Systems and methods for hinged bedding assemblies

Abstract

In many aspects, the systems and methods described herein include mattress having a top sleeping layer disposed on top of a support layer. The support layer includes polyurethane foam having channels comprising one or more slits on both sides of a surface to act as hinges for articulation. The channels may be aligned with the joints of the articulated sections of the foundation or frame of the adjustable bedding assembly. When the sections articulate about the joints, the channels allow the overlying top layer to conform to the sections while reducing wear and tear therein.

Description

FIELD OF THE INVENTION[0001]This invention relates to mattresses and mattress assemblies for adjustable beds, and more generally, assemblies for adjustable furniture.BACKGROUND OF THE INVENTION[0002]Adjustable bed constructions typically include a mattress placed on top of a rigid foundation having articulating arms that move the entire mattress or portions thereof. The foundation includes a plurality of sections that may be adjusted relative to one another such that mattresses that are disposed on the foundation, bend and conform with the articulated sections of the rigid foundation to provide comfort or therapy as needed. However, repeated bending and articulation of the mattresses near the joints of the articulated sections often cause wear and tear and reduce the lifespan of the mattresses.[0003]For example, in conventional innerspring mattresses, springs distort near the joints and at the edges from bending. Conventional innerspring mattresses include stabilizing and reinforcin...

AI Technical Summary

Benefits of technology

[0007]More particularly, the mattresses described herein include a top layer disposed on top of a support layer of polyurethane foam having channels including one or more slits on both sides of its surface to act as hinges for articulation. The channels may be aligned with the joints of the articulated sections of the foundation or frame of the adjustable bedding assembly. When the foundation sections articulate about the joints, the channels allow the mattress to conform to the sections while reducing wear and tear therein. The channels are beneficial in that they help minimize tearing near the bending regions.

[0009]As described above, the support foam layer of the mattress of the present invention includes a first channel and a second channel. In certain embodiments, the support foam layer includes more than two channels. Additionally, at least one of the first channel and the second channel has a depth that extends partially into the thickness of the support foam layer, extending about 1 / 15 to about 13 / 15 of the thickness of the support foam layer. The first channel and the second channel may have a depth from about 1 / 10 to 7 / 10 of the thickness of the support foam layer, or about ¼ to about ½ of the thickness of the support foam layer. The depth of at least one of the first channel and second channel extends perpendicular from the bottom and top surface, respectively, of the support foam layer. In certain embodiments, the channel is sufficiently deep to allow flexing and to reduce mechanical stress on the point of articulation of the mattress. Further, at least one of the first channel and the second channel has a width that allows for consistent firmness in the top layer, and may be about ⅛ inch to about 1.5 inches wide. The width of the channels may range from about ⅙ inch to about 1 inch, or about ¼ inch to about ½ inch.

Problems solved by technology

However, repeated bending and articulation of the mattresses near the joints of the articulated sections often cause wear and tear and reduce the lifespan of the mattresses.

Consequently, such stabilizing and reinforcing structures are limited in their use in articulated beds.

As a result, articulated mattresses of the prior art may have a shorter useful life and do not provide the uniform body support necessary for this application.

Conventional foam mattresses that are currently being used in adjustable bed constructions, also suffer from the similar drawbacks.

In particular, foam mattresses are typically disposed on top of the rigid articulated foundation and experience significant wear and tear near the joints that compromise the integrity of the foam structure and reduce its lifespan.

In addition, since the mattresses are artificially forced to bend along the joints of the foundation, they tend to not fully conform with the articulated sections.

Consequently, portions of the foam mattress, when articulated, may be raised or lowered unevenly or slide out of position.

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