion forms a curve like that dividing the yin-yang symbol. The first portion and the second portion may be formed from different materials that have different properties, such as foams that have different ILD values.

FIG.11Cillustrates a compressible element1142C that has a first portion having a circle shape and extending from a point on the edge toward the center of the compressible element1142C. The compressible element1142C also has a second portion having a circle shape and extending from an opposite point on the edge toward the center of the compressible element1142C. In some implementations, the first and second portions extend to the center of the compressible element. The compressible element1142C also includes a third portion and fourth portion. The third and fourth portions correspond to the remainders of the cylindrical region. In some implementations, the first portion, the second portion, the third portion, and the fourth portion are each formed from different materials that have different properties, such as foams that have different ILD values. In some implementations, the third and fourth portions are formed from the same material. In implementations in which the first and second portions do not extend to the center of the compressible element1142C, the third and fourth portions may be a single monolithic portion.

FIG.11Dillustrates a compressible element1142D that has been divided into a plurality of approximately equal triangle-like slices of the cylinder. In this example, the compressible element1142D includes seven equal-sized (or approximately equal sized) portions. In some implementations, more or fewer portions are included. In this example, the portions have an approximately triangular shape with slightly curved edges. In some implementations, the portions are each formed from different materials that have different properties, such as foams that have different ILD values.

FIG.11Eillustrates a compressible element1142E that has been divided into three portions by straight parallel lines. In some implementations, the portions are each formed from different materials that have different properties, such as foams that have different ILD values. For example, the middle portion may be formed of a more rigid foam than the outside portions so as to better facilitate transfer of force to an axle running through the middle portion. The firmness of the corresponding portion of the mattress may then be based on the properties of the outside portion of the compressible element1142E that is facing up.

FIG.11Fillustrates a compressible element1142F that has a first portion having a heart shape and a second portion corresponding to the remainder of the cylinder. The first portion and the second portion may be formed from different materials that have different properties, such as foams that have different ILD values.

FIG.11Gillustrates a compressible element1142G that has a first portion and second portion that are separated by a curved, spikey border. The border may allow a smoother change in overall firmness as the orientation of the compressible element1142G is rotated. The first portion and the second portion may be formed from different materials that have different properties, such as foams that have different ILD values.

FIG.11Hillustrates a compressible element1142H that has a first portion and second portion. The first portion is ring-shaped and surrounds the outside edge of the compressible element1142H. The second portion is elliptical shaped and positioned within the first portion. In some implementations, the space between the first portion and the second portion is left empty. The first portion and the second portion may be formed from different materials that have different properties, such as foams that have different ILD values. In some implementations, the first portion and the second portion are formed from the same material.

In some implementations, the space between the first portion and the second portion may be filled with a third portion and a fourth portion. Each of the first portion, second portion, third portion, and fourth portion may be formed from different materials. In some implementations, the first portion and the second portion are formed from a first material and the third portion and the fourth portion are formed from a second material. The first material may have a higher ILD than the second material.

FIGS.11I-11Nillustrate compressible elements that have regions with apertures to allow for additional or different compression properties. InFIGS.11I and11l, the compressible elements11421and1142J are divided into quadrants. The quadrants may correspond to partial circles, each having an arc length of 90 degrees. In this example, two of the quadrants include a grid of apertures, the other quadrants do not include apertures. Here, a quadrant will have different compressibility properties than the other adjacent quadrants but similar properties to the opposite quadrant.

In some implementations, this arrangement of quadrants may allow for different compressibility based on which quadrant is oriented upward. For example, if a quadrant with apertures is oriented upward, a compression force applied to the top of the compressible elements will compress the apertures allowing for more overall compression of the compressible element than when a quadrant without apertures is oriented upward. Other implementations may also include quadrants with other patterns of apertures or materials that cause adjacent. For example, a quadrant may be formed using two different materials that have different compression properties such that each quadrant is made from the same material as the opposite quadrant and a different material than the adjacent quadrants.

In some implementations, the support assembly (which is further described in at leastFIGS.3,6A &6B) is formed from a material that is similar in compressibility to the more compressible quadrants. This arrangement may allow both the upward and downward facing quadrants to compress under load. In some implementations, compressible elements with opposite pairs of quadrants having substantially the same compressibility are formed using two different types of material, such as two types of foam with different ILD values.

InFIGS.11K-M, the compressible elements1142K,1142L, and1142M are shown with various horn-shaped regions of apertures. The horn-shaped regions may allow for smooth (gradual) transitions in changes of compressibility as the compressible elements' orientations change.FIG.11Nincludes a compressible element1142N that includes a grid of apertures on one half (semi-circle) and no apertures on the other half (semi-circle). The compressible element1142N may function in a manner similar to the compressible element942in which two separate types of material were used on each half.

In some implementations, the compressible elements are formed using a rapid fabrication technology, such as 3D printing. For example, a compressible element may be formed with a mesh-like pattern having various regions with different densities. The mesh-like pattern may include mesostructured cellular patterns. In some implementations, the compressible element may be treated after fabrication with a compound to reduce surface imperfections and reduce friction. For example, the compressible element may be treated using an acetone bath to reduce friction.

In some implementations, the compressible elements may be formed from filled bladders, such as rubber bladders filled with one or more fluids (e.g., liquids or gasses). The bladders may be permanently sealed such that they are not adjustable. The bladders may, for example, have any of the shapes described inFIGS.11I-N.

FIG.12is a schematic diagram of an example side panel1222. The side panel1222is an example of the side panels222B and222D. The side panel1222may be formed from a foam material. The side panel1222includes apertures1280A,1280B,1280C,1280D,1280E,1280F,1280G,1280H,1280I,1280J,1280K, and1280L (referred to collectively as apertures1280). Some implementations include more or fewer apertures.

The apertures1280permit axles of rotatable assemblies to pass through the side panel1222. These axles may then be rotated to adjust the firmness of the rotatable assemblies. In some implementations, the apertures1280allow adjustment of the rotation of the rotatable assemblies without removing the side panel1222.

As noted previously, the entire adjustable firmness mattress100may be enclosed in a fabric cover. The fabric cover may include an opening through which the apertures1280may be accessed. The opening may include buttons, snaps, a zipper, or another means for securing the opening in a closed position.

FIG.13is a schematic diagram of a portion of an example side panel1322with an example axle1340. The side panel1322is an example of the side panels222B and222D. The side panel1322may be similar to the side panel1222. The side panel1322includes an aperture1380.

In this figure, an end of an axle1340is passing through the aperture1380. The end of the axle1340includes a keyed receiver1346. The keyed receiver1346is configured to receive an adjustment tool, such as a wrench, with a corresponding insert. The adjustment tool can then be used to rotate the axle1340(and the corresponding rotatable assembly). In this example, the keyed receiver1346has a hexagonal shape with a notch. The notch in the keyed receiver limits the orientation of the adjustment tool when it is inserted into the keyed receiver1346. The indicator1348points to a portion of a marker1382of the side panel1322that corresponds to the current firmness level of the rotatable assembly associated with the axle1340. In some implementations, the keyed receiver1346causes a handle of the adjustment tool to point in the same direction as the indicator1348so as to serve as a proxy for the indicator while adjustments are being made. In this example, the marker1382represents different firmness levels with numeric scores. In some implementations, the marker1382may include different indicators of firmness levels, such as colors.

In some implementations, the keyed receiver1346is coupled to the axle1340with a torque limiter. The torque limiter may limit the amount of torque transmitted from the keyed receiver1346to the axle1340. Beneficially, the torque limiter may prevent delivering a rotational force that exceeds the bond strength between the axle and the compressible elements, potentially damaging a rotatable assembly.

FIG.14is a schematic diagram of a portion of an example side panel1422and example axles1440A,1440B,1440C, and1440D. The side panel1422is an example of the side panels222B and222D. The side panel1422may be similar to the side panel1322. The side panel1422includes apertures1480A,1480B,1480C, and1480D.

In this figure, ends of the axles1440A,1440B,1440C, and1440D are passing through the apertures1480A,1480B,1480C, and1480D. The axles1440A,1440B,1440C, and1440D may be similar to the previously described axle1340.

In this example, the ends of the axles1440A,1440B,1440C, and1440D include keyed receivers1446A,1446B,1446C, and1446D with indicators1448A,1448B,1448C, and1448D, respectively, that point to values on markers1482A,1482B,1482C, and1482D. The sequential values of the indicators1448A,1448B,1448C, and1448D may represent the state of the adjustable firmness support layer106(which may be referred to as a personal firmness sequence). The personal firmness sequence may, for example, specify different firmness values for an individual's legs, hips, torso, shoulders, and head. The personal firmness sequence may be more or less granular depending on the number of individually controllable rotatable assemblies included in the implementation.

In some implementations, individuals may determine and record their personal firmness sequences. In some implementations, a software application may help an individual determine their personal firmness sequence. For example, the software application may prompt the user for various information such as their height, weight, age, gender, preferred sleeping position (e.g., side, back, stomach), and injuries or pressure points. This information may then be used to determine appropriate firmness levels for the individual along the length of the mattress and a corresponding personal firmness sequence.

In some implementations, an array of pressure sensors may be used to determine a personal firmness sequence. The array of pressure sensors may be embedded within a layer of the mattress, such as the comfort layer102or the transition layer104. The sensors may record pressure at various positions on the mattress when an individual is reclining on the mattress. Based on those measurements (and in some implementations the previously discussed information provided by the individual), a personal firmness sequence may be determined.

FIG.15is a schematic diagram of the example side panel1422and an example adjustment tool1590. The adjustment tool1590may be similar to a wrench and may have a first end with an insert that is shaped to fit into a keyed receiver of an axle and a second end with a handle (or grip). The length of the adjustment tool1590may provide leverage for the user to amplify the amount of force applied to an axle. In some implementations, a fabric cover of the adjustable firmness mattress100may include a pocket to hold the adjustment tool1590.

FIGS.16A and16Bare schematic diagrams of an example internal adjustable firmness structure1630and an example adjustment tool1690.FIG.16Ais a side view of the internal adjustable firmness structure1630andFIG.16Bis an orthographic projection view of the internal adjustable firmness structure1630.

The example internal adjustable firmness structure1630may be similar to the previously described internal adjustable firmness structure230, and the adjustment tool1690is an example of the adjustment tool1590. Here, the adjustment tool1690is attached to a keyed receiver of an axle of a rotatable assembly1634of the internal adjustable firmness structure1630. The adjustment tool1690includes a handle that sticks out in a direction parallel to the axle of the rotatable assembly1634, which may make it easier for an individual to grab and use to rotate the rotatable assembly1634.

FIG.17is a schematic diagram of a portion of an example internal adjustable firmness structure1730that includes linkage structures1792A and1792B. The internal adjustable firmness structure1730may be similar to the previously described internal adjustable firmness structure430.

As shown inFIG.17, the portion of the internal adjustable firmness structure1730includes rotatable assemblies1734A,1734B,1734C,1734D, and1734E (referred to collectively as rotatable assemblies1734). The rotatable assemblies1734may be similar to the rotatable assembly334. The internal adjustable firmness structure1730may include additional rotatable assemblies that are not shown inFIG.16.

In this example, adjacent rotatable assemblies are coupled together by linkage structures. Here, the linkage structure1792A couples the rotatable assemblies1734A and1734B; and the linkage structure1792B couples the rotatable assemblies1734C and1734D. Although not shown in this figure, some implementations include additional linkage structures that couple other of the rotatable assemblies. The linkage structures1792A and1792B may include loops or other structures that may at least partially surround the axles of the rotatable assemblies and an elongate member that joins the loops. In some implementations, the linkage structures include additional loops and elongate members and are coupled to more than two rotatable assemblies. The linkage structures1792A and1792B may be formed from a material such as plastic or rubber. The linkage structures1792A and1792B prevent adjacent rotatable assemblies from moving apart from one another. For example, the linkage structures1792A and1792B may maintain a spacing (S) between adjacent rotatable assemblies.

FIG.18illustrates an example motor-controlled adjustable firmness mattress system1800. The motor-controlled adjustable firmness mattress system1800includes an adjustable firmness mattress1801, a foundation1810, a transmission assembly1820, a sensor assembly1830, and a computing device1840. The adjustable firmness mattress1801may be similar to the adjustable firmness mattress100.

The foundation1810is a physical platform that supports the adjustable firmness mattress1801at a desired height. In some implementations, the foundation1810may include a box spring or another type of support for the adjustable firmness mattress1801. In this example, the foundation1810includes a control system1812and a motor assembly1814.

The transmission assembly1820is a device that transmits power from the motor assembly1814to one or more rotatable assemblies of the adjustable firmness mattress1801. For example, the transmission assembly1820may include one or more pulleys. The pulleys may be individually controlled and may wrap around axles of the rotatable assemblies to deliver power from the motor assembly1814to rotate the rotatable assemblies.

The control system1812may include a computing device that can send control signals to activate or deactivate the motor assembly1814to adjust the rotatable assemblies. The control system1812may also communicate with the sensor assembly1830to receive various measurements, such as pressure measurements. Based on the received measurements, the control system1812may determine adjustments to make to the rotatable assemblies of the adjustable firmness mattress1801. In some implementations, the control system1812does not activate the motor assembly1814for specific rotatable assemblies if pressure measurements associated with the rotatable assembly exceed a threshold level (e.g., to prevent damage to the motor assembly1814, transmission assembly1820, or rotatable assemblies caused by operating when an individual is reclining on the adjustable firmness mattress1801).

The sensor assembly1830may include, for example, an array of pressure sensors. In some implementations, the sensor assembly1830may also include other types of sensors such as temperature sensors. For example, the sensor assembly1830may also include rotational or positional sensors associated with one or more of the rotatable assemblies to determine the actual orientation of those rotatable assemblies. The rotational or positional sensors may, for example, include magnets and magnetic sensors or accelerometers or other components to determine position or orientation. Based on measurements from the rotational or positional sensors, the control system1812may activate or deactivate the motor assembly1814to alter the orientation of one or more of the rotatable assemblies. The sensor assembly1830may communicate with the control system1812, the computing device1840, or both.

The computing device1840can be any type of computing device including a mobile computing device, such as a smartphone or smartwatch. The computing device1840may include memory that stores instructions for an application that, when executed by a processor of the computing device1840, can communicate with the control system1812over a network. The application may send instructions to the control system1812that cause the control system1812to activate the motor assembly1814to rotate one or more of the rotatable assemblies of the adjustable firmness mattress1801.

The application may also cause the computing device1840to generate and output a user interface through which an individual may input instructions to adjust the rotatable assemblies.

Although not shown in this figure, some embodiments of the foundation1810include additional components such as a heating system or cooling system that may be controlled by one or both of the control system1812or the computing device1840.

Although the foundation1810is shown as a flat foundation here, in some implementations the foundation1810is an adjustable bed foundation that allows repositioning of one or more regions of the adjustable firmness mattress1801(e.g., raising the head or feet ends of the adjustable firmness mattress1801).

FIG.19illustrates an example architecture of a computing device1950that can be used to implement aspects of the present disclosure, including any of the plurality of computing devices described herein, such as the computing device1840, a computing device of the control system1812, or any other computing devices that may be utilized in the various possible embodiments.

The computing device illustrated inFIG.19can be used to execute the operating system, application programs, and software modules described herein.

The computing device1950includes, in some embodiments, at least one processing device1960, such as a central processing unit (CPU). A variety of processing devices are available from a variety of manufacturers, for example, Intel or Advanced Micro Devices. In this example, the computing device1950also includes a system memory1962, and a system bus1964that couples various system components including the system memory1962to the processing device1960. The system bus1964is one of any number of types of bus structures including a memory bus, or memory controller; a peripheral bus; and a local bus using any of a variety of bus architectures.

Examples of computing devices suitable for the computing device1950include a desktop computer, a laptop computer, a tablet computer, a mobile computing device (such as a smartphone, an iPod® or iPad® mobile digital device, or other mobile devices), or other devices configured to process digital instructions.

The system memory1962includes read only memory1966and random access memory1968. A basic input/output system1970containing the basic routines that act to transfer information within computing device1950, such as during start up, is typically stored in the read only memory1966.

The computing device1950also includes a secondary storage device1972in some embodiments, such as a hard disk drive, for storing digital data. The secondary storage device1972is connected to the system bus1964by a secondary storage interface1974. The secondary storage devices1972and their associated computer readable media provide nonvolatile storage of computer readable instructions (including application programs and program modules), data structures, and other data for the computing device1950.

Although the example environment described herein employs a hard disk drive as a secondary storage device, other types of computer readable storage media are used in other embodiments. Examples of these other types of computer readable storage media include magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, compact disc read only memories, digital versatile disk read only memories, random access memories, or read only memories. Some embodiments include non-transitory computer-readable media. Additionally, such computer readable storage media can include local storage or cloud-based storage.

A number of program modules can be stored in secondary storage device1972or system memory1962, including an operating system1976, one or more application programs1978, other program modules1980(such as the software engines described herein), and program data1982. The computing device1950can utilize any suitable operating system, such as Microsoft Windows™, Google Chrome™ OS or Android, Apple OS, Unix, or Linux and variants and any other operating system suitable for a computing device. Other examples can include Microsoft, Google, or Apple operating systems, or any other suitable operating system used in tablet computing devices.

In some embodiments, a user provides inputs to the computing device1950through one or more input devices1984. Examples of input devices1984include a keyboard1986, mouse1988, microphone1990, and touch sensor1992(such as a touchpad or touch sensitive display). Other embodiments include other input devices1984. The input devices are often connected to the processing device1960through an input/output interface1994that is coupled to the system bus1964. These input devices1984can be connected by any number of input/output interfaces, such as a parallel port, serial port, game port, or a universal serial bus. Wireless communication between input devices and the interface1994is possible as well, and includes infrared, BLUETOOTH® wireless technology, 802.11a/b/g/n, cellular, ultra-wideband (UWB), ZigBee, or other radio frequency communication systems in some possible embodiments.

In this example embodiment, a display device1996, such as a monitor, liquid crystal display device, projector, or touch sensitive display device, is also connected to the system bus1964via an interface, such as a video adapter1998. In addition to the display device1996, the computing device1950can include various other peripheral devices (not shown), such as speakers or a printer.

When used in a local area networking environment or a wide area networking environment (such as the Internet), the computing device1950is typically connected to the network through a network interface2000, such as an Ethernet interface or WiFi interface. Other possible embodiments use other communication devices. For example, some embodiments of the computing device1950include a modem for communicating across the network.

The computing device1950typically includes at least some form of computer readable media. Computer readable media includes any available media that can be accessed by the computing device1950. By way of example, computer readable media include computer readable storage media and computer readable communication media.

Computer readable storage media includes volatile and nonvolatile, removable and non-removable media implemented in any device configured to store information such as computer readable instructions, data structures, program modules or other data. Computer readable storage media includes, but is not limited to, random access memory, read only memory, electrically erasable programmable read only memory, flash memory or other memory technology, compact disc read only memory, digital versatile disks or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and that can be accessed by the computing device1950.

Computer readable communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” refers to a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, computer readable communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, radio frequency, infrared, and other wireless media. Combinations of any of the above are also included within the scope of computer readable media.

The computing device illustrated inFIG.19is also an example of programmable electronics, which may include one or more such computing devices, and when multiple computing devices are included, such computing devices can be coupled together with a suitable data communication network so as to collectively perform the various functions, methods, or operations disclosed herein.

Although this disclosure has primarily focused on rotatable assemblies that are oriented to rotate about a widthwise axis, other implementations are possible. For example, the rotatable assemblies may be oriented to rotate about a lengthwise axis. Rotatable assemblies that are oriented to rotate about a lengthwise axis, for example, may allow for individual adjustment of firmness for two individuals who share a mattress.

Embodiments are possible in which the rotatable assemblies are oriented in any direction that is orthogonal to the depth (top-to-bottom) direction of the mattress. Embodiments are possible that include multiple layers of rotatable assemblies, in which the rotatable assemblies in one layer are oriented to rotate about a lengthwise axis and the rotatable assemblies of another layer are oriented to rotate about a widthwise axis.

In some implementations, an adjustable firmness layer includes regions of constant firmness and regions of adjustable firmness. For example, the adjustable firmness layer may include rotatable assemblies that are oriented to rotate about widthwise axes and are disposed in a middle portion lengthwise of the adjustable firmness region (e.g., the region that would likely be supporting the hips and torso of a reclining individual).

Some implementations include rotatable assemblies that include a single compressible element that spans the entire (or substantially entire) width of the mattress. In these embodiments, the rotatable assemblies are not interleaved.

Some implementations include rotatable assemblies that have different cross-sectional shapes. As previously described, the rotatable assemblies may have circular cross-sections. The rotatable assemblies may also have a cross-section with a non-circular, constant width shape, such as a Reuleaux triangle.

The rotatable assemblies may also have square cross-sections. Beneficially, rotatable assemblies with square cross-sections may abut one another with little to no gap (e.g., to reduce any feel of unevenness or lumpiness). The rotatable assemblies may be re-oriented by lifting the rotatable assembly out of the adjustable firmness layer, rotating it, and placing it back in the adjustable firmness layer. In these implementations, the transition layer may be removable so as to provide access to the rotatable assemblies. The sides of the rotatable assemblies may be color coded based on the provided level of firmness.

In some implementations, the rotatable assemblies include spherical compressible elements. The rotatable assemblies may be mounted on axles that rotate the orientation of the spheres. In some implementations, the spheres are arranged in a grid in which adjacent spheres are offset in both the lengthwise and widthwise directions. For example, the spheres may be arranged such that their edges touch or nearly touch along a diagonal direction. Some implementations include a first set of axles oriented to rotate about a widthwise direction and a second set of axles oriented to rotate about a lengthwise direction. These axles may be arranged such that the rows of spheres alternate between rotating about a lengthwise axis and about a widthwise axis.

In some implementations, the rotatable assemblies may include sheets of compressible material which are wrapped around the axle of the rotatable assemblies (e.g., like a spool). For example, one end of a sheet of material may be fixedly attached to an axle of the rotatable assembly and the other end may be fixed elsewhere. As the rotatable assembly is rotated, the material may be pulled tighter around the axle causing compression of the material and increasing the firmness of the rotatable assembly. As another example, one end of a sheet of material may be fixedly attached to an axle of the rotatable assembly and the other end of the material may be wrapped around another axle disposed in a substructure or elsewhere. In some implementations, the end of the material not attached to the rotatable assembly may be free (i.e., unattached). As the rotatable assembly is rotated, more or less (depending on the direction of rotation) of the material is wrapped around the axle of the rotatable assembly altering the firmness of the rotatable assembly.

In some implementations, the transition layer or comfort layer may be replaceable to alter the firmness, feel, or function of the mattress. For example, a fabric cover may include a zipper that allows access to the comfort layer or transition layer. These layers may then be removed and replaced. For example, a replacement transition layer may include sensors to evaluate pressure, sleep patterns, heart rate, temperature, or breathing.

Various techniques may be used to manufacture the components described herein. In some implementations, a mold is used to form one or more of the bridge assembly or support assembly. A liquified foam material may be poured into the mold and allowed to cure into the shape of the bridge assembly or support assembly. Different molds may be used for different size mattresses.

Likewise, the compressible elements may be formed in a mold. In some implementations, an axle is placed in the mold before the liquid foam material is poured into the mold. The compressible elements may then form around the axle to couple the compressible elements to the axle. The axle may include shapes or cutouts in which the foam material may further bond. In some implementations, the mold may include structures to create apertures in regions of the compressible elements. These structures may, for example, include hollow tubes (e.g., PVC rods) that are positioned within the mold. The mold may include various alignment components to control the position of these structures (and the apertures formed thereby).

Although the examples in this disclosure primarily relate to a mattress, the technology described herein may also be included in other structures to provide for adjustable firmness. For example, chairs, including office chars, couches and other furniture, car seats, pillows, and cushions may include similar technologies.

The various embodiments described above are provided by way of illustration only and should not be construed to limit the disclosure. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of this disclosure.