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US-20260123768-A1 - PARTITIONED FOAM CORE AND FOAM MATTRESS

US20260123768A1US 20260123768 A1US20260123768 A1US 20260123768A1US-20260123768-A1

Abstract

A foam mattress with an adjustable firmness by inserting or removing filling bodies into openings on at least one side thereof is disclosed. The adjustment of the firmness may be performed by an owner/user of the mattress. The ridged patterns may form openings that enable the insertion and or removal of filling bodies that provide further adjustments to the firmness (or softness) of the mattress in addition to the other factors discussed above. The mattress may also be partitioned to allow the firmness on a first portion of the mattress to be adjusted independently of the firmness of a second portion of the mattress, and vice versa.

Inventors

  • Shuimu Huang
  • Eason CHEN
  • RUNLAN REN
  • Liang Chen
  • Qinghuang ZENG

Assignees

  • Guangdong Sweetnight Technical Innovation Ltd. Co.

Dates

Publication Date
20260507
Application Date
20241105

Claims (20)

  1. 1 . A foam mattress comprising: a plurality of foam layers including a first foam layer and a second foam layer, wherein second foam layer is disposed underneath the first foam layer, wherein a top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges with corresponding ones of a first plurality of openings between ones of the first plurality of ridges; at least one filling body disposed in a corresponding one of the first plurality of openings, wherein a firmness of the mattress is adjustable by inserting or removing the at least one filling body from the corresponding one of the plurality of openings.
  2. 2 . The mattress of claim 1 , further comprising a plurality of filling bodies including the at least one filling body, wherein the firmness of the mattress is further adjustable by inserting or removing ones of the plurality of filling bodies from corresponding ones of the plurality of openings.
  3. 3 . The mattress of claim 2 , further comprising a partition separating the mattress into a first portion and a second portion, wherein a first subset of the plurality of openings is located on a first side of the mattress associated with the first portion, and wherein a second subset of the plurality of openings is located on a second side of the mattress associated with the second portion.
  4. 4 . The mattress of claim 3 , wherein a firmness of the first portion of the mattress is adjustable, using a first subset of the plurality of filling bodies and wherein a firmness of the second portion of the mattress is adjustable using a second subset of the plurality of filling bodies, wherein the firmness of the first portion of the mattress and the firmness of the second portion of the mattress are adjustable independently of one another.
  5. 5 . The mattress of claim 1 , wherein the at least one filling body includes an outer wrapping having a zipper and an inner core of material removably placed within the outer wrapping.
  6. 6 . The mattress of claim 5 , wherein a material of the inner core for the at least one filling body is different from foam used in one of the first and second foam layers.
  7. 7 . The mattress of claim 5 , wherein a material of the inner core for a first filling body is different from a material of the inner core for a second filling body.
  8. 8 . The mattress of claim 5 , wherein a material of the inner core for a first filling body is a hard sponge material.
  9. 9 . The mattress of claim 1 , wherein the firmness of the mattress is further adjustable in zones corresponding to portions of a human body.
  10. 10 . The mattress of claim 1 , wherein the plurality of foam layers further comprises: wherein the plurality of foam layers further comprises a third foam layer disposed above the first foam layer, wherein the third foam layer is a top foam layer; and a fourth foam layer disposed underneath the second foam layer, wherein the fourth foam layer has a top surface in contact with a bottom surface of the second foam layer, and wherein the top surface of the fourth foam layer is formed with a second ridged pattern having a second plurality of ridges.
  11. 11 . A method comprising: adjusting a firmness of a foam mattress, wherein adjusting the firmness of the foam mattress comprises: manipulating a first filling body in one of a plurality of openings on a side of a foam mattress, wherein the foam mattress comprises a first foam layer and a second foam layer, wherein second foam layer is disposed underneath the first foam layer, wherein a top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges with corresponding ones of the plurality of openings between ones of the first plurality of ridges.
  12. 12 . The method of claim 11 , wherein adjusting the firmness of the foam mattress further comprises inserting the first filling body into the one of a plurality of openings.
  13. 13 . The method of claim 11 , wherein adjusting the firmness of the foam mattress further comprises removing the first filling body from the one of the plurality of openings.
  14. 14 . The method of claim 11 , wherein foam mattress comprises a partition dividing the foam mattress into a first portion having a first subset of the plurality of openings on a first side of the foam mattress, and a second portion having a second subset of the plurality of openings on a second side of the foam mattress, and wherein the method further includes: independently adjusting respective firmness of the first portion and the second portion independently from one another by manipulating a first one of a plurality of filling bodies in one of the first subset of the plurality of openings and manipulating a second one of the plurality of filling bodies in one of the second subset of the plurality of openings.
  15. 15 . The method of claim 11 , wherein adjusting the firmness of the foam mattress further comprises: manipulating a second filling body in a different one of the plurality of openings, wherein a core material of the second filling body is different from a core material of the first filling body.
  16. 16 . A foam mattress comprising: a plurality of foam layers, the plurality of foam layers including: a first foam layer; a second foam layer disposed underneath the first foam layer, wherein a top surface of the second foam layer is formed with a first ridged pattern having a first plurality of ridges with corresponding ones of a first plurality of openings between ones of the first plurality of ridges; and a third foam layer disposed underneath the second foam layer, wherein a top surface of the third foam layer is formed with a second ridged pattern having a second plurality of ridges with corresponding ones of a second plurality of openings between ones of the first plurality of ridges; and at least one filling body disposed in a corresponding one of the first plurality of openings or second plurality of openings, wherein a firmness of the mattress is adjustable by inserting or removing the at least one filling body from the corresponding one of the first plurality of openings or second plurality of openings.
  17. 17 . The foam mattress of claim 16 , wherein the second ridged pattern is different from the first ridged pattern.
  18. 18 . The foam mattress of claim 16 , wherein the foam mattress includes a partition that subdivides the foam mattress into a first portion and a second portions, wherein, using first and second ones of a plurality of filling bodies, a firmness of the first portion and a firmness of the second portion are independently adjustable with respect to one another.
  19. 19 . The foam mattress of claim 16 , wherein the at least one filling body is one of a plurality of filling bodies, wherein each of the plurality of filling bodies includes an outer wrapping and a core material enclosed within the outer wrapping.
  20. 20 . The foam mattress of claim 19 , wherein a core material of a first one of the plurality of filling bodies is different from a core material of a second one of the plurality of filling bodies.

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. The disclosure further contemplates a foam mattress with an adjustable firmness by inserting or removing filling bodies into openings on at least one side thereof. The adjustment of the firmness may be performed by an owner of the mattress. The ridged patterns may form openings that enable the insertion and or removal of filling bodies that provide further adjustments to the firmness (or softness) of the mattress in addition to the other factors discussed above. In some embodiments, the mattress may be partitioned to allow the firmness on a first portion of the mattress to be adjusted independently of the firmness of a second portion of the mattress. 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