FIELD OF THE INVENTION

[0001 j The present invention relates to mattresses, and more particularly to mattress and foundation assemblies.

BACKGROUND OF THE INVENTION

[0002] Conventional mattresses can be found in a wide variety of shapes and sizes.

Many mattresses are constructed entirely or partially out of foam material. For example, poiyurethane foam is commonly used in many mattresses, pillows, and cushions, and can be used alone or in combination with other types of cushion materials. In some mattresses, viscoelastic material is used, providing the mattress with an increased ability to conform to a user and to distribute the weight of the user.

[0003] Mattresses are typically supported by foundations (e.g., frames, box-springs, etc.), relying on the weight of the mattress and the resultant friction between the mattress and the foundation to prevent the mattress from moving relative to the foundation. However, after a period of normal use, mattresses may slip relative to their foundations and require repositioning. This problem may be exacerbated in the case of an adjustable foundation.

[0004] Based at least in part upon the limitations of existing mattresses and the high consumer demand for improved mattresses in a wide variety of applications, new mattresses are welcome additions to the art.

SUMMARY OF THE INVENTION jOOOSj The invention provides, in one aspect, a mattress assembly including a foundation that defines first and second axes oriented along the length and the width of the foundation, respectively. The mattress assembly further includes a mattress supported atop the foundation and means for securing the mattress to the foundation to inhibit sliding movement of the mattress relative to the foundation along at least one of the first and second axes.

[0006] Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompany ing drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Fig, 1 is a perspective view of a mattress assembly according to an embodiment the invention.

10008] Fig. 2 is an enlarged view of a latch of the mattress assembly of Fig. 1.

[0009] Fig. 3 is a perspective view of a mattress assembly according to another embodiment of the invention.

[0010] Fig. 4 is a cross-sectional view of a magnet of the mattress assembly of Fig. 3.

[0011] Fig, 5 is a partial perspective view of a mattress assembly according to yet another embodiment of the Invention.

[0012] Fig. 6 is a partial to view of a securing assembly of the mattress assembly of

Fig. 5.

[0013] Fig. 7 is a cross-sectional view of a pocket of the securing assembly of Fig. 6

[0014] Fig. 8 is a side view of a projection of the securing assembly of Fig. 6.

[0015] Fig. 9 is a cross-sectional view of a mattress assembly according to a further embodiment of the invention.

[0016] Fig. 10 is a top view of a foundation of the mattress assembly of Fig. 9,

[0017] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

[0018] Fig. 1 illustrates a mattress assembly 108 according to one embodiment of the invention including a mattress 1 10 and a foundation 1 1 3. The foundation 1 1 1 defines first and second orthogonal axes 1 16, 118 oriented along the length and the width of the foundation 111, respectively. The mattress 110 illustrated in Fig. 3 includes a top surface 1 Ϊ 2 positioned to support a user and a bottom surface 114 that rests directly upon the foundation 111. The foundation 3 1 1 may include a frame, support, box-spring, or other structure suitable for supporting the weight of the mattress 110 and user(s) thereon. The mattress 1 10 may include one or more layers of foam material, although one or more layers of other material may be used instead or in addition to the foam layers, if desired. The material comprising one or more of the foam layers may include, for example, viscoelastic or non- viscoelastic foam, latex foam, any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. In the illustrated embodiment of Fig. 1 , the mattress 1 10 has only a single viscoelastic foam layer, and the top and bottom surfaces 1 12, 114 of the mattress 1 10 are substantially planar. Alternatively, multiple viscoelastic or non- viscoelastic foam layers may be used, and either or both of the top and bottom surfaces 1 12, 1 14 may include one or more convolutions or other non-planar shapes, |001 { With continued reference to Fig. 1, the viscoelastic foam in the mattress 110 includes a cellular structure in which the wails of the individual cells are substantially intact (i.e. non-reticulated viscoelastic foam). In other embodiments, the viscoelastic foam may be reticulated. Reticulated viscoelastic foam has characteristics that are well suited for use in the mattress 1 10, including an enhanced ability (i.e., when compared to non-reticulated viscoelastic foam) to permit the movement of air therethrough, thereby providing enhanced air and/or heat movement within, through, and away from the viscoelastic foam. Reticulated foam is a cellular foam structure in which the cells of the foam are essentially skeletal, in other words, the cells of the reticulated foam are each defined by a plurality of apertured windows surrounded by cell struts. The cell windows of reticulated foam can be entirely gone (leaving only the cell struts) or substantially gone. In some embodiments, the foam is considered "reticulated" if at least 50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts). Such structures can be created by destruction or other removal of cell window material, or preventing the complete formation of cell windows during the manufacturing process of the foam.

[0020J The viscoelastic foam in the mattress 1 10 provides a relatively comfortable substrate for a user's body, can at least partially conform to the user's body to distribute force applied thereby, and can be selected for responsiveness to a range of temperatures generated by the body heat of a user. The viscoelastic foam layer of the mattress 1 10 provides a relatively soft and comfortable surface for a user's body or body portion (hereinafter referred to as "body"). In some embodiments, the viscoelastic foam in the mattress 110 has a hardness of at least about 20 N and no greater than about 80 N for desirable softness and body -con forming qualities. In other embodiments, the viscoelastic foam may have a hardness of at least about 30 N and no greater than about 70 N. In still other embodiments, the viscoelastic foam may have a hardness of at least about 40 N and no greater than about 60 N. Unless otherwise specified, the hardness of any foam material referred to herein is measured by exerting pressure from a plate against a sample of the material to a compression of 40% of an original thickness of the material at approximately room temperature (e.g., 21 - 23 Degrees Celsius), wherein the 40% compression is held for a set period of time following the International Organization of Standardization (ISO) 2439 hardness measuring standard.

[0021] The viscoelastic foam in the mattress 1 10 also includes a density providing a relatively high degree of material durability. The density of the viscoelastic foam in the mattress 1 10 can also impact other characteristics of the foam, such as the manner in which mattress 110 responds to pressure, and the feel of the foam. In some embodiments, the viscoelastic foam in the mattress 110 has a density of no less than about 30 kg/m ³ and no greater than about 150 kg m ³ . in other embodiments, the viscoelastic foam may have a density of at least about 40 kg/m ³ and no greater than about 135 kg/m ³ . In still other embodiments, the viscoelastic foam may have a density of at least about 50 kg/m ^J and no greater than about 120 kg/m '.

1 022 J With reference to Fig, 1, the mattress 1 10 and the foundation 1 1 1 are substantially rectangular, having four sides. Alternatively, the mattress 1 .10 and/or the foundation 1 ! 1 may be configured having any number of different shapes and therefore, sides.

[0023] With continued reference to Figs. 1 and 2, the mattress assembly 108 further includes a securing assembly 120 configured to secure the mattress 1 10 to the foundation 1 1 1 . The securing assembly 120 inhibits sliding movement of the mattress 1 10 relative to the foundation 1 1 1 along at least one of the first and second axes 1 16, 1 18. The securing assembly 120 may include latches, magnets, fittings, or any other structure configured to inhibit sliding movement of the mattress 3 10 relative to the foundation 1 1 1, depending on the particular embodiment being described. In the embodiment illustrated in Figs. 1 and 2, the securing assembly 120 includes a plurality of latches 124 coupling the mattress 1 10 to the foundation 111.

[0024| With reference to Fig, 2, each of the latches 124 includes a buckle 128 attached to the mattress 110 and a catch 132 attached to the foundation 1 1 1. Alternatively, the buckle 128 may be attached to the foundation 1 1 1, and the catch may be attached to the mattress 110. The catch 132 in engageable with the buckle 128 to secure the mattress 110 to the foundation 1 1 1. The buckle 328 may be formed as a separate piece and attached to the mattress 0 by any suitable method, such as with stitches. Similarly, the catch 132 ma be formed as a separate piece and attached to the foundation 1 11 by any suitable method, such as with fasteners 140. In other embodiments, the buckle 128 may be integrally formed with the mattress 1 10 and the catch 132 may be integrally formed with the foundation 111. In still other embodiments, one of the buckle 128 and the catch 132 may be formed as a separate piece and the other of the buckle 128 and the catch 132 may be integrally formed with the mattress 1 10 or the foundation 11 1 , respectively.

[0025] The latch 124 may be formed from a flexible materia!, such as a polymeric material. The elastic properties of the flexible material facilitates engaging and disengaging the latch 124, and the latch 124 can be configured such that an elastic recovery force biases latch 124 toward an engaged position and inhibits inadvertent disengagement of the latch 124. In other embodiments, one or more components of the latch 124 may be a rigid material, in such embodiments, elastic properties of the mattress 1 10 or the foundation 1 11 may produce an elastic recovery force as described above, when the latch 124 is in the engaged position.

[0026] In the embodiment illustrated in Figs, 1 and 2, the securing assembly 120 includes a latch 124 associated with each side of the mattress 1 10 and the foundation 1 1 1 to inhibit sliding movement of the mattress 110 relative to the foundation 111 along both axes 116, 1 18. Alternatively, fewer latches 124 (e.g., two latches 124) may be used. As such, the securing assembly 120 may include any number of latches 324 arranged along any combination of sides of the mattress 110 and the foundation 1 1 1.

[0027] Figs. 3 and 4 illustrate a mattress assembly 208 according to another embodiment of the invention. This embodiment employs much of the same structure and has many of the same properties as the embodiment of the mattress assembly 108 described above in connection with Figs. 1 and 2, Accordingly, the following description focuses primarily upon the structure and features that are different than the embodiment described above in connection with Figs. 1 and 2. Reference should be made to the description above in connection with Figs, 1 and 2 for additional information regarding the structure and features, and possible alternatives to the structure and features of the mattress assembly 208 illustrated in Figs. 3 and 4 and described below. Structure and features of the embodiment shown in Figs. 3 and 4 that correspond to structure and features of the embodiment of Figs. 1 and 2 are designated hereinafter in the 200 series of reference numbers.

[0028] With reference to Fig. 3, the mattress assembly 208 includes a mattress 210 and a foundation 21 1. The foundation 211 defines first and second orthogonal axes 216. 218 oriented along the length and the width of the foundation 21 1 , respectively. The mattress 210 illustrated in Fig. 3 includes a top surface 212 positioned to support a user and a bottom surface 214 that rests directly upon the foundation 21 1. The foundation 211 may include a frame, support, box-spring, or other structure suitable for supporting the weight of the mattress 210 and user(s) thereon. The mattress 210 may include one or more layers of foam material (e.g., viscoelastic foam), although the mattress 210 may also include one or more layers of other material, if desired. n the illustrated embodiment, the mattress 210 has only a single viscoelastic foam layer, and the top and bottom surfaces 212, 214 of the mattress 210 are substantially planar.

[0029] In the embodiment illustrated in Fig. 3, the mattress 210 and the foundation

21 1 are substantially rectangular, having four sides. Alternatively, the mattress 210 and/or the foundation 211 may be configured having any number of different shapes and therefore, sides,

[0030] With continued reference to Fig. 3, the mattress assembly 208 further includes a securing assembly 220 configured to secure the mattress 210 to the foundation 21 1 , The securing assembly 220 inhibits sliding movement of the mattress 210 relative to the foundation 21 1 along the first and second axes 216, 218. In the illustrated embodiment, the securing assembly 220 includes a plurality of magnets 244a, 244b that are magnetically latchable to couple the mattress 210 to th foundation 21 1.

[ΘΘ31 j In the illustrated embodϊmenζ the magnets 244a, 244b are permanent magnets, generating their own persistent magnetic fields. The magnets 244a, 244b may be any suitable type of permanent magnet (e.g., ferrite, alnico, samarium-cobalt, neodyrnium, etc.). Alternatively, the magnets 244a, 244b may be electromagnets and may selectively generate magnetic fields is response to an applied electrical current,

[0032] With reference to Fig. 4, the foundation 21 1 includes a fabric cover 248 secured to an underlying frame (not shown) of the foundation 211 by any suitable method (e.g., stitches, staples, elastic elements, adhesives, etc.). In the illustrated embodiment, half of the plurality of magnets (referred to hereafter as the lower magnets 244a) are sewn into the cover 248 (e.g., between two layers of the cover 248). In some embodiments, the foundation 21 1 may not include a fabric cover 248, and the lower magnets 244a may be glued to the foundation 21 1 by a suitable adhesive. In other embodiments, the lower magnet 244a may be sewn directly to the foundation 21 1. With reference to Fig. 3, the remaining half of the magnets (referred to hereafter as the upper magnets 244b) are secured to the mattress 230 in positions corresponding to the positions of the lower magnets 244a on the foundation 211. The upper magnets 244b are oriented so as to promote magnetic attraction between the upper magnets 244b and the lower magnets 244a. The upper magnets 244b may be secured to the mattress 210 by any suitable method, such as those described above with reference to the lower magnets 244a. Accordingly, when the mattress 210 is placed atop the foundation 211, the upper and lower magnets 244b, 244a become magnetically latched and inhibit sliding movement of the mattress 210 relative to the foundation 211 along the first and second axes 216, 218.

[0033] in the illustrated embodiment, the upper and lower magnets 244b, 244a are respectively arranged along opposing sides of the mattress 210 and the foundation 21 1 corresponding to the length dimension of the mattress 210 and the foundation 21 1. Alternatively, the plurality of magnets 244 may be arranged in any way, including but not limited to around the perimeter of the mattress 210 and the foundation 21 1 , in an S, Z, or X shaped pattern, in a plurality of parallel rows and columns, or in a series of concentric rectangles. In addition, any number of magnets 244a, 244b may be used.

[0034] Figs. 5-8 illustrate a mattress assembly 308 according to another embodiment of the invention. This embodiment employs much of the same structure and has many of the same properties as the embodiments of the mattress assemblies 108 and 208 described above in connection with Figs. 1-4. Accordingly, the following description focuses primarily upon the structure and features that are different than the embodiments described above in connection with Figs. 1-4. Reference should be made to the description above in connection with Figs. 1-4 for additional information regarding the structure and features, and possible alternatives to the structure and features of the mattress assembly 308 illustrated in Figs. 5-8 and described below. Structure and features of the embodiment shown in Figs. 5-8 that correspond to structure and features of the embodiments of Figs. 1 -4 are designated hereinafter in the 300 series of reference numbers.

[0035] With reference to Fig. 5, the mattress assembly 308 includes a mattress 310 and a foundation 31 1. The foundation 311 defines first and second orthogonal axes 316, 318 oriented along the length and the width of the foundation 311, respectively. The mattress 310 illustrated in Fig. 5 includes a top surface 332 positioned to support a user and a bottom surface 314 that rests directly upon the foundation 31 1 . The foundation 3.1 1 may include a frame, support, box-spring, or other structure suitable for supporting the weight of the mattress 310 and user(s) thereon. The mattress 310 may include one or more layers of foa material (e.g., viscoelastic foam), although the mattress 310 may also include one or more layers of other material, if desired. In the illustrated embodiment, the mattress 310 has only a single viscoelastic foam layer, and the top and bottom surfaces 312, 314 of the mattress 310 are substantially planar. |0036] In the embodiment illustrated in Fig. 5, the mattress 310 and the foundation

31 1 are substantially rectangular, having four sides. Alternatively, the mattress 310 and/or the foundation 33 1 may be configured having any number of different shapes and therefore, sides.

[0037] With continued reference to Fig. 5, the mattress assembly 308 further includes a securing assembly 320 configured to secure the mattress 310 to the foundation 31 1. The securing assembly 320 inhibits sliding movement of the mattress 3.10 relative to the foundation 311 along the first and second axes 316, 318. In the illustrated embodiment, the securing assembly 320 includes a rigid projection 352 insertable into a pocket 356 to couple the mattress 310 to the foundation 31 1.

[0038] With reference to Fig. 5, the rigid projection 352 is a bar including a middle portion 360 and end portions 364a, 364b attached the foundation 31 1 by conventional fasteners 340 (Fig. 8). The bar 352 is formed from a rigid material (e.g., steel, aluminum, ABS, HDPE, PVC, etc.) in order to resist sliding movement of the mattress 310 relative to the foundation 31 1 without bending. The pocket 356 comprises a textile or polymeric rectangle sewn along three sides, onto the bottom surface 314 of the mattress 310 (Fig. 5). The pocket 356 is configured to snugly receive the middle portion 360 of the projection 352. Aiternatively, the projection 352 may be associated with the mattress 310 and the pocket 356 may be associated with the foundation 31 1. In other embodiments, the projection 352 and the pocket 356 may be any other type of cooperating structure, and may be attached to the foundation 31 1 and the mattress 310 with fasteners, adhesive, staples, stitches, or any other suitable structure or process. In still other embodiments, the projection 352 and/or the pocket 356 may be integrally formed with the foundation 311 and the mattress 310, respectively.

[0039) in the embodiment illustrated in Fig. 5, the projection 352 and the pocket 356 are each disposed along a side of the foundation 31 1 and the mattress 310 corresponding with the respective widths of the foundation 31 1 and the mattress 310. In other embodiments, the projection 352 and the pocket 356 may be arranged along any of the sides.

[0040] Figs. 9 and 10 illustrate a mattress assembly 408 according to another embodiment of the in vention. This embodiment employs much of the same structure and has many of the same properties as the embodiments of the mattress assemblies 108, 208, and 308 described above in connection with Figs. 1 -8. Accordingly, the following description focuses primarily upon the structure and features that are different than the embodiments described above in connection with Figs. 1 -8. Reference should be made to the description above in connection with Figs. 1-8 for additional information regarding the structure and features, and possible alternatives to the structure and features of the mattress assembly 408 illustrated in Figs. 9 and 10 and described below. Structure and features of the embodiment shown in Figs, 9 and 10 that correspond to structure and features of the embodiments of Figs. 1-8 are designated hereinafter in the 400 series of reference numbers.

(0041] With reference to Fig. 9, the mattress assembly 408 includes a mattress 410 and a foundation 41 1. The foundation 411 defines first and second orthogonal axes 416, 418 (Fig. 10) oriented along the length and the width of the foundation 411, respectively. The mattress 410 illustrated in Fig. 9 includes a top surface 412 positioned to support a user and a bottom surface 414 that rests directly upon the foundation 41 1. The foundation 41 1 may include a frame, support, box-spring, or other structure suitable for supporting the weight of the mattress 410 and user(s) thereon. The mattress 410 may include one or more layers of foam material (e.g., viscoelastic foam), although the mattress 410 may also include one or more layers of other material, if desired. n the illustrated embodiment, the mattress 410 has only a single viscoelastic foam layer, and the top and bottom surfaces 412, 414 of the mattress 410 are substantially planar.

[0042] In the embodiment illustrated in Figs. 9 and 10, the mattress 410 and the foundation 41 1 are substantially rectangular, having four sides. Alternatively, the mattress 410 and/or the foundation 41 1 may be configured having any number of different shapes and therefore, sides.

[0043] The mattress 410 can include an internal chamber 464 that can be partially or fully occupied by reticulated foam (whether viscoelastic or otherwise), or that can instead be substantially empty. Airflow may be generated through the interna! chamber 464 at times when cooling of the mattress 410 is needed. The internal chamber 464 may have any shape and size desired, and may be defined by a number of cavities and voids extending to various locations within the mattress 410. In some embodiments, the mattress 410 may have a series or cluster of internal chambers 464 each having any shape desired (e.g., round, oval, elliptical, or otherwise rotund internal chambers, internal chambers each having a square, triangular, or other polygonal shape, elongated internal chambers each having an S-shape, Z- shape, or other shape, internal chambers having an irregular shape, internal chambers having any combination of such shapes, and the like). Also, any number of the internal chambers 464 may be coupled together and can thereby be in fluid communication with one another.

[0044] In the illustrated embodiment of Fig. 9, the internal chamber 464 extends to a first cavity 468 in the mattress 410, in fluid communication with the internal chamber 464. When the mattress 410 is positioned upon the foundation 41 1 , the first cavity 468 aligns with a second cavity 472 in the foundation 41 1 , In the illustrated embodiment, the first and second cavities 468, 472 have a square cross-section; however, in other embodiments, the first and second cavities 468, 472 can have any other shape (e.g., round, rectangular, hexagonal, etc.). A fitting 476 (see also Fig. 10) corresponding to the shape of the first and second cavities 468, 472 is anchored to the foundation 41 1 and includes a tapered end 480 to facilitate alignment of the first and second cavities 468, 472 when the mattress 410 is placed upon the foundation 41 1. Alternatively, the fitting 476 may be anchored to the mattress 410. The fitting 476 includes a flexible material, such as a flexible polymer, metal or other similar flexible material to accommodate a greater tolerance in the relative position of the first and second cavities 468, 472. In some embodiments, the fitting 476 may extend at least partially into the internal chamber 464.

[0045] With reference to Fig. 9, a fan 484 is positioned in the second cavity 472 and is operable to generate an airflow through the internal chamber 646. The fan 484 may include any number of fan blades, and can take any form desired, including an axial fan, a centrifugal fan, and the like. In other embodiments, the fan 484 may be omitted.

[0046] The second cavity 472 can function as an outlet for the airflow created by the fan 484. In some embodiments, the fan 484 may be retained in this position within the foundation 411 by compressive force of the foundation 41 1 surrounding the fan 484 or by the fitting 476. The fitting 476 and internal chamber 464 form a duet to provide fluid flow throughout the mattress assembly 408.

[0047 J In the illustrated embodiment, the fan 484 is positioned in the foundation 41 1 , below the bottom surface 414 of the mattress 410, Positioning the fan 484 in the foundation 41 1 can present the advantage of at least partially isolating the user from noise and vibration caused by fan operation. Embodiments in which the fan 484 is positioned in the foundation 41 1 also permit a user to select a mattress 410 and a foundation 4.1 1 separately, such that any suitable mattress 410 can be supported upon the foundation 411, and any foundation 41 Ϊ can be used to support the mattress 410. In other embodiments, the fan 484 may be located in other positions, such as immediately adjacent the internal chamber 464, immediately adjacent the bottom surface 414 of the mattress 410, and the like. In still other embodiments, the fan 484 may be positioned at least partially in the internal chamber 464 of the mattress 410.

[0048] With reference to Fig. 10, the fitting 476 is one of a plurality of fittings 476 extending from the foundation 41 1. The fittings 476 function as a securing assembly 420 to secure the mattress 410 to the foundation 41 1. In other embodiments, any number and arrangement of fittings 476 may be included. Interference between the fittings 476 and the cavities 468, 472 inhibits sliding movement of the mattress 410 reiative to the foundation 41 1 along the first and second axes 416, 418.

[0049] Various features of the invention are set forth in the following claims.

I I