AU2006100807A4

AU2006100807A4 - Mattress

Info

Publication number: AU2006100807A4
Application number: AU2006100807A
Authority: AU
Inventors: Danny Collins; Brent Dankesreither; Craig Healy
Original assignee: Australian Comfort Group Pty Ltd
Current assignee: Australian Comfort Group Pty Ltd
Priority date: 2006-09-19
Filing date: 2006-09-19
Publication date: 2006-10-19
Anticipated expiration: 2014-09-19

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION INNOVATION PATENT Invention Title: Mattress The following statement is a full description of this invention, including the best method of performing it known to us: 00487409k ID 2

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CMattress Field of the invention The present invention relates generally to a mattress and, more particularly, to a multiple sleeper mattress that provides a different firmness for each sleeper.

00 oO Background of the invention OA multiple sleeper mattress generally refers to double, queen and king standard sized mattresses for two sleepers, however it also encompasses any custom sized mattresses for more than one sleeper.

Typically, one or both of the sleepers will compromise by choosing a mattress with a comfort that suits the other person, or is a compromise between the two preferred comfort levels. This is particularly relevant where the sleepers have greatly differing weights. If one person is much heavier than the other and the mattress is relatively soft, the lighter person may end up sleeping on an inclined surface. While it is appreciated that comfort is measured by a number of factors, one factor is the firmness of the mattress.

A person sleeping on a mattress that is too firm or too soft for them may experience insomnia, discomfort or interrupted sleep.

Mattress manufacturers have been attempting for decades to provide a mattress that caters for the different needs of two different sleepers. A number of complicated systems have been developed that provide the user with access to layers of foam of differing firmness, such that the user can alter the firmness of the two sides of the mattress by rearranging the layers of foam. Whilst these systems may provide a solution to the problem, they are relatively expensive and time consuming to manufacture, and therefore purchase. They are also complicated for the user and could result in incorrect configuration by the user.

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Cl It is therefore an object of the present invention to provide an improved mattress for multiple sleepers.

Summary of the invention Accordingly, the present invention provides a mattress, including: 00 0 C 5 a unitary base layer extending substantially across the width of the mattress of a e resiliently compressible construction and of relatively greater thickness; a unitary upper layer of padded material extending substantially across the width of the mattress; a central layer of relatively lesser thickness disposed between the base and upper layers; and a cover surrounding the base, upper and central layers to form an integral structure, wherein the cover is not removable or openable without destroying it; wherein the central layer includes at least two portions each extending the length of the mattress and each extending substantially across half of the width of the mattress, wherein at respective positions along the length of the mattress the firmness of each of the portions differs relative to the other.

The base layer and/or the central layer may vary in firmness along its length.

The base or central layer may include a border around its edge of relatively greater firmness to the rest of the layer.

Preferably, the base layer is made from foam or rubber material, such as latex.

Alternatively, the base layer may include an array of springs. The base layer is preferably at least twice the thickness of the central layer. There may be an additional support layer underneath the base layer and within the cover.

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N The upper layer may be of a quilted construction, with layers of foam and wool quilting. Such a layer is commonly termed a 'pillow top'.

SAdvantageously, the central layer is made solely of two portions, which meet at a butt joint. The two portions may be joined together along their length by means such as adhesive or heat bonding. Alternatively, the length of the edge of one portion may be 00 concave, whilst the other is convex. The two portions locate into each other and may be held by adhesive, otherwise they are held together by the pressure of the surrounding cover.

A transitional portion may be provided between the two portions to assist in reducing the feel of a join between the two portions. The transitional portion may have a firmness that is between the firmness of the respective portions. For example, if one portion is relatively soft whilst the other portion is relatively firm, the transitional portion might have a mid-level firmness.

The cover is preferably made of cloth and may be constructed from a number of pieces of material permanently sewn together to form the integral structure. The cover may include ticking.

According to a second aspect of the invention, there is provided a method of manufacturing a mattress, the method including the steps of: providing a unitary base layer of resiliently compressible construction and of relatively greater thickness; placing a central layer of relatively lesser thickness on top of the base layer, the base layer being made from at least two portions each extending the length of the mattress and each extending substantially across half the width of the mattress, wherein at respective positions along the length of the mattress the firmness of each of the portions differs relative to the other; placing a unitary upper layer of padded material on top of the central layer; 004874095.

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N surrounding the base, upper and central layers with a cover and sewing closed to a form an integral structure.

SPreferably, the central layer is provided as a single layer by the two portions being previously bonded together, eg by adhesive.

00 Brief description of the drawings N The invention will now be described, by way of example only, with reference to 0 the accompanying drawings, in which: Figure 1 is a perspective view of a mattress according to an embodiment of the present invention placed on a base to form a mattress and base set; Figure 2 is a not to scale cross-sectional end view of the mattress of Figure 1; and Figure 3 is a not to scale cross-sectional end view of a mattress according to another embodiment of the present invention.

Detailed description of the embodiments A mattress 10 is shown in the Figures which is of a queen size, although it will be appreciated that the only difference between standard multiple sleeper mattress sizes is in their width and length dimensions. This invention also extends to custom sized mattresses, which may have a greater or lesser length or width than standard sized mattresses.

The mattress 10 is typically used in conjunction with a base 12, which may be either a sprung base, as illustrated in Figure 1, or a slat base of a bed frame.

The mattress 10 includes a unitary base layer 14 that extends substantially across the width of the mattress, as best shown in Figure 2. It will be appreciated that Figures 2 and 3 are representative only and are not to scale. The base layer 14 is of a resiliently compressible construction and comprises a block of latex of relatively greater 004874095, ID 6

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S thickness than the other layers of the mattress. It will be appreciated that the base layer may have an array of springs. The mattress 10 may also include a support layer 16 underneath base layer 14 and is made from a more rigid material than the latex layer 14.

The mattress also includes a unitary upper layer 18 of relatively padded material 00 that also extends substantially across the width of the mattress, as shown in Figure 2.

The upper layer 18 will typically be of a quilted construction, with layers of foam and 0 wool quilting providing what is commonly referred to as a 'pillow top' layer. It will be N appreciated that the upper layer may be a single layer of relatively soft foam.

A central layer 20 is disposed between the base layer 14 and the upper layer 18.

A cover 22 surrounds the base layer 14, the upper layer 18 and the central layer and the optional support layer 16. The cover 22 may be constructed by surrounding the sides with bands of material 24a, 24b and top and base layers 26a, 26b, which are all joined together at seams 28 to fully enclose the layers and form an integral structure that is not removable or openable without destroying it. The layers of the mattress are not accessible to the user without destroying the cover 22. It will be appreciated that the cover 22 may not include all of the seams 28. The cover may optionally include ticking to create a quilted pattern, represented on Figure 1 by numeral 30, however the ticking would be provided over the entire top layer 26a, and may also be provided on the base layer 26b and loops 24a, 24b.

The central layer 20 shown in Figure 2 includes two portions 32, 34 that extend the length of the mattress. The central layer 20 will typically be at least half the thickness of the base layer 14. The two portions 32, 34 each extend substantially across half the width of the mattress and meet at a butt joint 36. Before placing the central layer 20 on top of the base layer 14, an adhesive is generally sprayed over the entire top surface of the base layer 14. The central layer 20 is then laid on top of the adhesive.

The two portions 32, 34 may individually be laid on top of the adhesive, by lining the outer edges of the two portions with the outer edge of the base layer 14. Alternatively, the central layer 20 may be joined by adhesive at the butt joint 36 before the construction of the mattress 10 is started. The central layer 20 is then treated as a 004874095.

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N single layer during the construction process of the mattress. This is particularly S advantageous as it reduces production time and lowers the chances of operator error when laying the two portions 32, 34 on separately. The upper layer 18 is then laid on top of the central layer 20, again with an adhesive layer in between. The layers are thereafter surrounded by the cover 22 and sewn closed to produce an integral structure.

00 SThe two portions 32, 34 are layers of foam where, at respective positions along the length of the mattress, the firmness of each of the portions differs relative to each C other. The firmness of a layer of foam can be achieved in a number of ways, including N the density of the foam, the chemical structure of the foam and by providing physical holes in the surface of the foam of different dimensions.

The firmness of a single portion 32 or 34 may be varied along its length, as is common in the mattress industry, providing a different firmness for the hip area than for the feet for example. In one embodiment of the present invention, at the hip level for example on each portion 32, 34, the firmness is different.

One method of grading the firmness of a mattress 10 by some manufacturers is to provide ratings of 1, 2, 3 or 4, with a rating 1 being the softest and rating 4 being the firmest. It will be appreciated that there may be other ratings systems used and there may be a greater range than four firmness levels. The two different portions 32, 34 are provided as different firmness ratings. Thus, a couple can pre-order to have a mattress made where one person requires a firmness rating 2 and the other person requires a firmness rating 4. Therefore portion 32 is provided with foam of firmness rating 2 and portion 34 is provided with foam of firmness rating 4. Labels 38 are provided on the outside of the cover 22 to indicate the firmness of the two sides of the mattress 10, as shown in Figure 1.

As can be seen in an alternate embodiment in Figure 3, the central layer 22 can be provided as two portions 32, 34 and a transitional portion 40. The transitional portion provides a firmness transition between the two portions 32, 34. Hence, if portion 32 had a firmness rating 2 and portion 34 had a firmness rating 4, then the transitional portion 40 would have a firmness rating 3. The benefit of the transitional portion 40 is to 004874095 O 8 C additionally increase the seamless feel of the mattress 10 between the two sides. The two portions 32, 34 and the transitional portion 40 would all typically be joined by adhesive at butt joints 36.

The main advantage of the mattress 10 according to the present invention is in 5 the simplicity of manufacture compared to prior art systems. The mattress 10 can be o00 made using existing production lines and materials and therefore the costs associated with its manufacture are significantly less than the complicated mattresses of the prior art.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims

004874095. O9 CLAIMS c/ 1. A mattress, including: a unitary base layer extending substantially across the width of the mattress of a resiliently compressible construction and of relatively greater o00 5 thickness; IDa unitary upper layer of padded material extending substantially across the width of the mattress; a central layer of relatively lesser thickness disposed between the base and upper layers; and a cover surrounding the base, upper and central layers to form an integral structure, wherein the cover is not removable or openable without destroying it; wherein the central layer includes at least two portions each extending the length of the mattress and each extending substantially across half of the width of the mattress, wherein at respective positions along the length of the mattress the firmness of each of the portions differs relative to the other.
2. A mattress according to claim 1, wherein the central layer is made solely of two portions, which meet at a butt joint.
3. A mattress according to claimi or 2, wherein a transitional portion is provided between the two portions to assist in reducing the feel of a join between the two portions.
4. A mattress according to claim 1, 2 or 3, wherein the base layer is at least twice the thickness of the central layer. 004874095. IND N
5. A method of manufacturing a mattress, the method including the steps of: providing a unitary base layer of resiliently compressible construction and of relatively greater thickness; placing a central layer of relatively lesser thickness on top of the base 00 5 layer, the base layer being made from at least two portions each extending _the length of the mattress and each extending substantially across half the Iwidth of the mattress, wherein at respective positions along the length of the mattress the firmness of each of the portions differs relative to the other; placing a unitary upper layer of padded material on top of the central layer; surrounding the base, upper and central layers with a cover and sewing closed to form an integral structure.