High comfort mattresses and methods for constructing them

Abstract

In one embodiment, a mattress is constructed of a core having a first side and a second side. A first padding layer is positioned at the first side of the core and comprises a foam material having a contoured surface facing away from the core. A second padding layer of a foam material is positioned adjacent the contoured surface of the first padding layer.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS [0001] This application is related to copending U.S. application Ser. No. ______, filed on the same date as the present application (“No-Flip Mattress Systems and Methods”), the complete disclosure of this application is herein incorporated by reference.BACKGROUND OF THE INVENTION [0002] This invention relates generally to the field of mattresses, and in particular to high comfort mattresses. More specifically, the invention relates to arrangements of padding layers that may be used in combination with a mattress core to increase the comfort level of a mattress. [0003] An uncomfortable mattress can be a significant factor in contributing to a poor night's sleep. Traditionally, mattresses have been constructed using a core of springs topped with a layer of padding. Some manufacturers have incorporated this padding into the quilting. Such mattresses are generally referred to as pillow top mattresses. [0004] One way to improve the comfort level ...

AI Technical Summary

Benefits of technology

[0005] The invention provides a variety of high comfort mattress systems and methods for making such mattresses. In one embodiment, a mattress comprises a core having a first side and a second side. The mattress also includes a first padding layer that is positioned at the first side of the core. The first padding layer has at least one contoured surface. A second padding layer is adjacent to the contoured surface. By using a padding layer against the contoured surface, the “lumpiness” of the mattress is eliminated while still permitting the contoured surface to reduce the pressure points on a sleeper's body. Also, this combination of materials better conforms to the shape of the sleeper's body. In this way, a luxurious feel is produced. Also, by using a contoured padding layer, material costs can be reduced because two pieces of a contoured material can be produced from a single layer of padding material. The first and second padding layers may be incorporated into the quilting or ticking (such by using a gusset) to form a pillow top mattress, or may be by incorporated directly into the mattress, known as a plush top arrangement.

Problems solved by technology

An uncomfortable mattress can be a significant factor in contributing to a poor night's sleep.

This design can be undesirable because the fibers can matt down in the valleys so that the convolutions lose their cushioning effect.

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