Mattress including a pressure relief and methods of manufacturing the same

Abstract

A mattress includes a base layer, the top layer, and a pressure relief layer. The top layer is disposed above the base layer. The pressure relief layer is disposed between the base layer and the top layer and includes a tray and one or more pods. The tray defines a first channel that extends the width of the tray and extends downward through a top surface to a depth of 50 percent to 80 percent of a thickness of the tray. The tray has a monolithic construction and is formed of a foam. The one or more pods are disposed within the first channel of the tray and have a rectangular base and extend upward from the base while remaining in contact with the side walls defining the channel for at least 25 percent of the height of the one or more pods.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims benefit of, and priority to, U.S. Provisional Patent Application Ser. No. 63 / 675,028, filed Jul. 24, 2024, the entire contents of which are hereby incorporated by reference.BACKGROUND1. Technical Field

[0002] The present disclosure relates to mattresses and, more specifically, to mattresses including a pressure relief layer and methods of manufacturing the same.2. Discussion of Related Art

[0003] A main function of a pressure-relieving layer in a multi-layer cushion is to provide a comfortable sleeping experience and to disperse pressure effectively, especially for parts of a human body such as shoulders, waist, and buttocks. Selection of the pressure-relieving layer is crucial for sleep quality and comfort.

[0004] A common pressure-relieving layer in a multi-layer cushion is designed according to an individual's sleep preferences, weight, and physical needs. These requirements often dictate the preferred mattress construction for each individual. For example, people with back problems may choose memory foam or latex to reduce pressure points on the body, while those who prefer a soft feeling may prefer a multi-layer cushion filled with fibers. However, constructing a mattress with all the same materials does not appropriately account for the variances in the regions of the human body that exert different forces.

[0005] Therefore, it is necessary to design a pressure-relieving layer to solve the above-mentioned technical problems.SUMMARY

[0006] This disclosure relates generally to a pressure relief layer and mattress including a pressure relief layer. The pressure relief layers disclosed herein may define a channel that includes one or more pods, or structures disposed therein. The channels may allow for pressure relief layer to a user disposed on the mattress.

[0007] In an aspect of the present disclosure, a mattress includes a base layer, the top layer, and a pressure relief layer. The base layer defines a baseline and a base width. The top layer is disposed above the base layer and has a top plate and a top width that is the same as the base length and the base width. The pressure relief layer is disposed between the base layer and the top layer and includes a tray and one or more pods. The tray has a top surface and a bottom surface with the thickness of the pressure relief layer defined as the distance between the top surface and the bottom surface. The bottom surface defines a tray length and a tray width that is the same as the base length and the base width. The tray defines a first channel that extends the width of the tray and extends downward through a top surface to a depth of 50 percent to 80 percent of the thickness of the tray. The tray has a monolithic construction and is formed of a foam having a first firmness. The one or more pods are disposed within the first channel of the tray. The one or more pods have a rectangular base and extend upward from the base while remaining in contact with the side walls defining the channel for at least 25 percent of the height of the one or more pods.

[0008] In aspects, a bottom surface of the pressure relief layer is secured to a top surface of the base layer. A top surface of the tray may be secured to a bottom surface of the top layer. A top surface of the one or more pods may be unsecured to the bottom surface of the top layer. The top surface of the one or more pods may be in contact with the bottom surface of the top layer.

[0009] In some aspects, the one or more pods are formed of a memory foam. The tray may be formed of a polyurethane foam.

[0010] In certain aspects, the mattress includes a secondary layer disposed between the top layer and the pressure relief layer. The base layer may be formed of foam. The base layer may include pocketed springs.

[0011] In particular aspects, the tray defines a second channel and a third channel that each extend the width of the tray and extend downward through the top surface of the tray. Each of the first channel, the second channel, and the third channel may be spaced apart from one another along the length of the pressure relief layer. The one or more pods may be disposed within each of the second channel and the third channel.

[0012] In some aspects, the mattress includes a side cap that extends the entire length of the pressure relief and a thickness equal to or greater than a thickness of the tray. The side cap may cover the ends of the first channel. The side May define a total thickness of the mattress and may be disposed along each side of the mattress.

[0013] In another aspect of the present disclosure, a mattress includes a base layer, a top layer, and a pressure relief layer. The base layer defines a base length and a base width. The top layer is disposed above the base layer and has a top length and a top width the same as the base length and the base width. The pressure relief layer is disposed between the base layer and the top layer and defines a plurality of zones along the length of the pressure relief layer with each zone of the plurality of zones extending across the entire width of the pressure relief layer. The plurality of zones, in order, including a first support zone, a first pressure relief zone, a second support zone, a second pressure relief zone, a third support zone, a third pressure relief zone, and a fourth support zone. The pressure relief layer includes a tray that defines at least one channel in each of the pressure relief zones that extends the width of the tray. The second support zone and the third support zone each have a length of at least 10 inches on either side of the second pressure relief zone.

[0014] In aspects, the pressure relief layer may include one or more pods disposed in each of the at least one channels. The one or more pods may be formed of at least one of memory foam, an air bladder, a water bladder, gel foam, or combinations thereof.

[0015] In some aspects, each of the at least one channels extend from a top surface of the tray to adapt in a range of 50 percent to 80 percent of the thickness or height of the tray. The first pressure relief zone may include four channels spaced apart from one another. The top surface of the tray may be secured to a bottom surface of the top layer.

[0016] In another aspect of the present disclosure, a pressure relief structure includes a tray and one or more pods. The tray has a top surface and a bottom surface with the thickness of the pressure relief layer defined as the distance between the top surface and the bottom surface. The bottom surface defines a tray length and a tray width. The tray defines a first channel that extends the width of the tray and extends downward through a top surface to a depth of 50 percent to 80 percent of the thickness of the tray. The tray has a monolithic construction and is formed of a foam having a first firmness. The one or more parts are disposed within the first channel, the one or more pods each have a rectangular base and extend upward from the base all remaining in contact with side walls defining the channel for at least 25 percent of the height of the one or more pods.

[0017] In aspects, the pressure relief structure may be a standalone sleeping pad or mattress pad.

[0018] Further, to the extent consistent, any of the embodiments or aspects described herein may be used in conjunction with any or all of the other embodiments or aspects described herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Various aspects of the present disclosure are described hereinbelow with reference to the drawings, which are not necessarily drawn to scale, which are incorporated in and constitute a part of this specification, wherein:

[0020] FIG. 1A is a perspective view of a mattress in accordance with embodiments of the present disclosure;

[0021] FIG. 1B is an exploded perspective view of the mattress of FIG. 1A with the encasement removed and the layers separated;

[0022] FIG. 2 is a top plan view of a pressure relief layer of the mattress of FIG. 1;

[0023] FIG. 3 is a top plan view of a tray of the pressure relief layer of FIG. 2;

[0024] FIG. 4 is a side view of the tray of FIG. 3;

[0025] FIG. 5 is a perspective view of the pressure relief layer of FIG. 2;

[0026] FIG. 6A is a perspective view of support pod of the pressure relief layer of FIG. 5;

[0027] FIGS. 6B-6P are profile, top, or perspective views of alternative support pods for the pressure relief layer of FIG. 5;

[0028] FIG. 7 is a profile view of a support pad provided in accordance with embodiments of the present disclosure;

[0029] FIG. 8 is a perspective view of another support pad provided in accordance with embodiments of the present disclosure;

[0030] FIG. 9 is a perspective view of another mattress provided in accordance with embodiments of the present disclosure;

[0031] FIG. 10 is a perspective view of another pressure relief layer provided in accordance with embodiments of the present disclosure;

[0032] FIGS. 11A-11C are pressure distribution maps of users supported on a mattress without a pressure relief layer;

[0033] FIGS. 12A-12C are pressure distribution maps of the same users of FIGS. 11A-11C supported on another mattress with a pressure relief layer; and

[0034] FIG. 13 is a flow chart of a method of manufacturing a pressure relief layer and a multilayer mattress in accordance with the present disclosure.DETAILED DESCRIPTION

[0035] The present disclosure will now be described more fully hereinafter with reference to example embodiments thereof with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. These example embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Features from one embodiment or aspect can be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments can be applied to apparatus, product, or component aspects or embodiments and vice versa. The disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms “a,”“an,”“the,” and the like include plural referents unless the context clearly dictates otherwise. In addition, while reference may be made herein to quantitative measures, values, geometric relationships, or the like, unless otherwise stated, any one or more if not all of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to manufacturing or engineering tolerances or the like.

[0036] As used herein, the term “foam” is the general term for a material that is formed with a cellular structure with pores defined therein. Foam may refer to open-cell or closed-cell foam. Foams detailed herein may be formed generally from polymers such as polyurethane foam, latex, polypropylene, thermoplastic polymers, or combinations thereof.

[0037] As used herein, the term “memory foam” refers to a foam that softens when pressed and conforms to a shape when pressed and then slowly returns to its original shape when pressure is released. A memory foam may be a viscoelastic foam. The recovery time for a memory foam is in a range of 5 seconds to 10 seconds.

[0038] As used herein, the term “gel-infused foam” refers to a foam that includes gel beads infused in the foam material. The gel beads infused in the foam may improve functional characteristics of the foam material. In some embodiments, the gel-infused foam may have improved temperature regulation or air flow when compared to the foam without the gel beads infused therein. The gel-infused foam may dissipate body heat better when compared to the foam without the gel beads infused therein. The gel-infused foam may maintain a cooler surface temperature when compared to the foam without the gel beads infused therein. In certain embodiments, gel beads are infused into memory foam to create a gel-infused memory foam.

[0039] As used herein, the term “copper foam” refers to a foam that includes copper particles infused or distributed in the foam material. The copper particles may be in the form of copper filaments. The copper particles infused in the foam may improve functional characteristics of the foam material. In some embodiments, the copper foam may have improved temperature regulation or air flow when compared to the foam without the copper particles infused therein. The copper foam may dissipate body heat better when compared to the foam without the copper particles infused therein. The copper foam may maintain a cooler surface temperature when compared to the foam without the copper particles infused therein. The copper foam may have antimicrobial properties such that growth of bacteria, dust mites, or other microorganisms is reduced compared to foam without the copper particles infused therein. In certain embodiments, copper particles are infused into memory foam to create a copper memory foam. In particular embodiments, copper particles are infused into a gel-infused foam or a gel-infused memory foam to create a copper gel-infused foam or a copper gel-infused memory foam, respectively.

[0040] It will be appreciated that foam may refer to memory foam, gel-infused foam, gel-infused memory foam, copper foam, copper memory foam, copper gel-infused foam, copper gel-infused memory foam, open-cell foam, or closed-cell foam. In addition, gel-infused foam may refer to any foam including gel beads including gel-infused memory foam, copper gel-infused foam, or copper gel-infused memory foam. Further, copper foam may refer to any foam including copper particles infused including copper memory foam, copper gel-infused foam, or copper gel-infused memory foam.

[0041] Foam may be measured by density, firmness, support factor, recovery time, and other measurements. The density of a foam is measured by a value of pounds per cubic foot or kilograms per cubic meter. In embodiments, the foams disclosed herein have a density in a range of 0.5 pounds per cubic foot to 10 pounds per cubic foot, e.g., 1 pound per cubic foot to 6 pounds per cubic foot.

[0042] The firmness of foam may be measured by Indentation Force Deflection (IFD) which is represented by a numerical number which is the force in pounds to compress the foam a percent of its initial thickness. For example, when a force in pounds compresses a foam 25 percent of its initial thickness, this would be represented with a 25 percent IFD number. When the foam is compressed to 50 percent of its initial thickness, this would be represented with a 50 percent IFD number. The element to compress the foam may be a cylindrical indenter having circular contact with the foam, the circular contact having a surface area of 50 square inches. Thus, if a 4-inch-thick piece of foam is compressed 1 inch by a 35-pound force applied to the cylindrical indenter, this would be represented as 25 percent IFD 35. The IFD may be measured under ASTM D3574 B1. The firmness of foam may also be measured under ASTM D3574 C for Compression Force Deflection (CFD).

[0043] The support factor of foam may be referred to as the compression modulus and determines the ability of the foam to support weight. The compression modulus may be a ratio of the 65 percent IFD over the 25 percent IFD. For example, a foam with a 65 percent IFD of 70 and a 25 percent IFD of 35 would have a support factor of 2.0. The higher the support factor, the greater the ability of the foam to provide support without bottoming out.

[0044] The recovery time for foam, especially memory foam, may be measured by a compression test and measuring the recovery time. The recovery time may be measured by ASTM D3574 M Foam Recovery Time Testing (2008). The recovery time for memory foams described herein may be in a range of 5 seconds to 10 seconds.

[0045] Other standards may be used to quantify the foams disclosed herein. For example, ASTM D3574 D Constant Deflection Compression Set Test which measure the permanent deformation of foam may be used, ASTM D3574 E Tensile Test which measures a foams ability to withstand tensile forces and stretch before breaking, ASTM D3574 F Tear Resistance test that evaluates a foams resistance to tearing, or ASTM D3574 I Dynamic Fatigue test that evaluates the loss of thickness or IFD over time may all be used to describe a foam.

[0046] The foams described herein may have a density in a range of 1 to 6 pounds per cubic foot. In some embodiments, the foams described herein may have a density in a range of 1.5 to 2.8 pounds per cubic foot. In some embodiments, the density of a memory foam described herein may be in a range of 2.5 to 5.5 pounds per cubic foot. In embodiments, the foams disclosed herein have a 25 percent ILD in a range of 7-50, e.g., 10-34. Some of the foams described herein may have a 25 percent CFD in a range of 15 to 30. The foams described herein may have a compression set of less than a 10 percent thickness loss and have an IFD loss over time of less than 15 percent for the life of the product. This may be represented by the fatigue resistance of the foams described herein being less than a 10 percent loss in thickness and less than 15 percent IFD loss. The tensile strength of the foams described herein may be greater than 12 pounds per square inch and the tear resistance of the foams disclosed herein may be greater than 1.5 pounds per inch.

[0047] Referring now to FIGS. 1A and 1B, a mattress 1 is provided in accordance with embodiments of the present disclosure. The mattress 1 may be described as having a head end 2 and a foot end 8 with a length of the mattress 1 being defined therebetween and sides 4, 6 that extend between the head end 2 and the foot end 8. The mattress 1 includes a plurality of layers, from the top to the bottom, a top support layer 10, a secondary support layer 20, a pressure relief layer 30, a main support layer 60, and a base layer 70. A thickness of the mattress 1 being defined between a top surface of the topmost layer, e.g., the top support layer 10, and a bottom surface of the bottommost layer, e.g., base layer 70.

[0048] The top support layer 10 may be a foam layer. In some embodiments, the top support layer 10 may be a memory foam layer or a gel-infused memory foam layer. The top support layer 10 extends over the entire surface of the mattress 1. In certain embodiments, the top support layer 10 may extend over substantially the entire surface of the mattress 1.

[0049] The secondary support layer 20 may be a foam layer. In some embodiments, the secondary support layer 20 may be a memory foam layer, a gel-infused memory foam layer, a gel grid structure, or combinations thereof. The secondary support layer 20 may be the same or different from the top support layer 10. The secondary support layer 20 may extend over substantially the entire surface of the mattress 1. In some embodiments, the mattress 1 is provided without the secondary support layer 20. In such embodiments, the top support layer 10 may be directly above and in contact with the pressure relief layer 30, which is described in greater detail below. The top support layer 10 may be bonded, adhered, or heat-fused to the support layer 20 to secure the top support layer 10 to the secondary support layer 20.

[0050] The main support layer 60 is positioned below the pressure relief layer 30. The main support layer 60 may be formed of foam, include a plurality of pocket springs, or a combination thereof. When the support layer 60 includes pocket springs, the pocket springs may be formed of traditional metal coil springs, gel springs, or combinations thereof. In some embodiments, the mattress 1 may include a base layer 70 disposed below the main support layer 60. The base layer 70 may be formed of foam. The main support layer 60 may be bonded, adhered, or heat-fused to the base layer 70 to secure the main support layer 60 to the base layer 70.

[0051] With particular reference to FIG. 1A, the layers of the mattress 1 may be encased or capped with side caps 80 of foam that extend along the sides 4, 6 and / or the head end 2 and the foot end 8 to encase the edges of the mattress 1. The side caps 80 may be between 1 inch wide and 4 inches wide. The side caps 80 may be disposed in a single or multiple layers in the thickness of the mattress. For example, the side caps 80 may extend along the sides 4, 6 of the mattress and be disposed on the sides of the pressure relief layer 30 such that the side caps 80 have a thickness equal to the pressure relief layer 30. The side caps 80 may seal or close the ends of channels defined in the pressure relief layer 30. In some embodiments, the side caps 80 may have a thickness equal to the thickness of the entire mattress 1 such that that side caps 80 define a thickness of the mattress 1. The side caps 80 may be formed of any of the foams disclosed herein. In addition, the entire mattress 1 may be within a cover or ticking (not explicitly shown) that encases the layers of the mattress 1 discussed above. In embodiments, the cover of the mattress 1 is sewn shut to prevent access to an interior of the cover, including the layers of the mattress 1. In certain embodiments, the cover of the mattress 1 may be selectively closed to allow access to the layers of the mattress.

[0052] With additional reference to FIG. 2, the pressure relief structure or layer 30 is described in accordance with embodiments of the present disclosure. The pressure relief layer 30 provides pressure relief for pressure points of a user of the mattress 1. The pressure relief layer 30 may maintain consistent pressure relief due to the variable nature of material forming the pressure relief layer 30. The pressure relief layer 30 may have pressure relief zones 34 and support zones 32. In embodiments, the pressure relief layer 30 has three pressure relief zones 34. The pressure relief zones 34 may be positioned at a distance between the head end 2 and the foot end 8 to be positioned at the shoulders, the hips, and the knees of a user of the mattress 1. The position of the pressure relief zones 34 may increase the comfort of a user of the mattress 1. In some embodiments, the pressure relief layer 30 may include one, two, or more than three pressure relief zones.

[0053] Referring now to FIGS. 2-4, the pressure relief layer 30 may include a tray 40. The tray 40 may be a continuous layer of foam. As shown, the tray 40 defines a first pressure relief zone 34 adjacent the head end 2 of the mattress 1, a second pressure relief zone 34 positioned at a mid-position of the mattress 1, and a third pressure relief zone 34 adjacent the foot end 8 of the mattress 1. The first pressure relief zone 34 may be spaced in a range of 6 inches to 11 inches, e.g., 8.5 inches, from the head end 2 of the mattress 1. Similarly, the third pressure relief zone 34 may be spaced in a range of 6 inches to 11 inches, e.g., 8.5 inches, from the foot end 8 of the mattress 1. The second pressure relief zone 34 may be positioned at or along the midline of the mattress 1 between the head end 2 and the foot end 8. The first pressure relief zone 34 and / or the second pressure relief zone 34 may have a width in a range of 12 inches to 22 inches, e.g., 16.5 inches. The second pressure relief zone 34 may have a width in a range of 1.5 inches to 4.5 inches, e.g., 3 inches. The second pressure relief zone 34 may be spaced apart in a range of 10 inches to 17 inches, e.g., 13.5 inches, from one of or both of the first and third pressure relief zones 34.

[0054] The tray 40 defines at least one channel 44 at each one of the pressure relief zones 34. In embodiments, the tray 40 defines four channels 44 one or more of the pressure relief zones 34. Each of the channels 44 may have the same or similar dimensions as one another. In such embodiments, the first and third pressure relief zones 34 may have multiple channels 44 and the second pressure relief zone 34 may have a single channel 44. For example, the first and third pressure relief zones 34 may have four channels 44 with a divider 42 of the tray 40 extending between and separating the respective channels 44. With particular reference to FIG. 4, the tray 40 includes a shelf section 46 that extends between the dividers 42 of the tray 40 and support zones 32 of the tray 40 between the pressure relief zones 34. As shown, each of the channels 44 has a depth that is less than the total thickness of the tray 40 such that the shelf sections 46 interconnect the tray 40. In certain embodiments, the entire tray 40 is of monolithic or unitary construction. The monolithic or unitary construction may increase a longevity of the pressure relief layer 30. In other embodiments, the tray 40 may be formed of multiple components that are bonded together to form the tray 40.

[0055] The tray 40 may be formed of a foam such as a polyurethane foam or a memory foam. In embodiments, the tray 40 may be formed of latex, air bladders, gel grids, thermoplastic elastomers, or water bladders. The tray 40 may have a homogenous construction throughout or may be formed of a combination of materials.

[0056] In some embodiments, the pressure relief layer 30 has a thickness of 3 inches and the channels 44 have a depth of 2 inches such that the shelf sections 46 have a thickness of 1 inch. The pressure relief layer 30 may have a thickness in a range of 2 inches to 12 inches and the channels may have a depth in a range of 25 percent to 80 percent of the thickness of the pressure relief layer 30.

[0057] With reference to FIG. 5, the pressure relief layer 30 includes a plurality of pods 50 disposed within the channels 44. The pods 50 may be individual elements disposed within the channels 44 or may be a continuous element disposed within each channel 44. The pods 50 may be formed of a plurality of materials including a foam (e.g., a polyurethane foam, a memory foam, a gel-infused foam, a copper infused foam), latex, an air bladder, a gel bladder, a gel grid, a water bladder, coil springs, gel springs, or combinations thereof. One or more of the pods 50 have a height equal to the depth of the channels 44 such that a top surface or point of pods 50 are planar with a top surface of the tray 40 when the pod 50 is disposed within a respective channel 44. As shown, the pods 50 substantially fill the channels 44 while leaving some void space within the channels 44. The void space may allow for the pods 50 or portions of the tray 40 to expand into the channels 44. The pods 50 and the void space may be less supportive than the tray 40 and / or the layers above the tray 40 (e.g., top support layer 10 or secondary support layer 20) to allow for relief to a user directly above the channels 44.

[0058] The shape of the pods 50 may be consistent for each channel 44 and in each channel 44. In some embodiments, the shape of the pods 50 may vary from channel 44 to channel 44 and may vary within each channel 44. As shown, the shape of pods 50 is the same and repeated through each of the channels 44. With particular reference to FIG. 6A, the base of each pod 50 is square and extends up as a rectangular prism for a portion of the height with the base of each pod 50 in contact with the sidewalls defining the channel 44. At a point spaced apart from the base (e.g., between 25 percent and 100 percent of the height of the pod 50), the corners of the pod 50 angle inward in a pyramidal manner towards a top contact surface 54 of the pod 50. The top portion of the pod 50 may have a frustopyramidal shape. The top of each pod 50 may be rounded at the corners and the apex to form the top contact surface 54. Rounding the corners and the apex may prevent concentration points of forces. Each pod 50 may be in contact with the sidewalls defining the channel 44 for the entire height of the channel 44. The pods 50 may be formed of foam and may have a firmness that is less than a firmness of a foam forming the tray 40. In certain embodiments, the pods 50 may a firmness the same or greater than a firmness of a foam forming the tray 40.

[0059] FIGS. 6B-6P show examples of other shapes for each pod 50. The shape of the pods 50 may be a profile view representing a cross-section for the entire length of the channel 44 or may be individual units that are placed in the channels 44. FIG. 6B illustrates a cylindrical pod 50. When cylindrical, the pod 50 may be a spring or a pocket spring. FIG. 6C shows a top view of a pod 50 having a frustopyramidal shape. FIGS. 6D-6I show a profile or cross-section of a shape of a respective pod 50. FIG. 6J illustrates a pod 50 in the form of a rectangular prism that substantially or totally fills a respective channel 44. FIGS. 6K-6P are perspective views of other shapes for the pods 50 that may be used alone or in combination with other shapes of pods 50.

[0060] The base of the pods 50 may be secured or bonded to the top surface of the shelves 46 of the tray 40 defining each of the channels 44. The base of the pods 50 may be adhered or heat fused to the top surface of the shelves 46. The remainder of the pods 50 may be unsecured to the tray 40. In some embodiments, the entire or part of the side surfaces of the pods 50 may be secured to the tray 40. For example, side surfaces of the pods 50 may be adhered or bonded to sidewalls of the tray 40 defining the respective channel 44. The top surface of each pod 50 may be free from the layer directly there above (e.g., top support layer 10 or secondary support layer 20) or may be secured to the layer directly there above. Securing the top surface of each pod 50 to the top layer directly there above may provide stability to the pressure relief layer 30.

[0061] Referring now to FIG. 7, a mattress topper 130 is provided in accordance with the present disclosure. The mattress topper 130 has a head end 102 and a foot end 108. The mattress topper 130 has a monolithic or unitary construction. The mattress topper 130 may be formed of foam (e.g., polyurethane foam, memory foam, gel-infused foam, or copper-infused foam). The mattress topper 130 may have a plurality of zones similar to the pressure relief layer 30 detailed above (e.g., support zones 132 and pressure relief zones 134). However, instead of channels, the mattress topper 130 may have grooves or material removed in each of the pressure relief zones 134 in similar positions along the length of the mattress topper 130. As shown, the mattress topper 130 includes pods or ridges 150 in each of the pressure relief zones 134. The ridges 150 have a semicircular top shape and may define slits 151 between each of the ridges 150. The ridges 150 and / or the slits 151 may provide relief to features of a user positioned directly over the pressure relief zones 134. The shape of the ridges 150 of the pressure relief zones 134 may have a variety of shapes to provide pressure relief to a user positioned thereon. Unlike the pressure relief layer 34 detailed above, the top surface of the mattress topper 130 may be in direct contact with a user positioned thereon. It will be appreciated that a sheet or blanket may be positioned between the mattress topper 130 and a user thereon while still being considered in direct contact without another layer of foam disposed between the mattress topper 130 and the user. Moreover, in some embodiments, the mattress topper 130 may have a cover to protect the foam of the mattress topper 130 with the mattress topper 130 still being considered in direct contact with the user thereon.

[0062] With reference to FIG. 8, another mattress topper 230 is provided in accordance with the present disclosure. The mattress topper 230 may have a head end 202 and a foot end 208. The mattress topper 230 may have a single pattern repeated along the length of the mattress topper 230. As shown, the mattress topper 230 has a sinusoidal ridge pattern with ridges 250 and troughs 252 defined between the ridges 250. The troughs 252 may provide pressure relief to a user positioned thereon.

[0063] Referring now to FIG. 9, another mattress 301 is provided in accordance with embodiments of the present disclosure. The mattress 301 has a head end 302 and a foot end 308 and pressure relief zones 334 and support zones 332 similar to the mattress 1 detailed above. The mattress 301 includes a plurality of support members 340, 350 distributed throughout the area defined by the mattress 301 to define the pressure relief zones 334 and the support zones 332 similar to the pressure relief zones 34 and the support zones 32. The individual support members 340, 350 may be independent of one another or may be tied together within the respective zones 334, 332 and / or between the zones 334, 332. Each support member 340, 350 may be a foam element, a coil spring, a gel spring, or combinations thereof. When a support member 340, 350 is provided in the form of a coil spring or a gel spring, the respective spring may be pocketed within a fabric or foam enclosure. Each support member 340, 350 may act as a spring having a spring constant measured in pounds per inch of compression. The spring constant in support members 340, 350 may be constant or may be progressive. When the spring constant is progressive, the increase may be at a steady rate or at a progressive rate. In certain embodiments, one or more of the support members 340, 350 may have a spring constant in compression and a recovery rate that differs from the spring constant in compression. For example, a support member 340, 350 including memory foam may compress as a function of the spring constant but the memory foam may reduce the recovery rate as the load is removed.

[0064] In some embodiments, the compression of the support members 350 of pressure relief zones 334 may vary from the support members 340 of the support zones 332 in size. The increase in size may cause each support member 350 to have an increased load as compared to the support members 340 based on the surface area of the top surface of the support members 340. For example, the support members 340 may have a diameter of 6 inches and a surface area of 28 inches and the support members 350 may have a diameter of 9 inches and a surface area of 63 inches. Thus, when a user rests on the surface, an equal load of the user distributed on the surface will result in 2.25 times the load on each of the support members 350 compared to each of the support members 340. Thus, the support members 350 having the same spring constant as the support members 340 will compress 2.25 times farther than the support members 340 and provide pressure relief in those areas. In certain embodiments, the spring constant of the support members 340, 350 are different from one another such that the support members 350 have a spring constant that is less than the spring constant of the support members 340.

[0065] While the mattress 301 is described as an entire mattress, it is contemplated that the mattress 301 may be a pressure relief layer within a mattress (e.g., pressure relief layer 30 in mattress 1). In addition, the mattress 301 may include side caps 380 that surround the coils on the head end, the foot end, or the sides. The mattress 301 may include a cover or ticking in the form of a fabric that covers the coils and or the side caps 380.

[0066] Referring now to FIG. 10, a mattress 401 is disclosed in accordance with embodiments of the present disclosure. The mattress 401 has a head end 402 and a foot end 408 and includes support zones 432 and pressure relief zones 434 defined therebetween similar to the support zones 32 and the pressure relief zones 34 detailed above with respect to the mattress 1.

[0067] The support zones 432 may be formed as a tray 440 in a similar manner to the tray 40 detailed above. For example, the support zones 432 may be a tray 440 that defines channels 444 in the locations to receive bladders 450. The bladders 450 may be filled with air, water, or gel. The bladders 450 are configured to deform or compress more than the support zones 432. The bladders 450 may be distinct from one another or may be in fluid communication with one another. The air, water, or gel within the bladders 450 may be sealed therein. In some embodiments, one or more of the bladders 450 may be in fluid communication with a pump or a compressor 460. The pump 460 may vary the pressure of the fluid within the bladder 450 based on a controller 470 that is adjustable by a user. The controller 470 may be a manual controller dedicated to the pump 460 or may be an application on another device (e.g., a smart phone or smart speaker). In certain embodiments, the controller 470 may adjust the pressure within the bladder 450 based on one or more conditions. The controller 470 may be in signal communication with one or more sensors that are configured to detect conditions of the bladder 450, the user, or the environment around the bladder 450. The controller 470 may control the pressure of all bladders 450 to be equal to one another or may adjust the pressure of each bladder 450 individually.

[0068] The bladders 450 may include a single bladder in each pressure relief zone 434. In certain embodiments, a pressure relief zone 434 may include more than one bladder 450. Having multiple bladders 450 in a single pressure relief zone 434 may allow for body contouring of the bladders 450 within the pressure relief zone 434. Multiple bladders 450 in a single pressure relief zone 434 may be in fluid communication with one another or may be separate from one another.

[0069] The support zones 432 may be formed of a foam material or formed of bladders. The support zones 432 provide greater support than the bladders 450 of the pressure relief zones 434 such that the pressure relief zones 434 compress or deform more than the support zones 432 under equal load. When the support zones 432 formed of bladders, the bladders may be filled with air, water, or gel. The bladders may be filled to a higher pressure than the bladders 450 of the pressure relief zones 434.

[0070] Referring to FIGS. 11A-12C, pressure distribution maps of various regions of human bodies are provided in accordance with the present disclosure. The distribution maps show the pressure required to support the human body at different positions of the body when the human body lies on a mattress, mattress topper, or other supported cushion. In the specific example, the mattress used in FIGS. 11A-12C has the construction without a pressure relief layer and the mattress used in FIGS. 12A-12C includes a similar construction but with the inclusion of a pressure relief layer.

[0071] FIGS. 11A-C illustrate a pressure distribution map on a multi-layer cushion without a pressure-relief layer. In contrast, FIGS. 12A-C illustrate a pressure distribution map on a multi-layer cushion with a pressure relief layer, e.g., pressure relief layer 30, 130, 230, 330, 430. As shown in the pressure distribution maps, the gradient from top to bottom includes a high pressure, a moderate to high pressure, a low pressure, and a minimal pressure as indicated in the legend below. The pressure distribution maps were obtained using a pressure mapping system. A legend for the pressures measured by the pressure mapping system are below:Pressure CharacteristicsColor(PSI) (ranges)(High) > 6060 > (Moderate) > 3232 > (Low) > 3(Minimal) < 3

[0072] As clearly visible in the pressure distribution maps, when a pressure relief layer is present, the peak pressure is reduced in each of the targeted zones. For example, as shown in FIGS. 11A and 12A the comparison of a pressure analysis of the same male's buttocks illustrates that without a pressure relief layer, the pressure in the buttocks reaches levels in the high pressure zones and when the pressure relief layer is present, there are no high pressure zones and the moderate pressure zones are almost entirely removed. Thus, the pressure relief layer supporting the buttocks significantly reduces the pressure on the user. Similarly, as shown in FIGS. 11B and 12B illustrating a comparison of a pressure analysis of the same male's back, the high pressure zones are removed when the pressure relief layer is present and the areas of moderate pressure zones are greatly reduced. Further, as shown in FIGS. 11C and 12C illustrating a comparison of a pressure analysis of the same female's waist, the low and minimal pressure zones are eliminated with the use of the pressure relief layer. In addition, the high pressure zones of the back were also eliminated. From the pressure distribution maps provided, it is clear that the pressure relief layers may significantly reduce the pressure in targeted zones. In addition, it is shown that other areas may also have reduced pressure. For example, FIG. 12C illustrates that the pressure across the back of the user was also greatly reduced.

[0073] With reference to FIG. 13, a method of manufacturing a pressure relief layer and a multilayer mattress is generally referred to as method 1300. During the description of method 1300 reference may be made to mattress 1 and pressure relief layer 30 as shown in FIGS. 1-6A. The pressure relief layer 30 produced by method 1300 may be used as a standalone cushion or layer, e.g., a mattress topper or pad, or may be a layer in a multilayer mattress, e.g., mattress 1.

[0074] The method 1300 may include a process 1330 of manufacturing a pressure relief layer 30. The process 1330 includes forming a tray 40 of the pressure relief layer 30 (Step 1332). Forming the tray 40 may include forming a rectangular prism out of foam. The tray 40 may be a monolithic piece of foam with dimensions at least as large as the final pressure relief layer 30. The tray 40 may then be trimmed to the dimensions of the pressure relief layer 30. In some embodiments, the tray 40 may have the length and width of a twin, twin XL, full, queen, king, or other mattress size. The thickness of the tray 40 may be in a range of 2 inches to 12 inches, e.g., 4 inches. In certain embodiments, the width of the tray 40 may be slightly less than that of the desired mattress to allow for side caps to be disposed on either side of the tray 40. With the tray 40 trimmed, pressure relief zones 34 are cut out of the tray 40 (Step 1334). The pressure relief zones 34 may be cut by cutting one or more channels 44 in each of pressure relief zones 34. The channels 44 may extend laterally across the tray 40 between the sides thereof. Each pressure relief zone 34 may include a single channel 44 or may include 2 or more channels 44, e.g., 4 channels. Each channel 44 may have a length, as measured between the head end 2 and the foot end 8, in a range of 2 inches to 16 inches and extend laterally through the entire width of the tray 40. Each channel 44 may have a length the same as each other channel 44 or one or more of the channels 44 may have a different length than other channels 44. The channels 44 may have a depth that extends from the top of the tray 40 in a range of 50 percent to 90 percent of the depth of the tray 40, e.g., 75 percent of the depth of the tray or 3 inches for a 4-inch tray. The depth of each channel 44 may be the same or may be different from one or more of the other channels 44. When the channels 44 are cut, a shelf layer 46 of the tray 40 may extend between support zones 32 of the tray 40.

[0075] With the channels 44 cut in the tray 40, pods or bladders 50 may be positioned in the channels 44 (Step 1336). The pods or bladders 50 may be secured within the channels 44 of the tray 40. The pods or bladders 50 may be secured by bonding, adhering, heat-fusing, or otherwise securing the pods or bladders 50 to the tray 40. The pods or bladders 50 may be secured within the channels 44 only along the top surface of the shelf layer 46, along only one or both of the sidewalls defining the channels 44, or combinations of the top surface of the shelf layer 46 and one or both of the sidewalls defining the channels 44. The pods or bladders 50 may be secured within the channels 44 such that a top surface of the pods or bladders 50 are positioned at or below top surfaces of the support zones 32 adjacent to the channels 44.

[0076] The process 1330 of forming the pressure relief layer 30 may be completed during or before the rest of the method 1300. The method 1300 may include positioning a main support layer 60 (Step 1310). Positioning the main support layer 60 may include securing the main support layer 60 to a base layer 70. In some embodiments, the main support layer 60 is secured to the base layer by bonding, adhering, or heat-fusing the main support layer 60 to the base layer 70. As noted above, the main support layer 60 may be foam, pocket springs, or combinations thereof. With the main support layer 60 positioned, the pressure relief layer 30 is positioned on the main support layer 60 (Step 1340). The pressure relief layer 30 may be secured to the main support layer 60 by bonding, adhering, or heat-fusing a bottom surface of the tray 40 to a top surface of the main support layer 60. In some embodiments, the pressure relief layer 40 is free to move relative to the main support layer 60. In certain embodiments, an intermediate layer or cover is positioned between the main support layer 60 and the pressure relief layer 40.

[0077] With the pressure relief layer 30 positioned, a top support layer 10 may be positioned on top of the pressure relief layer 30 (Step 1360). In some embodiments, a secondary support layer 20 is positioned over the pressure relief layer 30 and under the top support layer 10 (Step 1350). The layer directly above the pressure relief layer 30 (e.g., the top support layer 10 or the secondary support layer 20) is secured to the top surface of the pressure relief layer 30 (Step 1370). Securing the layer directly above the pressure relief layer 30 to the top surface of the pressure relief layer 30 may including bonding, adhering, or heat-fusing the layer to the top surface of the pressure relief layer 30. The layer may only be secured to the top surface of the tray 40 such that the pods 50 disposed within the channels 44 of the tray 40 are unsecured to the layer directly above the pressure relief layer 30. In certain embodiments, the pods 50 are secured to the layer directly above the pressure relief layer 30.

[0078] Once all the layers of the mattress 1 are positioned, the method 1300 may include positioning side rails along the sides 4, 6 of one or more of the layers (Step 1380). With all the layers positioned, the layers (e.g., top support layer 10, the secondary support layer 20, the pressure relief layer 30, the main support layer 60, or the base layer 70) are covered with a cover (not explicitly shown) (Step 1390). The cover may be selectively closed (e.g., with a zipper) or may be permanently closed (e.g., stitched closed).

[0079] Although the method steps are described in a specific order, it should be understood that other steps may be performed in between described steps, described steps may be adjusted so that they occur at slightly different times, or the described steps may occur in any order unless otherwise specified.

[0080] While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Any combination of the above embodiments is also envisioned and is within the scope of the appended claims. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope of the claims appended hereto.

Claims

1. A mattress comprising:a base layer defining a base length and a base width;a top layer disposed above the base layer and having a top length and a top width the same as the base length and the base width; anda pressure relief layer disposed between the base layer and the top layer, the pressure relief layer comprising:a tray having a top surface and a bottom surface, a thickness of the pressure relief layer defined as the distance between the top surface to the bottom surface, the bottom surface defining a tray length and a tray width, the tray length and the tray width the same as the base length and the base width, the tray defining a first channel extending the width of the tray and extending downward through the top surface to a depth of 50 percent to 80 percent of the thickness of the tray, the tray having monolithic construction and formed of a foam having a first firmness; andone or more pods disposed within the first channel, the one or more pods having a rectangular base and extending upward from the rectangular base while remaining in contact with sidewalls defining the channel for at least 25 percent of a height of the one or more pods.

2. The mattress according to claim 1, wherein a bottom surface of the pressure relief layer is secured to a top surface of the base layer.

3. The mattress according to claim 1, wherein a top surface of the tray is secured to a bottom surface of the top layer.

4. The mattress according to claim 3, wherein a top surface of the one or more pods is unsecured to the bottom surface of the top layer.

5. The mattress according to claim 4, wherein a top surface of the one or more pods is in contact with the bottom surface of the top layer.

6. The mattress according to claim 1, wherein the one or more pods are formed of a memory foam.

7. The mattress according to claim 6, wherein the tray is formed of polyurethane foam.

8. The mattress according to claim 1, further comprising a secondary layer disposed between the top layer and the pressure relief layer.

9. The mattress according to claim 1, wherein the base layer is formed of foam.

10. The mattress according to claim 1, wherein the base layer includes pocketed springs.

11. The mattress according to claim 1, wherein the tray defines a second channel and a third channel that each extend the width of the tray and extend downward through the top surface of the tray, each of the first channel, the second channel, and the third channel spaced apart from one another along the length of the pressure relief layer, one or more pods disposed within each of the second channel and the third channel.

12. The mattress according to claim 1, further comprising a side cap extending the entire length of the pressure relief layer and having a thickness equal to or greater than a thickness of the tray, the side cap covering ends of the first channel.

13. The mattress according to claim 12, wherein the side cap defines a total thickness of the mattress and is disposed along each side of the mattress.

14. A mattress comprising:a base layer defining a base length and a base width;a top layer disposed above the base layer and having a top length and a top width the same as the base length and the base width; anda pressure relief layer disposed between the base layer and the top layer, the pressure relief layer defining a plurality of zones along the length of the pressure relief layer with each of zone of the plurality of zones extending across the entire width of the pressure relief layer, the plurality of zones, in order, including a first support zone, a first pressure relief zone, a second support zone, a second pressure relief zone, a third support zone, a third pressure relief zone, and a fourth support zone, the pressure relief layer including a tray, the tray defining at least one channel in each of the pressure relief zones that extend the width of the tray, the second support zone and the third support zone having a length of at least 10 inches on either side of the second pressure relief zone.

15. The mattress according to claim 14, wherein the pressure relief layer includes one or more pods disposed in each of the at least one channels.

16. The mattress according to claim 15, wherein the one or more pods are formed of at least one of memory foam, an air bladder, a water bladder, copper foam, gel foam, or combinations thereof.

17. The mattress according to claim 14, wherein each of the at least one channels extend from a top surface of the tray to a depth in a range of 50 percent to 80 percent of the thickness of the tray.

18. The mattress according to claim 14, wherein the first pressure relief zone includes four channels spaced apart from one another.

19. The mattress according to claim 14, wherein a top surface of the tray is secured to a bottom surface of the top layer.

20. A pressure relief structure comprising:a tray having a top surface and a bottom surface, a thickness of the pressure relief layer defined as the distance between the top surface and the bottom surface, the bottom surface defining a tray length and a tray width, the tray length, the tray defining a first channel extending the width of the tray and extending downward through the top surface to a depth of 50 percent to 80 percent of the thickness of the tray, the tray having monolithic construction and formed of a foam having a first firmness; andone or more pods disposed within the first channel, the one or more pods having a rectangular base and extending upward from the rectangular base while remaining in contact with sidewalls defining the channel for at least 25 percent of a height of the one or more pods.

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