Technical Field

[0001] The present disclosure relates generally to mattresses and, more particularly, relates to a mattress configured to be rolled and stored, for example, in a container.

Background

[0002] Mattresses provide support for a user during sleep. The construction of mattresses can vary significantly to allow the properties of the mattress to be tailored to user preferences. For example, a mattress may include one or more of upholstery layers, foam layers, and a cavity housing various coil springs.

[0003] Some mattresses are constructed only from foam layers. This allows the mattress to be manufactured and shipped cost-effectively, as foam material and manufacturing processes are low-cost, and the mattress can be rolled and stored, for example, in a container such as a box. The mattress and box are typically configured to be lightweight and of compact dimensions so that a single person can handle the boxed mattress. This enhances storage, shipping and delivery.

[0004] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.

Summary

[0005] According to some disclosed embodiments, there is provided a mattress comprising at least two laminated layers. The at least two layers include a first layer and a second layer. The first layer defines a support surface configured to support a user, the first layer being formed from a resiliently deformable, fluid-impervious material, and which defines a plurality of perforations arranged to communicate fluid through the layer. The second layer is joined to the first layer to cover an end of at least some of the perforations. The second layer is formed from a fluid-pervious material and arranged to allow fluid to be communicated between the at least some of the perforations and a location external to the second layer.

[0006] The second layer may define side-walls arranged substantially perpendicularly to the support surface, and be arranged to allow fluid to be communicated between the at least some of the perforations and a location external to the side- walls.

[0007] The second layer may be at least partially surrounded by a border arranged to at least partially define sides of the mattress, and the border may be formed from a fluid-impervious material and define a plurality of apertures extending through the border, the apertures being arranged to communicate fluid from the second layer to a location external to the border.

[0008] The border may be formed from a material having a greater density than the material of the first layer. The border may be dimensioned to define a width which is greater than a thickness of the border.

[0009] The second layer may comprise two portions separated by a barrier, the barrier being at least partially formed from a fluid-impervious material arranged to inhibit fluid being communicated between the two portions.

[0010] The mattress may include a third layer which defines a further support surface configured to support the user, the third layer being formed from a resiliently deformable, fluid-impervious material, and defining a plurality of perforations arranged to communicate fluid through the layer, the third layer being joined to the second layer and arranged so that an end of at least some of the perforations of the third layer are covered by the second layer. [0011] The third layer may be formed from a material having a greater density than the material of the first layer.

[0012] The first layer and the third layer may be formed from a closed-cell foam. The second layer may be formed from an open-cell foam.

[0013] The first layer may define a thickness which is greater than a thickness defined by the second layer.

[0014] The mattress may include a cover dimensioned to enclose the at least two layers, the cover including an upper portion releasably connected to a lower portion.

An asymmetric seam may be defined between the upper portion and the lower portion such that at least a portion of the seam is angled towards one of the upper portion and the lower portion.

[0015] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Brief Description of Drawings

[0016] Embodiments will now be described by way of example only with reference to the accompany drawings in which:

[0017] Figure 1 is a perspective view of an embodiment of a mattress;

[0018] Figure 2 is an exploded perspective view of the mattress shown in Figure 1; [0019] Figure 3 is a plan view of the mattress shown in the previous figures;

[0020] Figure 4 is a side view of the mattress shown in the previous figures; [0021] Figure 5 is an end view of the mattress shown in the previous figures;

[0022] Figure 6 is a perspective view of the mattress shown in the previous figures enclosed in a cover;

[0023] Figure 7 is an exploded perspective view of the mattress and cover shown in Figure 6;

[0024] Figure 8 is an exploded perspective view of the mattress and cover shown in Figure 7 together with a mattress topper accessory and cover extender accessory;

[0025] Figure 9 is an exploded side view showing the components illustrated in Figure 8 with the cover extender secured to a base-side portion of the cover, and showing a detailed view of a zipper for securing the cover extender to the base-side portion of the cover; and

[0026] Figure 10 is a side view of the mattress and topper enclosed in the cover and cover extender, and showing a detailed view of a zipper for securing the cover extender to the pillow-side portion of the cover.

Detailed Description of Exemplary Embodiments

[0027] In the drawings, reference numeral 10 generally designates an embodiment of a mattress 10. The mattress 10 comprises at least two laminated layers 12, 14. The at least two layers 12, 14 include a first layer 12 defining a support surface 16 configured to support a user, and a second layer 14. The first layer 12 is formed from a resiliently deformable, fluid-impervious material, and defines a plurality of perforations 18 arranged to communicate fluid through the layer 12. The second layer 14 is joined to the first layer 12 to cover an end of at least some of the perforations 18, and is formed from a fluid-pervious material. The second layer 14 is arranged to allow fluid to be communicated between at least some of the perforations 18 and a location external to the second layer 14. [0028] In the illustrated embodiment, the mattress 10 comprises three layers 12, 14, 20, where the second layer 14 is in the form of a mid-layer 14 sandwiched between the first layer 12 and a third layer 20, in the form of outer layers 12, 20. It will be appreciated that the mattress 10 may comprise more or less layers, for example, the mattress 10 may include one or more additional fluid-permeable mid-layers.

Conversely, in another embodiment, the mattress 10 may include only a single outer layer 12 which is joined to the second layer 14.

[0029] Each outer layer 12, 20 defines the support surface 16 which is dimensioned and arranged, in use, to support a user during sleep. Perforations 18, 22 (Fig. 2), being through-holes, are defined in each support surface 16 and extend through the respective layer 12, 20. In the embodiment shown, the perforations 18, 22 extend perpendicular to the associated support surface 16. However it will be appreciated that the perforations 18, 22 may be transverse to the surface 16.

[0030] Each outer layer 12, 20 is formed from a resiliently deformable, fluid- impervious material. Suitable materials include closed-cell foams such as latex, polyurethane and similar polymeric foams. This material inhibits fluid, such as air and/or water, travelling through the layer 12, 20. In the illustrated embodiment, the third layer 20 is formed from a polymeric foam having a greater density then a polymeric foam forming the first layer 12. This allows the mattress 10 to be orientated according to user preference for cushioning firmness, as the third layer 20 provides firmer cushioning whereas the first layer 12 provides softer cushioning.

[0031] The mid-layer 14 is formed from a fluid-pervious material and is typically resiliently deformable, such as an open-cell foam. This material allows fluid, such as air and/or water, to travel through the layer 14. The mid-layer 14 is arranged to cover at least some of the perforations 18, 22 to allow fluid to be communicated between the perforations 18, 22 and a location external to the mid-layer 14. The mid-layer 14 is laminated to each of the outer layers 18, 22 so that an end of at least some of the perforations 18, 22 abuts the mid-layer 14. Lamination of the layers 12, 14, 20 generally involves application of adhesive(s) between layers 12, 14, 20. However, additionally, or alternatively, this may involve other joining techniques, such as ultrasonic welding. In some embodiments, the mid-layer 14 is only joined to the outer layers 12, 20 around a peripheral region of the mid-layer 14, for example, to reduce consumption of adhesive. In the embodiment shown, the mid-layer 14 defines a thickness (perpendicular to the support surface 16) which is substantially less than a thickness of either outer layer 12, 20 to minimise the quantity of fluid-pervious material required to form the layer 14.

[0032] The mid-layer 14 includes side-walls (not visible) extending substantially perpendicular to the support surface 16. The side- walls are at least partially surrounded by a border 24 formed from a fluid-impervious material. In the embodiment shown, the border 24 forms a continuous peripheral region surrounding and abutting the side- walls of the mid-layer 14, and defines a section of each side 30 of the mattress 10. The border 24 defines apertures 26 extending through the border 24. The apertures 26 are arranged to convey fluid between the side- walls of the mid-layer 14 and a location external to the border 24, and consequently external to the mattress 10. It will be appreciated that in some embodiments the border 24 may be absent and, instead, the mid-layer 14 is dimensioned to extend to, or near to, the sides 30, to allow fluid to directly enter and exit the side-walls of the mid-layer 14.

[0033] In the illustrated embodiment, the border 24 is formed from a resiliently deformable closed-cell foam. The border 24 is dimensioned to define a width (parallel to the support surface 16) which is substantially greater than a thickness (perpendicular to the support surface 16). This arrangement and proportions enhance the border 24 returning to its original shape should the mattress 10 be rolled for storage. The foam of the border 24 has a greater density than the foam of any of the layers 12, 14, 20, and is configured to provide structure around the periphery of the mattress 10.

[0034] The mid-layer 14 is separated into two portions 141, 142 by a barrier 28. The barrier 28 is formed from a fluid-impervious material, such as a closed cell foam, and arranged to prevent or reduce fluid being communicated between the portions 141, 142. When the mattress 10 is being used by two users, the barrier 28 usefully prevents or reduces air and/or moisture being transferred between the portions 141, 142, thereby minimising one user disturbing the other user.

[0035] Figure 6 shows the mattress 10 enclosed in a cover 34. The cover 34 comprises two portions, being a pillow-side portion 341 and a base-side portion or gusset 342. In the embodiment shown, the pillow-side portion 341 includes padding and/or flocking, whereas the gusset 342 has felt-like properties. Each portion 341, 342 is formed from a fluid-pervious material, such as a knitted fabric.

[0036] The portions 341, 342 are releasably joined together along a seam 36. In the embodiment shown the cover portions 341, 342 are releasably connected by a zipper extending around a periphery of the cover 34 along the seam 36. The seam 36 is asymmetric so that a portion 361 of the seam 36 is angled towards the pillow-side portion 341. The seam 36 is arranged, in use, to be positioned along a central line extending along each side 30 of the mattress 10. The portion 361 of the seam 36 departs from this central line and is arranged, in use, extending diagonally towards one of the support surfaces 16. This seam portion 361 allows a user to readily identify which side of the cover 34 is intended to be used as the pillow-side (with the seam portion 362 angled towards a pillow end) and therefore identifies how to orientate the cover 34 for use.

[0037] Figures 7 to 10 illustrate a topper accessory 38 and gusset extender 40 being added to the mattress 10 to allow customising padding of a user-facing side of the mattress 10. In the embodiment shown, the topper 38 is a continuous layer of material, such as a‘memory foam’, having specific softness, resilience and/or thermal properties. In some embodiments (not shown), the topper 38 comprises an alternatively configured padded structure, such as a quilted blanket. In other embodiments (not shown) the topper 38 is integrally formed with the pillow-side portion 341 of the cover 34.

[0038] Best shown in Figures 8 and 9, the gusset extender 40 is configured as a loop of material dimensioned to encircle the mattress 10. The gusset extender 40 has a first zipper 42 arranged along one side to allow releasably connecting to the gusset 342, and a second zipper 44 arranged along an opposed side to allow releasably connecting to the pillow-side portion 341. The gusset extender 40 is typically formed from the same material as the gusset 342 and effectively extends the height of the gusset 342 to increase capacity of the cover 34. This allows the cover 34 to accommodate the topper 38 in addition to the mattress 10. The width of the gusset extender 40, being the dimension between the opposed zippers 42, 44, is defined according to a thickness of the topper 38.

[0039] Use of the mattress 10 involves the user selecting one of the outer layers 12,

20 according to firmness, operating the zipper to separate the cover portions 341, 342, removing the cover 34, orientating the mattress 10 so that the support surface 16 of the selected layer 12, 20 faces upwards, away from a structure supporting the mattress 10, such as a bed frame, the base 32 or floor, replacing the cover 34 and operating the zipper to secure the cover portions 341, 342 together, with the pillow-side portion 341 facing upwards.

[0040] During sleep, as the user emits heat from their body, this causes air in the perforations 18, 22 of the selected outer layer 12, 20 to be heated and rise towards the user. The rising air draws cooler air through the cover 34, into the apertures 26, through the mid-layer 14 and into the perforations 18, 22. This establishes a convection current causing air to circulate beneath the user.

[0041] Many users also move whilst sleeping. Movement of the user’s body causes portions of the selected layer 12, 20 to compress which forces air and/or moisture through the perforations 18, 22 towards the mid-layer 14. The air and/or moisture is received in, and travels through the mid-layer 14 to the border 24, where it is expelled via the apertures 26, through the cover 34 and away from the mattress 10. Similarly, movement of the user’s body causes portions of the selected layer 12, 20 to rebound which draws air and/or moisture in the opposite route as is described above.

[0042] When the mattress 10 is being used by two users simultaneously, one user may get up from the support surface 16 and then return. When the returning user lies on the support surface 16, air and/or moisture is forced away from the support surface 16 through the perforations 18, 22 and into the mid-layer 14. In this scenario, the barrier 28 inhibits the air and/or moisture from travelling between the mid-layer portions 141, 142, thereby inhibiting a sudden volume of air returning through the perforations 18, 22 of the selected layer 12, 20 and disturbing the other user.

[0043] The configuration of the perforations of the first layer 12 relative to the fluid- permeable second layer 14 advantageously allows air and/or moisture to be conveyed from outside of the mattress 10 towards and away from the user lying on the support surface 16. This therefore ventilates the mattress, enhancing cooling and comfort of the user.

[0044] The border 24 arranged around the periphery of the mattress 10 usefully provides structural support to maintain the shape of the mattress 10. Furthermore, the configuration of the border 24 means that if the mattress 10 is rolled for storage and then unpacked, the border 24 reliably restores its original shape to support the sides 30 of the mattress 10.

[0045] The barrier 28 arranged through the fluid-pervious second layer 14

advantageously inhibits fluid being conveyed between the two second layer portions 141, 142 to minimise multiple users of the mattress 10 disturbing each other during use.

[0046] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.