A Mattress

Introduction

This invention relates to a mattress, cushion, pillow and the like resilient support elements.

Background Art It is well known to manufacture mattresses, cushions, pillows and the like with a foam core encased in an outer cover. Various layered foam core constructions are known. Foam material may be removed to leave voids in the foam core to adjust the stiffness and support characteristics of the foam core.

The present invention is directed towards providing an improved construction of mattress, cushion, pillow or the like resilient support element.

Summary of the Invention

According to the invention there is provided a mattress including a composite layered resilient core element having a top foam layer, an intermediate vent layer, and a bottom foam layer having a number of spaced-apart air pockets communicating with the intermediate vent layer, said intermediate vent layer comprising a spacer fabric panel which facilitates air passage between the air pockets and an exterior of the core element.

In one embodiment the top foam layer is a visco-elastic foam.

In another embodiment the bottom foam layer is a visco-elastic foam.

In another embodiment the spacer fabric panel extends to at least one side edge of the core element.

In another embodiment the spacer fabric panel extends outwardly to all sides of the core element.

In another embodiment the spacer fabric panel has a depth in the range 5 mm - 30 mm.

In another embodiment the spacer fabric panel is 20 mm deep.

In another embodiment mattress further includes a resilient base mounted below the bottom foam layer.

In another embodiment the resilient base and the bottom foam layer with air pockets are housed within an outer frame of foam material which extends about side peripheral edges of the base layer and the bottom foam layer.

In another embodiment the spacer fabric panel extends outwardly over the top of the outer frame.

In another embodiment the outer frame comprises a high index foam material.

In another embodiment said resilient base comprises a resilient foam element.

In another embodiment resilient foam element incorporates a number of air pockets.

In another embodiment the resilient base comprises an upper layer of resilient foam, a central layer formed by a block of foam having a plurality of cut-out portions forming the air pockets and a bottom layer of resilient foam.

In another embodiment said resilient base includes a pocket spring assembly.

In another embodiment the resilient base comprises an upper layer of resilient foam, a central layer formed by the pocket spring assembly, and a bottom layer of resilient foam.

In another embodiment the composite resilient core is encased in a flexible outer

cover.

According to the invention there is provided a mattress comprising a flexible outer cover encasing a resilient core, said core being of composite construction and including a resilient base layer, an intermediate foam layer having a plurality of cutout portions forming air pockets throughout the intermediate foam layer, and a flexible top layer.

In a particularly preferred embodiment, the intermediate foam layer is a visco-elastic foam.

Preferably also the top layer is a visco-elastic foam.

Means may be provided to allow air passage between the air pockets and an exterior of the mattress core.

In another preferred embodiment a spacer fabric panel is interposed between a top of the intermediate foam layer and a bottom of the top foam layer. The spacer fabric is a highly breathable three-dimensional fabric. One suitable spacer fabric is 3-Mesh (Registered Trade Mark) material produced by Mueller Textil of Wiehl, Germany which is a three-dimensional spacer polyester fabric comprising two warp-knitted layers which are connected by pile monofilaments in a single knitting process.

The spacer fabric panel will typically be in the order of 5-30 mm deep, and most preferably about 20 mm deep.

In another embodiment, the base layer and the intermediate foam layer are housed within an outer frame of foam material which extends about side peripheral edges of the base layer and the intermediate foam layer.

In another embodiment, the outer frame comprises a high index foam material.

In a further embodiment the base layer comprises a foam layer.

In another embodiment, the base layer comprises an upper layer of resilient foam, a central layer formed by a block of foam having a plurality of cut-out portions forming air pockets throughout the central foam layer and a bottom layer of resilient foam.

In another embodiment, the base layer comprises an upper layer of resilient foam, a central layer formed by a pocket spring assembly and a bottom layer of resilient foam.

In another embodiment the flexible top layer is formed by a spacer fabric panel.

Brief Description of the Drawings

The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:

Fig. 1 is a sectional elevational view of a mattress according to the invention;

Fig. 2 is a detail exploded perspective view showing layers in a core of the mattress of the invention;

Fig. 3 is a sectional elevational view of a mattress according to another embodiment of the invention;

Fig. 4 is a sectional elevational view of a mattress according to a further embodiment of the invention;

Fig. 5 is a sectional elevational view of a mattress according to a still further embodiment of the invention;

Fig. 6 is a view similar to Fig. 2 showing the mattress core construction of

Fig. 5;

Fig. 7 is a sectional elevational view of another mattress core construction of

the invention;

Fig. 8 is a view similar to Fig. 7 showing a further mattress core construction;

Fig. 9 is a sectional elevational view of a cushion according to another embodiment of the invention and;

Fig. 10 is a sectional elevational view of another cushion.

Detailed Description of Preferred Embodiments

Referring to the drawings and initially to Figs. 1 to 2 thereof, there is illustrated a mattress according to the invention indicated generally by the reference numeral 1. The mattress 1 includes a flexible outer cover 2 which typically comprises a breathable fabric material. A resilient layered core 3 of composite layered construction is housed within the cover 2.

The core 3 has a top layer 4 of visco-elastic foam material. This may be any suitable depth and will typically be in the range 10 mm to 50 mm and preferably is about 25 mm deep for example. Mounted directly beneath the top layer 4 and bonded to an underside of the top layer is an intermediate vent layer formed by a spacer fabric panel 5. The depth of the spacer panel 5 is in the order of 20 mm, however any suitable depth may be chosen. The depth will typically be in the range 5 mm to 30 mm

Mounted beneath the spacer fabric panel 5 is a bottom foam layer 6 formed from a block of visco-elastic foam having a plurality of cut-out portions forming air pockets 7 throughout the bottom foam layer 6. This may be any suitable depth. For example the depth could be in the range 20 mm to 150 mm and typically is about 50 mm deep for example. The air pockets may be any desired shape. Hexagonal air pockets are shown in the drawings by way of example.

The bottom foam layer 6 is supported on a resilient base layer 10. In this case the base layer 10 comprises an upper layer 11 of resilient foam (about 40 mm deep),

sitting on a central layer 12 of resilient foam (about 50 mm deep) having a plurality of cut-out portions forming air pockets 14 throughout the central foam layer 12. This central foam layer 12 in turn sits on a bottom layer 16 of resilient foam (about 60-115 mm deep).

It will be noted that the base layer 10 and the bottom foam layer 6 are housed within an outer frame 18 of foam material which extends about side peripheral edges of the base layer 10 and the bottom foam layer 6. This outer frame is formed from a high index foam material. Bottom edges of the spacer panel 5 are bonded to the top of the outer frame 18.

It will be appreciated that the mattress construction of the invention provides a mattress which gives good support while at the same time has a very soft feel.

It will be noted also that the spacer fabric panel 5 mounted directly above the air pockets 7 in the bottom foam layer 6 allows air to breath into and out of the air pockets 7 as indicated by the arrows A for an enhanced air flotation affect and improved comfort. The spacer fabric panel 5 also provides support for the top visco-elastic foam layer 4 to ensure the full benefit of the visco-elastic foam layer 4 is achieved.

If desired a spacer fabric panel may be mounted above or below the central foam layer 12 in the base 10 to similarly allow breathing of the air pockets 14.

Referring now to Fig. 3 there is shown another mattress according to a further embodiment of the invention indicated generally by the reference numeral 60. Parts similar to those described previously are assigned the same reference numerals. This construction is largely similar to that shown in Figs. 1 and 2 except that in this case the outer foam frame has been omitted.

Fig. 4 shows another mattress indicated generally by the reference numeral 70. This is essentially the same as the mattress 60 shown in Fig. 3 except that the bottom layer 16 of resilient foam in the embodiment of Fig. 4 is not as deep as the bottom layer 16 of resilient foam shown in the embodiment of Fig. 3.

It will be noted from Fig. 3 that an upper portion of the core 3 may be formed as a box pillow-top indicated generally by the reference numeral 62 which is then attached to any suitable base section 63 such as the base sections 63 shown in Figs. 3 and 4. The box pillow-top 62 includes the top layer 4, the spacer fabric panel 5, the bottom foam layer 6 incorporating the air pockets 7, and a layer 11 of resilient foam. The base section 63 comprises the central layer 12 with air pockets 14 and the bottom layer 16.

It will be appreciated that the depths of the various layers in the various embodiments may be varied as required to adjust the stiffness and general performance of the mattress. At the same time, the overall depth of the mattress will usually be kept within the normal range of about 150- 250 mm. It will be also noted that the sizes of the air pockets and dispositions of same may be varied to alter the performance characteristics of the mattress.

Referring now to Figs. 5 and 6 there is shown another mattress indicated generally by the reference numeral 30. Parts similar to those described previously are assigned the same reference numerals. In this case, the mattress 30 has a central layer 32 in the base portion 10 formed by a pocket spring assembly.

Referring now to Fig. 7 there is shown another mattress core indicated generally by the reference numeral 40. Parts similar to those described previously are assigned the same reference numerals. In this case the top visco-elastic foam layer 4 is mounted directly above the intermediate foam layer 6.

Referring now to Fig. 8 there is shown another mattress core indicated generally by the reference numeral 50. Parts similar to those described previously are assigned the same reference numerals. In this case a top layer 54 formed by a spacer fabric panel is provided.

Fig. 9 shows a pillow or cushion according to another embodiment of the invention indicated generally by the reference numeral 80. The cushion 80 comprises an air permeable outer cover 82 enclosing a resilient layered core 83 having a top layer

84 or visco-elastic foam, an intermediate vent layer formed by a spacer fabric panel

85 and a bottom layer 86 of visco-elastic foam.

The bottom layer 86 has a number of upwardly open spaced-apart air pockets 87 communicating with the spacer fabric panel 85 to facilitate air flow into and out of the air pockets 87.

Fig. 10 shows another pillow or cushion indicated generally by the reference numeral 90. This is similar to the cushion 80 except that in this case, a resilient base 88 of foam material is mounted below the bottom foam layer 86 having the air pockets 87.

The term mattress as used throughout this patent specification should be taken to include cushions, pillows and the like resilient support elements.

The various foam layers may be provided by any suitable foams. It is however preferred that the top layer and 4 the bottom layer 6 comprise a visco-elastic foam. Further, each layer may be of any suitable depth.

The invention is not limited to the embodiments hereinbefore described but may be varied in both construction and detail within the scope of the appended claims.