US-12616311-B2 - System and method for customizing a mattress

US12616311B2US 12616311 B2US12616311 B2US 12616311B2US-12616311-B2

Abstract

A mattress includes a first layer, a second layer, and a third layer having a substantially arch shape. The third layer includes a first portion extending in a longitudinal direction from a location proximate to a first longitudinal end towards a second longitudinal end and completely embedded, in a vertical direction, inside the first layer. A second portion extending in a longitudinal direction from the first portion towards the second longitudinal end and at least a part of a length of the second portion is completely embedded, in the vertical direction, inside the second layer. The third layer includes one of a plurality of coils arranged in a grid pattern, a plurality of cavities arranged in a grid pattern, a non-woven thermoplastic sheet having heat bonded strands, or a woven thermoplastic sheet having heat bonded strands.

Inventors

Kevin J. Kappenman

Assignees

Bed Patent Holdings Limited Liability Company

Dates

Publication Date: 20260505
Application Date: 20240719

Claims (10)

1 . A mattress, comprising: a first layer; a second layer supported on the first layer and arranged abutting the first layer; and a third layer including a first longitudinal end and a second longitudinal end and having a substantially arch shape, the third layer including a first portion extending in a longitudinal direction from a location proximate to the first longitudinal end towards the second longitudinal end and completely embedded, in a vertical direction, inside the first layer, and a second portion extending in a longitudinal direction from the first portion towards the second longitudinal end and at least a part of a length of the second portion is completely embedded, in the vertical direction, inside the second layer, wherein the third layer includes one of a plurality of coils arranged in a grid pattern, a plurality of cavities arranged in a grid pattern, a non-woven thermoplastic sheet having heat bonded strands, or a woven thermoplastic sheet having heat bonded strands.
2 . The mattress of claim 1 further including a cover layer arranged supported on the second layer such that the second layer is disposed between the first layer and the cover layer.
3 . The mattress of claim 2 , wherein the first portion is a first end portion of third layer and the second portion of the third layer includes a second end portion completely embedded inside first layer and a central portion extending from the first end portion to the second end portion, wherein a part length of the central portion is completely embedded inside the cover layer.
4 . The mattress of claim 3 , wherein the central portion includes at least one apex portion completely embedded inside the cover layer.
5 . The mattress of claim 4 , wherein the at least one apex portion includes a first apex portion and a second apex portion, and the central portion includes a trough portion arranged between the first apex portion and the second apex portion and completely embedded inside the second layer.
6 . The mattress of claim 5 , wherein the central portion further includes a first connecting portion connecting the first end portion to the first apex portion and a second connecting portion connecting the second end portion to the second apex portion, wherein the first connecting portion and the second connecting portion are embedded inside the second layer.
7 . The mattress of claim 1 , wherein the third layer includes a plurality of pockets and the plurality of coils is arranged inside the plurality of pockets such that one coil is arranged inside one pocket.
8 . The mattress of claim 7 , wherein each coil is a helical coil with a central axis of the coil extending in a vertical direction.
9 . The mattress of claim 1 , wherein the third layer includes a plurality of first walls arranged spaced apart from each other and a plurality of second walls extending substantially perpendicularly to the plurality of first walls and arranged spaced apart from each other, wherein the plurality of cavities is defined between the plurality of first walls and the plurality of second walls.
10 . The mattress of claim 9 , wherein the first walls and the second walls are made of flexible material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present Application is a continuation-in-part of U.S. application Ser. No. 17/562,576, filed on Dec. 27, 2021 and issued as U.S. Pat. No. 12,022,957 on Jul. 2, 2024, all of which is incorporated herein by reference. FIELD The present disclosure relates, generally, to a mattress. More particularly, the present disclosure pertains to a multi-layer mattress to facilitate an uneven compression of the mattress when the person lies on the mattress. BACKGROUND Mattresses used for sleeping have been made in more or less the same shape and primary materials for many years. Foam mattresses typically use multiple layers of foam having uniform thickness and often times having identical density and firmness throughout the entire thickness of the layers. Accordingly, foam mattresses may lack the ability to ergonomically support the human form or body, especially when considering the natural arcs and curves of the human forms or the tendency for some people to carry extra weight through their hips, waist and stomach area. The disclosed construction method addresses both the need for contouring support and the ability to enhance the strength of support (or resistance to compression) in one or more areas of the mattress. SUMMARY In one aspect of the disclosure, a mattress is disclosed. The mattress comprises a first layer and a second layer supported on the first layer and arranged abutting the first layer. The mattress further includes a third layer including a first longitudinal end and a second longitudinal end and having a substantially arch shape. The third layer includes a first portion extending in a longitudinal direction from a location proximate to the first longitudinal end towards the second longitudinal end and completely embedded, in a vertical direction, inside the first layer. The third layer also includes a second portion at least partially embedded inside the second layer. The second portion extends in a longitudinal direction from the first portion towards the second longitudinal end and at least a part of a length of the second portion is completely embedded, in the vertical direction, inside the second layer. The third layer includes one of a plurality of coils arranged in a grid pattern, a plurality of cavities arranged in a grid pattern, a non-woven thermoplastic sheet having heat bonded strands, or a woven thermoplastic sheet having heat bonded strands. In some additional, alternative, or selectively cumulative embodiments, the mattress further includes a cover layer arranged supported on the second layer such that the second layer is disposed between the first layer and the cover layer. In some additional, alternative, or selectively cumulative embodiments, the first portion is a first end portion of third layer and the second portion of the third layer includes a second end portion completely embedded inside first layer and a central portion extending from the first end portion to the second end portion, wherein a part length of the central portion is completely embedded inside the cover layer. In some additional, alternative, or selectively cumulative embodiments, the central portion includes at least one apex portion completely embedded inside the cover layer. In some additional, alternative, or selectively cumulative embodiments, wherein the at least one apex portion includes a first apex portion and a second apex portion, and the central portion includes a trough portion arranged between the first apex portion and the second apex portion and completely embedded inside the second layer. In some additional, alternative, or selectively cumulative embodiments, the central portion further includes a first connecting portion connecting the first end portion to the first apex portion and a second connecting portion connecting the second end portion to the second apex portion, wherein the first connecting portion and the second connecting portion are embedded inside the second layer. In some additional, alternative, or selectively cumulative embodiments, the third layer includes a plurality of pockets and the plurality of coils is arranged inside the plurality of pockets such that one coil is arranged inside one pocket. In some additional, alternative, or selectively cumulative embodiments, each coil is a helical coil with a central axis of the coil extending in a vertical direction. In some additional, alternative, or selectively cumulative embodiments, the third layer includes a plurality of first walls arranged spaced apart from each other and a plurality of second walls extending substantially perpendicularly to the plurality of first walls and arranged spaced apart from each other. The plurality of cavities is defined between the plurality of first walls and the plurality of second walls. In some additional, alternative, or selectively cumulative embodiments, the first walls and the second walls are made of flexible material. BRIEF DESCRIPTION OF THE DRA