Mattress innerspring bladder system

Abstract

A mattress innerspring bladder system enables a tuned force response across a top surface of a mattress. The system comprises a mattress frame defining a top area and a bottom area; an innerspring comprising a plurality of mattress springs connected to the mattress frame and positioned between the top area and the bottom area; and a plurality of bladders positioned inside the innerspring. Each bladder of the plurality of bladders is elongated and positioned between spring convolutions of more than one mattress spring of the plurality of mattress springs, and selective inflation of the plurality of bladders defines a tuned force response perpendicular to and across the top area.

Description

TITLEMattress Innerspring Bladder SystemFIELD OF THE INVENTION

[0001] The present invention relates generally to an innerspring bladder system. In particular, although not exclusively, the invention relates to an inflatable bladder system for a mattress innerspring having a plurality of bladders positioned between mattress spring convolutions and coupled with the innerspring.BACKGROUND

[0002] A mattress innerspring is generally defined by an interconnected mesh of individual coil springs. A persistent challenge for the mattress industry concerns how a force response of such individual coil springs can be effectively adjusted or modulated to provide appropriate mattress support across the full area of a mattress innerspring and / or in designated areas of a mattress innerspring.

[0003] Pneumatic bladder systems have been proposed previously for use in conjunction with mattress coil springs in an effort to adjust the spring rate of the coil springs. However, such prior art bladder systems have generally failed to define a comprehensive innerspring system that provides a wide range of force response adjustment across the area of a mattress innerspring.

[0004] Therefore, there is a need for an improved mattress innerspring bladder system.OBJECT OF THE INVENTION

[0005] It is an object of the present invention to overcome and / or alleviate one or more of the disadvantages of the prior art or provide the consumer with a useful or commercial choice.SUMMARY OF THE INVENTION

[0006] In one aspect, although it need not be the only or the broadest aspect, the invention resides in a mattress innerspring bladder system, comprising: a mattress frame defining a top area and a bottom area; an innerspring comprising a plurality of mattress springs connected to the mattress frame and positioned between the top area and the bottom area; and a plurality of bladders positioned inside the innerspring; wherein each bladder of the plurality of bladders is elongated and positioned between spring convolutions of more than one mattress spring of the plurality of mattress springs, and whereby selective inflation of the plurality of bladders defines a tuned force response perpendicular to and across the top area.

[0007] Preferably, the top area is defined by a mattress length and width, and each bladder of the plurality of bladders extends across the mattress length and width.

[0008] Preferably, each bladder is adjacent to another bladder to form rows of bladders across the mattress length or width.

[0009] Preferably, an end of each bladder includes a handle for pushing or pulling the bladder through the innerspring and across the mattress length or width during manufacture of the system.

[0010] Preferably, the handle comprises a pocket defined by a fold in the end of the bladder.

[0011] Preferably, each bladder can be pressurised by filling it with a fluid.

[0012] Preferably, each bladder can be pressurised to define a force response perpendicular to the top area of the innerspring.

[0013] Preferably, each bladder can be selectively pressurised to tune a variable force response across the top area of the innerspring.

[0014] Preferably, the system further comprises an elongated paddle fortemporarily attaching to the handle of a bladder to push or pull the bladder through the innerspring during manufacture of the system.

[0015] Preferably, at least a first and a second bladder of the plurality of bladders are stacked, such that the first bladder is between convolutions of a first spring and the second bladder is positioned below or above the first bladder and between other convolutions of the same first spring.

[0016] Preferably, a third bladder is stacked with the first and second bladders, such that the third bladder is positioned between the first and second bladders and between other convolutions of the same first spring.

[0017] Preferably, more than three bladders extend across a row of mattress springs, and the more than three bladders are stacked one above the other and between convolutions of each spring in the row.

[0018] Preferably, the plurality of bladders comprises pneumatic bladders.

[0019] Preferably, the system further comprises a compressor connected to a controller and a valve network for selectively inflating and deflating individual bladders in the plurality of bladders.

[0020] Preferably, the system further comprises a plurality of groups of bladders, wherein all bladders in at least one group of bladders are fluidly connected to each other while not being fluidly connected to bladders in another group.BRIEF SUMMARY OF THE DRAWINGS

[0021] To assist in understanding the invention and to enable a person skilled in the art to put the invention into practical effect, preferred embodiments of the invention are described below by way of example only with reference to the accompanying drawings, in which:

[0022] FIG. 1 is a side view of a portion of a mattress innerspring system, according to an embodiment of the present invention.

[0023] FIG. 2 is a top perspective view of the portion of the mattress innerspring system of FIG. 1 .

[0024] FIG. 3 is a side view of the mattress innerspring system of FIG. 1 , where the bladders are shown inflated.

[0025] FIG. 4 is a top perspective view of the mattress innerspring system of FIG. 1 , where the bladders are shown inflated.

[0026] FIG. 5 is a side view of a portion of a mattress innerspring system, according to an alternative embodiment of the present invention.

[0027] FIG. 6 is a top perspective view of the portion of the mattress innerspring system of FIG. 5.

[0028] FIG. 7 is a side view of the mattress innerspring system of FIG. 5, where the bladders are shown inflated.

[0029] FIG. 8 is a top perspective view of the mattress innerspring system of FIG. 5, where the bladders are shown inflated.

[0030] FIG. 9 is a further top perspective view of the mattress innerspring system of FIG. 1 , showing a single bladder in the process of being installed between two rows of springs.

[0031] FIG. 10 is a further top perspective view of the mattress innerspring system of FIG. 1 , showing the withdrawal of an insertion tool.

[0032] FIG. 1 1 is a top perspective view of a single bladder of the system of FIG. 1 or 5, showing the insertion tool being inserted into a pocket of a bladder.

[0033] FIG. 12 is a top perspective view of a single bladder of the system of FIG. 1 or 5, showing the insertion tool being withdrawn from a pocket of a bladder.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0034] The present invention relates to an improved mattress innerspring bladder system. Elements of the invention are illustrated in concise outline form in the drawings, showing only those specific details that are necessary to understanding the embodiments of the present invention, but so as not to clutter the disclosure with excessive detail that will be obvious to those of ordinary skill in the art in light of the present description.

[0035] In this patent specification, adjectives such as first and second, left and right, above and below, top and bottom, upper and lower, upward and downward, etc., are used solely to define one element or method step from another element or method step without necessarily requiring a specific relative position or sequence that is described by the adjectives. Words such as “comprises” or “includes” are not used to define an exclusive set of elements or method steps. Rather, such words merely define a minimum set of elements or method steps included in a particular embodiment of the present invention.

[0036] According to one aspect, the present invention is a mattress innerspring bladder system, comprising: a mattress frame defining a top area and a bottom area; an innerspring comprising a plurality of mattress springs connected to the mattress frame and positioned between the top area and the bottom area; and a plurality of bladders positioned inside the innerspring; wherein each bladder of the plurality of bladders is elongated and positioned between spring convolutions of more than one mattress spring of the plurality of mattress springs, and whereby selective inflation of the plurality of bladders defines a tuned force response perpendicular to and across the top area.

[0037] Advantages of some embodiments of the present invention include enabling effective variability of a tuned force response across an entire top surface of a mattress.

[0038] Also, some embodiments enable improved manufacturability of a mattress innerspring bladder system, where handles positioned at ends of individual bladders can be used to effectively install the bladders in an innerspring.

[0039] Also, some embodiments enable an improved tunable force response by stacking several bladders vertically between spring convolutions.

[0040] Those skilled in the art will appreciate that not all of the above advantages are necessarily included in all embodiments of the present invention.

[0041] FIG. 1 is a side view of a portion of a mattress innerspring system 100, according to an embodiment of the present invention. The system 100 includes a plurality of coil springs 105 arranged in rows and columns (where a row extends into the drawing sheet of FIG. 1 and a column extends horizontally across the drawings sheet). The springs 105 are shown arranged in a “nonalternating” manner, such that each 360 degree convolution of each spring 105 has the same rotational orientation (along the longitudinal axis of the spring 105) as the corresponding convolution of each other spring 105. That provides open spaces 110 that extend between the rows of springs (i.e. , into the drawing sheet of FIG. 1 ) and along the entire length or width of the mattress.

[0042] As shown, in each row of springs 105 a plurality of four elongated bladders 115 are stacked vertically on top of each other between the convolutions of a single spring 105, and each bladder 1 15 also extends laterally between the convolutions of an adjacent spring 105 in an adjacent row of springs 105.

[0043] FIG. 2 is a top perspective view of the above described portion of the mattress innerspring system 100. As shown, the bladders 115 are deflated and thus relatively flat, extending as planar elements across the full length and width of the innerspring system 100.

[0044] As known in the art, the top distal end of each spring 105 is connected to a top wire mesh 200 of a mattress frame that defines a top side of the mattress innerspring system 100, and the bottom distal end of each spring 105 is connected to a bottom wire mesh 205 of the mattress frame that defines a bottom side of the mattress innerspring system 100.

[0045] FIGs. 3 and 4 are further side and top perspective views, respectively, of the mattress innerspring system 100, but where the bladders 1 15 are shown inflated. Those skilled in the art will appreciate that the bladders 1 15 can be pneumatic and inflated with air, or alternatively can be inflated with other fluids such as water or water-based mixtures.

[0046] The stacked and inflated bladders 115 can be pressurised to define a force response perpendicular to the top area of the innerspring. Further, different portions of the mattress innerspring, for example portions defining different sides of a bed, can be tuned for the requirements of different people or tuned for the requirements of different areas of a human body, such as the head, shoulders, waist and / or legs.

[0047] According to some embodiments, the mattress innerspring system 100 can further include a compressor connected to a controller and a valve network (not shown) for selectively inflating and deflating individual bladders 115 or groups of bladders 115 to define a tuned force response of the system 100.

[0048] FIG. 5 is a side view of a portion of a mattress innerspring system 500, according to an alternative embodiment of the present invention. Similar to the system 100, the system 500 also includes a plurality of coil springs 105 arranged in rows and columns. However, the springs 105 are shown arranged in an “alternating” manner, such that all the springs 105 in each column of springs 105 are rotated about their longitudinal axis by 180 degrees relative to all the springs 105 in each adjacent column.

[0049] In the system 500, the open spaces 110 of the system 100 do not exist, and the bladders 115 must be woven through the mattress innerspring. Accordingly, left and right sides of the top surfaces of the bladders 115 each define a sinusoidal wave, and the wave on the left side is 180 degrees out of phase with the wave on the right side.

[0050] FIG. 6 is a top perspective view of the portion of the mattress innerspring system 500. As shown, the bladders 115 are deflated and thus relatively flat, defining non-planar sinusoidal surfaces across the full length and width of the innerspring system 500.

[0051] Those skilled in the art will appreciate that the manufacturing techniques required to produce the mattress innerspring system 500 is relatively complex. As shown below, the visualisation of the system 500 is also quite complex when the bladders 115 are inflated.

[0052] FIGs. 7 and 8 are further side and top perspective views, respectively, of the mattress innerspring system 500, but where the bladders 1 15 are shown inflated.

[0053] FIG. 9 is a further top perspective view of the mattress innerspring system 100, but with most of the bladders 1 15 not shown. Rather, a single bladder 1 15 is shown in the process of being installed between two rows of springs 105.

[0054] An elongated insertion tool 900 can be slipped into a pocket 905 formed at a distal end of the bladder 115. The large arrow shown in FIG. 9 indicates that the insertion tool 900 enables the distal end of the bladder 1 15 to be slid or woven through the network of springs 105, which pulls a trailing end of the bladder 1 15 into a final installed position.

[0055] FIG. 10 is a further top perspective view of the mattress innerspring system 100, but with most of the bladders 1 15 not shown. A single bladder 1 15 is shown fully installed in the mattress innerspring system 100, and the large arrow indicates that the insertion tool 900 then can be simply withdrawn from the bladder 1 15 and from the system 100. The insertion tool 900 then can be used again to install additional bladders 115 in the system 100.

[0056] The pocket 905 can be formed by folding distal ends of a material of the bladder 1 15. According to alternative embodiments, handles or other hooklike devices can be attached to the bladder 1 15 to enable the insertion tool 900 to push the distal end of the bladder 1 15 into the mattress innerspring system 100.

[0057] FIGs. 1 1 and 12 are top perspective views of a single bladder 1 15, showing the insertion tool 900 being inserted into and being withdrawn from, respectively, the pocket 905.

[0058] According to some alternative embodiments, a bladder can include a feature to retain it in its position within a spring unit. For example, this can include an enlarged feature at the end of a bladder near the handle. This feature can be incorporated into the bladder and allow for the permanent inflation of an end section of the bladder. According to other embodiments, to further hold bladders in position a bladder design may also incorporate sections to facilitatemechanical attachment to a spring unit, without compromising the bladder functionality.

[0059] Those skilled in the art will appreciate that elements of the present invention can be manufactured from a wide range of different materials. For example, according to a typical embodiment the springs 105 can be made of steel or other metal alloys, the bladders 1 15 can be made of synthetic rubber or other polymers, and the insertion tool 900 can be made of wood, metal or plastic.

[0060] The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. Numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. Accordingly, this patent specification is intended to embrace all alternatives, modifications and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention.

Claims

CLAIMSWe claim:1 . A mattress innerspring bladder system, comprising: a mattress frame defining a top area and a bottom area; an innerspring comprising a plurality of mattress springs connected to the mattress frame and positioned between the top area and the bottom area; and a plurality of bladders positioned inside the innerspring; wherein each bladder of the plurality of bladders is elongated and positioned between spring convolutions of more than one mattress spring of the plurality of mattress springs, and whereby selective inflation of the plurality of bladders defines a tuned force response perpendicular to and across the top area.

2. The system of claim 1 , wherein the top area is defined by a mattress length and width, and each bladder of the plurality of bladders extends across the mattress length and width.

3. The system of claim 2, wherein each bladder is adjacent to another bladder to form rows of bladders across the mattress length or width.

4. The system of claim 1 , wherein an end of each bladder includes a handle for pushing or pulling the bladder through the innerspring and across the mattress length or width during manufacture of the system.

5. The system of claim 4, wherein the handle comprises a pocket defined by a fold in the end of the bladder.

6. The system of claim 1 , wherein each bladder can be pressurised by filling it with a fluid.

7. The system of claim 6, wherein each bladder can be pressurised to define a force response perpendicular to the top area of the innerspring.

8. The system of claim 7, wherein each bladder can be selectively pressurised to tune a variable force response across the top area of the innerspring.

9. The system of claim 4, further comprising an elongated paddle for temporarily attaching to the handle of a bladder to push or pull the bladder through the innerspring during manufacture of the system.

10. The system of claim 1 , wherein at least a first and a second bladder of the plurality of bladders are stacked, such that the first bladder is between convolutions of a first spring and the second bladder is positioned below or above the first bladder and between other convolutions of the same first spring.1 1 . The system of claim 10, wherein a third bladder is stacked with the first and second bladders, such that the third bladder is positioned between the first and second bladders and between other convolutions of the same first spring.

12. The system of claim 1 , wherein more than three bladders extend across a row of mattress springs, and the more than three bladders are stacked one above the other and between convolutions of each spring in the row.

13. The system of claim 1 , wherein the plurality of bladders comprises pneumatic bladders.

14. The system of claim 1 , further comprising a compressor connected to a controller and a valve network for selectively inflating and deflating individual bladders in the plurality of bladders.

15. The system of claim 1 , further comprising a plurality of groups of bladders, wherein all bladders in at least one group of bladders are fluidly connected to each other while not being fluidly connected to bladders in another group.

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