Mattress assembly with convertible topper

Abstract

A convertible mattress including a foundation unit, a support unit and a comfort unit. The foundation unit includes several spring elements that provide flexible support for an overlying grid which defines the foundation surface. The foundation unit may be supported by a bed frame which may further include side boards, a head board and foot board. The comfort unit, or innerspring, is located atop the foundation unit and contains several interconnected spring coils or a foam core structure. The top and bottom surface of the comfort unit contain minimal covering to provide a smooth surface over the ends of the coils of the innerspring. The comfort unit is located atop the support unit and has a generally horizontal top and bottom and generally vertical sides extending between the top and bottom that defines a central space containing support and cushioning components such as foam. A series of Velcro™ straps are attached to the perimeter of the support unit that connect to Velcro™ target straps located along the perimeter of the comfort unit. The straps secure the comfort unit to the support unit and enable quick and easy removal and replacement of the comfort unit. Different comfort units may contain different materials that have varying support characteristics. The comfort unit can be either one- or two-sided.

Description

RELATED APPLICATIONS[0001]There are no applications related to this application.FIELD OF THE INVENTION[0002]The present invention pertains generally to support structures for sleeping, and more specifically to adaptable support structures that can be easily replaced with alternate upper support layers containing different insert materials with varying support characteristics.BACKGROUND OF THE INVENTION[0003]Devices for supporting the human body while sleeping have evolved generally from pads, to pads in combination with or supported by springs such as the common mattress, and further in combination with stiffer springs such as in mattress foundations or box springs. In a conventional mattress, springs or coils are interconnected in a matrix array, and covered on each side with layers of padding and fabric. Much of the innovation in mattresses and box springs is in the area of spring design, seeking configurations which provide optimal support of the body, in combination with the pad...

AI Technical Summary

Benefits of technology

[0007]The present invention provides a sleep system including a foundation unit, a support unit or innerspring and a convertible topper. The foundation unit may be of conventional design and construction and contain flexible grid over the top surface of the foundation unit or may be constructed entirely of wood. The support unit or innerspring sits atop the foundation unit and provides support for the sleep surface of the mattress. It may contain the conventional interconnected spring coil array or may contain a high performance high support factor foam core structure. The comfort unit sits atop the support unit and may contain a variety of support and cushioning materials. Attachment means are installed on the sides of the support unit that attach to corresponding attachment means installed at the left and right sides of the comfort unit. The attachment means prevent lateral or sliding motion of the comfort unit relative to the support unit.

Problems solved by technology

There are certain design constraints on mattress innersprings, such as the gauge of wire of the coils, the diameter, height, and number of coils in the array.

Placing most of the comfort forming material (specifically, the fibrous materials) in a permanently attached pillowtop is made increasingly difficult by greater numbers of layers of material, and by the sheer size and weight of the mattress.

The approach also necessitates that equal numbers of compressible material layers be included on both sides of the innerspring, adding significantly to the cost of the mattress.

A large number of layers of material in the pillowtop, including high density foam, natural and man made fiber batts, in combination with other padded or quilted upholstery, has made pillowtops very bulky and rounded at the edges.

It is a difficult assembly to sew together around the periphery with a tape edge, requiring expert operation of a large sewing machine mounted at an oblique angle to the mattress.

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