A mattress

Abstract

A mattress having: a foam base 4, with side walls 8; a foam block 2 having at least four foam layers; and a cover encasing the base and block. The layers include: a first castellated foam base layer 1

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a mattress. More especially, the invention relates to a mattress which includes a plurality of internal foam layers to provide fora user improved heat dissipation and muscle recovery. BACKGROUND TO THE INVENTION

[0002] Hospital mattresses are an integral part of clinical environments. They are different from regular mattresses for reason that they are required to aid in patient recovery as opposed to solely providing comfort.

[0003] Hospital mattresses typically comprise an internal synthetic or natural foam layer which is encased in a waterproof and easy-to-clean cover. In use, the mattress surface remains static and relieves pressure over time by evenly distributing an individual’s weight over a large surface at a continuous low pressure.

[0004] However, one issue with these mattresses is that patients who utilise the mattress for extended periods of time need to be moved regularly to prevent the formation of pressure ulcers.

[0005] An alternative to a standard foam hospital mattress is an alternating air pressure mattress. Such mattresses use constantly alternating inflated air cells which can help relieve and redistribute pressure through a dynamic surface. The flow of air is controlled by a pump which is connected to the mattress, ensuring there is constant movement under the patient’s skin.

[0006] Such pumps are loud and need to be constantly turned on to provide support for the patient. Furthermore, due to vibration caused by the pump, some patients may also get nausea.

[0007] Hybrid pressure mattresses provide an alternative to standard mattresses, these being able to target which can target pressure relief without the need of air pumps.

[0008] The present invention seeks to provide a mattress which can provide pressure relief with enhanced heat dissipation without the need of an air pump. STATEMENT OF THE INVENTION

[0009] According to a first aspect of the invention there is provided a mattress comprising a foam base, with a floor and opposing, upwardly extending, side walls; a foam block comprising at least four foam layers, the layers comprising: a first castellated foam base layer, having a defined density and hardness; a second foam layer having a defined density and hardness different to the first layer; a third foam layer having a defined density and hardness different to the first and second layers; a patient interface foam layer having a defined density and hardness different to the first, second or third layer; wherein the foam base and foam block are encased in a cover.

[0010] Preferably, the mattress further comprises a fourth foam layer located between the third layer and the patient interface layer, having a defined density and hardness different to the first, second, third or patient interface layer.

[0011] Preferably, the castellated foam base layer comprises a plurality of patterned sets of castellations.

[0012] Preferably, the castellated foam base layer comprises three patterned sets of castellations.

[0013] Preferably, the cover includes an anti-microbial agent.

[0014] Preferably, the layers of foam are combustion modified. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] One embodiment of the invention will be described by way of example only with reference to the accompanying drawings, in which:

[0016] Figure 1 is an exploded view of a mattress constructed in accordance with a first embodiment of the invention;

[0017] Figure 2 is an end cross-sectional view of a mattress illustrated in figure 1 with no outer cover;

[0018] Figure 3 is a perspective view of a mattress illustrated in figure 2;

[0019] Figure 4 is an exploded view of a mattress constructed in accordance with a second embodiment of the invention;

[0020] Figure 5 is an end cross-sectional view of a mattress illustrated in figure 4 with no outer cover;

[0021] Figure 6 is a perspective view of the mattress of figures 1 or figure 4 with an outer cover;

[0022] Figure 7 is a perspective view of the mattress of figure 1 with part of the cover removed; and

[0023] Figure 8 is a side part-cross section view of a mattress constructed in accordance with a third embodiment of the invention, in use. DETAILED DESCRIPTION OF THE INVENTION

[0024] The invention will now be described with reference to the following examples of mattresses in accordance with the invention.

[0025] The mattress 2 shown in the figures comprises a firm base 4, upon which is positioned a foam block comprising a plurality of layers of foam materials each with different physical properties. Each layer of foam is secured to its neighbouring layer or layers by an adhesive.

[0026] The foam base 4 is a firm polyether-polyurethanefoam, preferably having a density range of 46 -70 kg / m3 and a hardness range of 200-275N. The foam base 4 may be rigid or semi-rigid.

[0027] The foam base 4 has a floor 6 and two opposing generally vertical side walls 8. As will be seen from figure 1, each side wall 8 has castellations 10 which extend downwardly from the top edge of the wall 8 to provide flexibility to the mattress 2. In the embodiment shown in the figures, the castellations 10 are in a generally central section of each wall 8. They may alternatively extend across the entire length.

[0028] The height of each wall 8 is preferably between 40-50mm; preferably 45mm. The floor 6 and walls 8 define a channel or recess in which a foam block sits and provide a structural rigidity to the overall mattress.

[0029] The foam block comprises a plurality of foam layers as detailed below.

[0030] The foam block comprises a castellated base layer 12 preferably made from a polyurethane foam having a density range of 38-54 kg / m3 and hardness range of 120-170N. By “castellated” it is meant that top surface is formed with plurality of grooves or slots.

[0031] The castellations 14 in the base layer 12 provide air flow and flexibility to the mattress. The castellations 14 extend from each side into and across the top surface of the foam in a rectangular grid formation. Other patterns of castellations may be adopted.

[0032] Second and third foam layers 16,18 are superimposed onto the base layer 12. The foam layers 16, 18 are made from at least two different foams and provide further structural support. For example, one of the layers may be formed from a polyurethane foam having a density range of 48-65 kg / m3 and a hardness range of 100-160N to provide comfort and cushioning to the mattress; whilsttheother layer may be formed from a polyurethane foam having a density range of 30-38 kg / m3 and a hardness range of 110-170N to provide durability and recovery to the mattress.

[0033] A patient interfacing foam layer 20 is superimposed onto the third foam layer 18 and comprises a polyurethane foam, having a density range of 50-70 kg / m3 and a hardness 55-90N.

[0034] By “patient interfacing layer” it is meant a layer which has a surface configured to support a person in use. This layer provides further comfort and cushioning to the mattress.

[0035] Combustion modified foams may be employed in any of the aforementioned foam layers to provide fire retardant properties.

[0036] As can be seen in figure 6 the mattress 2 is encased in a wipeable outer cover 22. The cover 22 is preferably made from a coated cotton material. This may be for example, without limitation, cotton coated in an acrylic copolymer.

[0037] The cover 22 may further include an antimicrobial agent to provide anti-microbial properties to the cover 22. In the embodiment shown, the antimicrobial agent is a polyurethane coating.

[0038] The cover 22 may include a fire-retardant lining on the internal and / or external surface of the cover 22.

[0039] The invention will now be described with reference to the following example of a mattress in accordance with the invention.

[0040] An example of a first embodiment is shown in figure 1. In this example, the mattress is comprised of a foam base 4 with a foam block consisting of four layers.

[0041] The foam base 4 is made from a polyether-polyurethane foam with the side walls 8 being 45mm in height. The density range of the foam is 48-52 kg / m3 and the hardness range 225-265N.

[0042] The layers of the foam block comprise:

[0043] (i) a castellated, polyurethane foam base layer 12 with a density range being between 40-42 kg / m3 and a hardness range of 130-160N.

[0044] (ii) a combustion modified polyurethane foam layer 16 with a density range of between 56.5-62.5 kg / m3 and a hardness range of 115-155N;

[0045] (iii) a combustion modified polyurethane foam layer 18 with a density range between 32-34 kg / m3 and a hardness range of 130-160N; and

[0046] (iv) a patient interface foam layer 20 comprised of a polyurethane foam of density 57-61 kg / m3 and a hardness range of 60-90N.

[0047] An example of a second embodiment is shown in figure 4. In this example the mattress is comprised of a foam base 24 with a foam block consisting of five layers.

[0048] The foam base 24 is made from a polyether-polyurethane foam with sides 26 being 45mm in height. The density range of the foam is 60-65 kg / m3 and the hardness range 240-270N

[0049] In this embodiment, the layers of the foam block comprise:

[0050] (i) a castellated, polyurethane foam layer 28 with a density range being between 48-52 kg / m3 and a hardness range of 120-145N.

[0051] (ii) a combustion modified polyurethane foam layer 30 with a density range of between 48-54 kg / m3 and a hardness range of 100-135N;

[0052] (iii) a combustion modified polyurethane foam layer 32 with a density range between 36-38 kg / m3 and a hardness range of 110-140N;

[0053] (iv) a polyether-polyurethane foam layer 34 with a density range between 50-56 kg / m3 and a hardness range of 180-200N; and

[0054] (v) a patient interface layer 36 formed from a polyurethane foam of density 65-70 kg / m3 and a hardness range of 60-90N.

[0055] Figure 7 shows the mattress 2 of figure 1 with cover 22 partly removed to show the foam layer construction. It can be seen that, whilst the foam base 4 is made from a firm or rigid foam, it is still flexible allowing it to bend or deform without breaking, due to nature of the foam material and enhanced by the castellations 10 in the side walls 8.

[0056] Figure 8 shows an alternative embodiment. Here the foam block is constructed from a castellated base layer 38, a medium density foam layer 40 and two layers of memory foam 42, 44. The medium density foam layer 40 is selected to provide durability and recovery, whilst the memory foam layers 42, 44 are selected to provide comfort and cushioning. The foam block construction could have additional layers to take the form, for example of the embodiment shown in figure 4.

[0057] In this embodiment, the top surface of the base layer 38 has two patterned sets of castellations. The castellations are generally tapered inwardly.

[0058] The first set 46, extending inwardly from each end, have less separation than the second set 48 which is located centrally and between the first sets 46.

[0059] A third set of castellations 50 are formed in the bottom surface of the base 38 and extend upwardly into the foam layer. As can be seen, the third set of castellations 50 are linearly offset from the second set of castellations 46 above them. This pattern of castellations provides good air flow and flexibility.

[0060] Alternative embodiments, not shown in the figures, may employ the use of a different number of foam layers and / or the arrangement of said layers.

[0061] It will be appreciated that the foregoing is merely an exemplary mattress in accordance with the invention and that modifications can readily be made without departing from the true scope of the invention.

Claims

1. A mattress comprising:a foam base, with a floor and opposing, upwardly extending, side walls;a foam block comprising at least four foam layers, the layers comprising:a first castellated foam base layer, having a defined density and hardness;a second foam layer having a defined density and hardness different to the first layer;a third foam layer having a defined density and hardness different to the first and second layers;a patient interface foam layer having a defined density and hardness different to the first, second or third layer;wherein the foam base and foam block are encased in a cover.

2. A mattress according to claim 1, wherein the mattress further comprises a fourth foam layer located between the third layer and the patient interface layer, having a defined density and hardness different to the first, second, third or patient interface layer.

3. A mattress according to claim 1, wherein the castellated foam base layer comprises a plurality of patterned sets of castellations.

4. A mattress according to claim 3, wherein the castellated foam base layer comprises three patterned sets of castellations.

5. A mattress according to any previous claim, wherein the cover includes an anti-microbial agent.

6. A mattress according to any previous claim, wherein the layers of foam are combustion modified.A

Images