Split-head mattress with enhanced support zone

Abstract

A split-head mattress includes: a first upper body zone; a second upper body zone, wherein the first upper body zone and second upper body zone are configured to move independently; a unitary lower body support zone connected; a gap separating the first upper body zone from the second upper body zone; wherein each of the first upper body zone and second upper body zones comprise: a shoulder support disposed at the connection with the unitary lower body support zone and extending toward the head end; an enhanced support zone disposed at the connection with the unitary lower body support zone and extending toward the head end, and having a first side that is adjacent to the shoulder support and a second side that is adjacent to the gap, an wherein the firmness of the enhanced support zone is greater than the firmness of the shoulder support.

Description

[0001] Split-head Mattress with Enhanced Support Zone

[0002] Field

[0003] One or more example embodiments relate to mattress systems having a split-head area with separate sections of the mattress that are independently operable to be raised and lowered.

[0004] BRIEF DESCRIPTION OF THE DRAWINGS

[0005] One or more example embodiments will now be described by reference with the following figures, in which:

[0006] Figure 1 shows one or more example embodiments in which a split-head mattress has two distinct sides of the mattress, a left side and a right side. At an end of the mattress that supports a person’s upper body a gap separates the two sides splitting the head-end portion of the mattress and forming a left upper body zone and a right upper body zone. These upper body zones of the mattress are configured to be raised and lowered independently of one another with each of the upper body zones having an enhanced support zone adjacent to the gap.

[0007] Figure 2 is a perspective view of an embodiment of the split-head mattress with an enhanced support zone, disposed on a base that is operable to independently raise and lower the two split sides of the mattress.

[0008] Figure 3 shows a cut-away view of the split-head portion of the mattress with each side of the split-head having coils of a first gauge placed over most of the area of each side of the mattress and a single row of coils having a second gauge placed at the inner edge of each side of the mattress separated by a gap. Figure 4 is another representation of an embodiment of a split-head mattress with an enhanced support zone in the split head portion of the mattress and showing representative wire gauges of coils in various parts of the mattress.

[0009] Figure 5 shows a cross sectional view of a conventional split-head mattress.

[0010] Figure 6 shows an embodiment with an enhanced support zone of two rows of coils.

[0011] Figure 7 is a photograph of an embodiment of a split-head mattress with an enhanced support zone, shown without a mattress cover and exposing the coil assemblies.

[0012] Figure 8 is a photograph of a completed split-head mattress with an enhanced support zone encased with a mattress cover.

[0013] DETAILED DESCRIPTION

[0014] Figure 1 shows a split-head mattress that has two distinct sides, a left side and a right side, suitable to support two people laying on each side of the mattress. Each side of the mattress has an upper body zone (10L, 10R) generally configured to support a person’s upper body, a mid-section zone (20L, 20R) generally configured to support a person’s mid-section, and a leg zone (30L, 30R) generally configured to support a person’s legs and feet when lying on the mattress. The upper body zones 10L and 10R include head supports 12L and 12R, respectively, and shoulder supports 14L and 14R, respectively. The mid-section zones 20L and 20R include mid-section supports 22L and 22R, respectively. Similarly, leg zones 30L and 30R include leg supports 32L and 32R, respectively. Reference numeral suffixes “L” and “R” designate the left and right sides of the mattress, respectively. Unless stated otherwise, use of reference numerals without a suffix are applicable to both sides of the mattress. In one exemplary embodiment, a foam casing forms the perimeter of the mattress which surrounds the head support structure 12, shoulder support structure 14, mid-section support structure 22, and leg support structure 32. Other embodiments can use other structures, other than foam casing, to form the perimeters of the mattress. For example, coils that are along the perimeter of the mattress that are firmer than coils within the perimeter of the mattress can be used either with or in place of foam casing. Various layers of material forming the upper surface of the mattress are disposed on top of these support structures and encased in a cover for the mattress.

[0015] In some exemplary embodiments, a center rail 40, made of foam, for example, is disposed between the left and right sides of the mattress in the mid-section zone 20 and leg zone 30. The center rail can act as a motion separator between the two sides of the mattress. In other embodiments a center rail is not present. Together the left and right sides of the mid-section zone 20 and leg zone 30 together with the center rail 40, if it is present, are encased in a cover that forms a singular bed surface in the mid-section zone 20 and leg zone 30 of the mattress. Each of the mid-section zones 20L and 20R includes a mid-section support structure 22L and 22R, respectively. Likewise, each of the leg zones 30L and 30R includes a leg support structure 32L and 32R, respectively.

[0016] The left and right upper body zones 10L and 10R include a shoulder support structure 14L and 14R, respectively, a head support structure 12L and 12R, respectively, and a top border 16L and 16R, respectively, arranged in that order in a longitudinal direction of the mattress that is a direction from the foot to the head of the mattress as shown in Fig. 1. The left upper body zone 10L is connected to an end of the left mid-section zone 20L and the right upper body zone 10R is connected to an end of the right mid-section zone 20R. A gap 50 separates the left upper body zone 10L from the right upper body zone 10R.

[0017] The left and right upper body zones 10L and 10R also include an enhanced support zone 18L and 18R, respectively. The left enhanced support zone 18L is disposed on a side of the left upper body zone 10L adjacent to the gap 50. Likewise, the right enhanced support zone 18R is disposed on a side of the right upper body zone 10R adjacent to the gap 50. In the embodiment show in Fig. 1, each enhanced support zone 18 extends in the longitudinal direction from the end of the upper body zone adjacent to the mid-section zone 20 to the top border 16.

[0018] The split-head mattress with enhanced support zones can be placed on an adjustable base 60, as shown for example, in Fig. 2. Here, the adjustable base is controllable to cause each of the upper body zones 10 of the mattress to raise and lower independently of each other. Fig. 2 shows the split head mattress on an adjustable base 60 with the left upper body zone 10L raised higher than the right upper body zone 10R. Non-limiting examples of adjustable bases include an Innova Sleep Systems Regent Queen QH04R9QH:3+4+6 split head adjustable base. Another embodiment can use two twin adjustable bases, one on each side of the split-head mattress, such as two Delight II CF04RSN: 4+7 adjustable bases. Other configurations of adjustable bases, including bases with an adjustable foot as well as an adjustable head, can be used with the splithead mattress.

[0019] The enhanced support zone 18 in the split-head mattress is configured to provide more support than the shoulder support structure 14 provides. The enhanced support zone can allow an occupant of the mattress, such as a person sleeping on one side of the mattress, to get closer to the edge of an upper body zone without feeling like the edge is compromised or weak if another occupant on the other side of the mattress has their side of the mattress raised. This enhanced support zone can provide the occupant with edge to edge support in the upper body zones 10L and 10R.

[0020] In certain non-limiting embodiments, the enhanced support zone 18 can have the same firmness as the head support structure 12, while being firmer than the shoulder support structure 14. In other embodiments enhanced support zone 18 can have a different firmness than the head support structure 12, so long as the enhanced support zone 18 is firmer than the shoulder support structure 14.

[0021] In certain embodiments, the leg support structure 32, the mid-section support structure 22, the shoulder support structure 14, the head support structure 12, and the enhanced support zone 18 all are formed from pocketed coil spring assemblies. See US Patent Application Publication No. 20130232699A1, which is incorporated herein by reference, for a description of examples of types of spring assemblies including pocketed springs that can be used for the support structures.

[0022] A non-limiting embodiment of a split-head mattress with an enhanced support zone is shown in Fig. 3. In this embodiment the upper body zones 100L and 100R, including the head support structure 12, shoulder support structure 14, the enhanced support zone, the mid-section zones and the leg zones all are pocketed coil spring assemblies. In this embodiment the head support structure 12 and shoulder support structure 14 in each of the upper body zones 100L and 100R, as well as the mid-section and leg zones on the left and right sides of the mattress all are formed from a single pocketed coil spring assembly 140L and 140R, respectively, having pocketed coils with springs of the same firmness. Accordingly, in this embodiment the firmness of the head support structure, the shoulder support structure, the mid-section zone, and the leg zone are all the same.

[0023] In Fig. 3, a single column of pocketed coils disposed on the right side of the spring assembly 140L forms enhanced support zone 180L for the left upper body zone 100L. In this embodiment the single column of pocketed coils that form the enhanced support zone 180 extends from the head to the foot of the mattress which can simplify manufacturing. The springs for this single column of pocketed coils are firmer than the springs for the spring assembly 140L. Accordingly, the springs for the enhanced support zone 180L are firmer than the springs for spring assembly 140L.

[0024] Likewise, a single column of pocketed coils disposed on the left side of the spring assembly 140R forms enhanced support zone 180R for the right upper body zone 100R and extends from the head to the foot of the mattress. The springs for this single column of pocketed coils are firmer than the springs for the spring assembly 140R. Accordingly, the springs for the enhanced support zone 180R are firmer than the springs for spring assembly 140R.

[0025] Figure 4 shows another embodiment of the split-head mattress with enhanced support zone. In this embodiment the enhanced support zones are made of a single column of pocketed coils, the springs of which have the same gauge wire as the springs in the head support structures. In this embodiment the head support structure and enhanced support zone are made of pocketed coils with springs made of 13.75 gauge wire and the shoulder support structure is made with springs of lighter gauge wire, 15.40 in this case. In this embodiment the springs in the spring assembly of the mid-section zone are heavier than the springs in the shoulder support structure, namely, 14.75 gauge compared to 15.50 gauge, but lighter than the springs in the head support and enhanced support zones. The springs in the leg zone have a wire gauge of 15.50. Springs with gauges other than those shown in Figure 4 so long as the springs in the enhanced support zone are firmer than the springs in adjacent zones such as head zone 12 and shoulder zone 14.

[0026] Figure 5 shows a cross sectional view of a conventional split-head mattress. While conventional split-head mattresses may have edge support along the outer perimeter of the mattress, the coils adjacent to the split have the same firmness as the coils in the center area of the mattress. This is shown in the top portion of Fig. 5. The bottom portion of Fig. 5 illustrates two bodies on the mattress, one on each side of the split-head portion of the mattress. Because the coils along the edge of the split-head portion of the mattress have the same firmness as those in the center of the split-head portion of the mattress, the bodies tend to lean towards the middle of the mattress. This can result in an uncomfortable feeling by the occupants.

[0027] Figure 6 shows an embodiment with an enhanced support zone of two rows of coils 18L and 18R. The coils in the enhanced support zone are firmer than the coils in the center portion of the split-head sections of the mattress. By using firmer coils with a lower gauge than the coils in the center portion of the mattress, the occupants will not have a tendency to lean towards the middle of the mattress where the split, or gap, is located. This structure can give the occupants a more secure and comfortable feeling that a conventional split-head mattress without an enhanced support zone.

[0028] Figure 7 is a photograph of an embodiment of a split-head mattress with an enhanced support zone, shown without a mattress cover and exposing the coil assemblies. Figure 8 is a photograph of a completed split-head mattress with an enhanced support zone encased with a mattress cover.

[0029] One or more example embodiments are not restricted to support members made of spring assemblies. The novel techniques described can be implemented using other types of support members such as foam support components rather than spring based components. For example, the various support structures shown in Fig. 1 can be made of foam rubber having the appropriate firmness and the enhanced support zones also can be formed of foam rubber having a different density and ILD measurement that the other adjacent zones of the mattress such that the enhanced support zone has the appropriate firmness according to the novel concepts described here. That is, foam rubber used in the enhanced support zone is firmer than the materials used for the shoulder support structure and / or the head support structure.

[0030] In embodiments using coils, the coils can be made from any type of suitable inner spring type coil conventionally used for sleep products such as pocketed coils, a Bonnell coil or other continuous wire units, although one or more example embodiments are not limited to these type of coils. Combinations of types of support units and enhanced support strips can be used depending on the application.

[0031] While one or more example embodiments have been particularly shown and described with reference to one or more example embodiments thereof, it would be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the claims.

Claims

Claims1. A split-head mattress, comprising: a first upper body zone configured to move from a horizontal position towards an upright position; a second upper body zone configured to move from the horizontal position towards the upright position, wherein the first upper body zone and second upper body zone are configured to move independently; a unitary lower body support zone connected to the first upper body zone and the second upper body zone; a gap separating the first upper body zone from the second upper body zone and extending in a longitudinal direction from where the first upper body zone and the second upper body zone are connected to the unitary lower body support zone to a head end of the first upper body zone and the second upper body zone; wherein each of the first upper body zone and second upper body zones comprise: a shoulder support disposed at the connection with the unitary lower body support zone and extending toward the head end; an enhanced support zone disposed at the connection with the unitary lower body support zone and extending toward the head end, and having a first side that is adjacent to the shoulder support and a second side that is adjacent to the gap, and wherein the firmness of the enhanced support zone is greater than the firmness of the shoulder support.

2. The split-head mattress according to claim 1, wherein the shoulder support and the enhanced support zone are comprised of spring assemblies comprising wire springs wherein a gauge of the wire springs in the enhanced support zone spring assembly is lower than a gauge of the wire springs in the shoulder support spring assembly.

3. The split-head mattress according to claim 2, wherein the wire springs in the enhanced support zone spring assembly have a wire gauge of 13,75 and the wire springs in the shoulder support spring assembly have a wire gauge of 15,50.

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