US-20260123767-A1 - PARTITIONED FOAM CORE AND FOAM MATTRESS

US20260123767A1US 20260123767 A1US20260123767 A1US 20260123767A1US-20260123767-A1

Abstract

A foam mattress is disclosed. The foam mattress includes a first foam layer and a second foam layer. A top surface of the second foam layer is in contact with a bottom surface of the first foam layer. The top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges. The first ridged pattern has a first dimension between two ridges of the first plurality of ridges and a second dimension at a bottom of between ridges of the first plurality of ridges, wherein a firmness of the mattress is dependent on a ratio of the first dimension and the second dimension.

Inventors

Shuimu Huang
Eason CHEN
RUNLAN REN
Liang Chen
Qinghuang ZENG

Assignees

Guangdong Sweetnight Technical Innovation Co., Ltd.

Dates

Publication Date: 20260507
Application Date: 20241105

Claims (20)

1 . A mattress comprising: a first foam layer; and a second foam layer, wherein a top surface of the second foam layer is in contact with a bottom surface of the first foam layer, and wherein the top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges; wherein the first ridged pattern has a first dimension between two ridges of the first plurality of ridges and a second dimension at a bottom of between ridges of the first plurality of ridges, wherein a firmness of the mattress is dependent on a ratio of the first dimension and the second dimension.
2 . The mattress of claim 1 , wherein a first instance of the mattress in which the second dimension is greater than the first dimension has a greater firmness than a second instance of the mattress in which the first dimension is greater than the second dimension.
3 . The mattress of claim 1 , wherein ones of the plurality of ridges have a first height from a trough between ones of the plurality of ridges to a top of ones of the plurality of ridges, and a second height between the trough of between ones of the plurality of ridges and a bottom surface of the second foam layer, and wherein the firmness of the mattress is further dependent on a ratio of the first height to the second height.
4 . The mattress of claim 3 , wherein a first instance of the mattress in which the second height is greater than the first height has a greater firmness than a second instance of the mattress in which the first height is greater than the second height.
5 . The mattress of claim 1 , wherein the bottom surface of the first foam layer is formed having the first ridged pattern such that the top surface of the second foam layer conforms to and is complementary with the first ridged pattern as formed on the bottom surface of the first foam layer.
6 . The mattress of claim 1 , wherein a top portion of ones of the first plurality of ridges is flat, and wherein a bottom portion between the ones of the first plurality of ridges is flat, and wherein a dimension of the top portion is equal to a dimension of the bottom portion.
7 . The mattress of claim 1 , wherein the first ridged pattern is sinusoidal in shape.
8 . The mattress of claim 1 , further comprising a third foam layer, wherein a top surface of the third foam layer is in contact with a bottom surface of the second foam layer, wherein the top surface of the third foam layer is formed with a second ridged pattern having a second plurality of ridges.
9 . The mattress of claim 8 , further comprising a fourth foam layer, wherein a top surface of the fourth foam layer is in contact with a bottom surface of the third foam layer.
10 . The mattress of claim 8 , further comprising a plurality of filling bodies, wherein ones of the filling bodies are disposed between selected ones of the second plurality of ridges.
11 . A method for manufacturing a mattress, the method comprising: forming a first foam layer; forming a second foam layer, wherein forming the second foam layer comprises forming, on a top surface of the second foam layer, a first ridged pattern having a first plurality of ridges; and bonding the first foam layer to the second foam layer such that a bottom surface of the first foam layer is in contact with the top surface of the second foam layer; wherein the first ridged pattern has a first dimension between two ridges of the first plurality of ridges and a second dimension at a bottom of between ridges of the first plurality of ridges, wherein a firmness of the mattress is dependent on a ratio of the first dimension and the second dimension.
12 . The method of claim 11 , further comprising: manufacturing a first instance of the mattress in which the second dimension is greater than the first dimension; and manufacturing a second instance of the mattress in which the first dimension is greater than the second dimension; wherein the firmness of the first instance of the mattress is greater than the firmness of the second instance of the mattress based on respective and relative values of the first and second dimensions.
13 . The method of claim 11 , further comprising: forming the second foam layer such that ones of the plurality of ridges have a first height from a trough between ones of the plurality of ridges to a top of ones of the plurality of ridges, and a second height between the trough of between ones of the plurality of ridges and a bottom surface of the second foam layer, and wherein the firmness of the mattress is further dependent on a ratio of the first height to the second height.
14 . The method of claim 11 , further comprising forming a bottom surface of the first foam layer such that the top surface of the second foam layer conforms to and is complementary with the first ridged pattern as formed on the bottom surface of the first foam layer.
15 . The method of claim 11 , further comprising forming the first ridged pattern such that a top portion of ones of the first plurality of ridges is flat and a bottom portion between the ones of the first plurality of ridges is flat, and wherein a dimension of the top portion is equal to a dimension of the bottom portion.
16 . The method of claim 11 , further comprising forming the first ridged pattern to be sinusoidal in shape.
17 . The method of claim 11 , further comprising: forming a third foam layer, wherein forming the third foam layer comprises forming a top surface of the third foam layer with a second ridged pattern having a second plurality of ridges; and bonding the top surface of the third foam layer to a bottom surface of the second foam layer.
18 . The method of claim 17 , further comprising disposing one or more filling bodies between selected ones of the second plurality of ridges.
19 . The method of claim 17 , further comprising: forming a fourth foam layer; and bonding a top surface of the fourth foam layer to a bottom surface of the third foam layer.
20 . A foam mattress comprising: a first foam layer; a second foam layer, wherein a top surface of the second foam layer is formed having a first ridged pattern having a first plurality of ridges, wherein the first ridged pattern has a first dimension between two ridges of the first plurality of ridges and a second dimension at a bottom of between ridges of the first plurality of ridges, wherein the top surface of the second foam layer is in contact with a bottom surface of the first foam layer; and a third foam layer, wherein a top surface of the third foam layer is in contact with a bottom surface of the second foam layer, and wherein the top surface of the third foam layer is formed having a second ridged pattern having a second plurality of ridges; wherein a firmness of the foam mattress is dependent on a ratio of the first dimension and the second dimension; and wherein ones of the plurality of ridges have a first height from a trough between ones of the plurality of ridges to a top of ones of the plurality of ridges, and a second height between the trough of between ones of the plurality of ridges and a bottom surface of the second foam layer, and wherein the firmness of the mattress is further dependent on a ratio of the first height to the second height.

Description

BACKGROUND 1. Field The present disclosure is directed to foam mattresses, and more particularly, foam mattresses with multiple layers. 2. Description of Related Art Foam mattresses are often times used as an alternative to spring mattresses. Many of these foam mattresses are partitioned into multiple layers. These layers serve different purposes to enhance various aspects of the mattress performance, such as its support, its comfort, and its durability. A top layer (i.e., the layer upon which a person lies) may be referred to as a comfort layer. The comfort layer may comprise various materials such as memory foam, gel-infused foam, or other soft materials. This layer may provide a cushioned feel for a person lying there upon, and may contour to the person's body. The comfort layer may also provide pressure relief. A transition layer may be disposed immediately under the comfort layer. This layer may provide a transition from the softness of the comfort layer to one or more layers underneath that provide support for the body weight of the person lying on the comfort layer. Higher density foam, which may provide additional support, may be used in making the transition layer. A support core provides foundational support for the mattress, being disposed underneath the transition layer. This layer is comprised of high-density foam, and provide the primary support for the mattress. In providing this support, the support core ensures the durability of the mattress and its ability to maintain its shape over time. Some mattresses may also include a base layer underneath the support core for additional stability and support. SUMMARY Various embodiments of a foam mattress are disclosed. In one embodiment, a foam mattress includes a first foam layer and a second foam layer. A top surface of the second foam layer is in contact with a bottom surface of the first foam layer. The top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges. The first ridged pattern has a first dimension between two ridges of the first plurality of ridges, and a second dimension in a trough (or bottom) between ridges of the first plurality of ridges. A firmness of the mattress is dependent on a ratio of the first dimension and the second dimension. In one embodiment, a first instance of the mattress in which the second dimension is greater than the first dimension has a greater firmness than a second instance of the mattress in which the first dimension is greater than the second dimension. In various embodiments, the firmness may further depend on vertical dimensions of the ridges. Ones of the plurality of ridges have a first height from a trough between ones of the plurality of ridges to a top of ones of the plurality of ridges, and a second height between the trough of between ones of the plurality of ridges and a bottom surface of the respective foam layer. The firmness of the mattress is further dependent on a ratio of the first height to the second height. Embodiments with more than two foam layers are also possible and contemplated. One or more of the additional foam layers may also include ridged patterns on their respective top surfaces. With regard to the bottom surfaces of various ones of the layers, the surfaces may either be substantially flat or may have a ridged pattern that is complementary to and conforms with that of the layer beneath it. BRIEF DESCRIPTION OF THE DRAWINGS The above and/or other aspects will become apparent and more readily appreciated from the following description of example embodiments, taken in conjunction with the accompanying drawings, in which: FIG. 1 is a perspective view of one embodiment of a foam mattress in accordance with the disclosure. FIGS. 2A and 2B illustrate side views of ridge patterns that may be cut into a layer of a foam mattress in accordance with the disclosure. FIGS. 3A and 3B illustrate side views of foam layers of a mattress having complementary and conformal ridge patterns. FIGS. 4A and 4B illustrate side views of mattresses having multiple layers with different ridge patterns. FIGS. 5A and 5B illustrate side views of mattresses having multiple layers with different ridge patterns and filling bodies disposed between selected ones of the ridges. FIG. 6 is a flow diagram illustrating a method for manufacturing a foam mattress according to the disclosure. DETAILED DESCRIPTION Foam mattresses are typically divided into two or more layered sections that may be placed on top of one another. These different foam layers may have varying degrees of firmness to meet the overall desired firmness of the mattress. The layers may be cut from foam using ordinary cutting technology. The foam layers of a given mattress may have different levels of firmness, and may be bonded to other foam layers to complete the mattress. Typical foam mattresses may be cut flat at the layer boundaries that bond the various foam layers to one another. This may incr