NZ581941A - A foam mattress with insertable rods - Google Patents

Abstract

Disclosed is a mattress (1) which comprises of a support element (2) and a plurality of rods (13). The support element is formed of a latex or flexible foam material, and has a pair of laterally opposing side walls, a pair of longitudinally opposing end walls and a pair of opposing faces each extending longitudinally between said end walls and extending laterally between said side walls. The support element includes a plurality of longitudinally spaced apertures (11) extending laterally across the support element from one of said side walls in between the opposing faces. The plurality of rods are each removably receivable in a respective one of the apertures.

Description

581941 PATENTS FORM 5 PATENTS ACT 1953 COMPLETE SPECIFICATION Our Ref: 934557NZ Dated: 15 December 2009 A mattress We, A.H. Beard Pty Ltd, an Australian company, ACN 000 060 677, of 38-64 Bryant Street, Padstow, New South Wales, 2211, Australia, hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: 1 0013E(2442207_1 ):IRG 581941 la A MATTRESS Technical Field The present invention relates to the field of bedding, and in particular relates to a mattress.

Background of the Invention The use of latex or flexible high density, high resilience foams (including visco-elastic foam) to form mattresses, and particularly to form support layers and/or comfort layers of mattresses, has gained popularity in recent years in place of inner spring mattresses. Such mattresses are typically structured with a softer top comfort layer laminated on to a more resilient and harder lower support layer that provides a higher level of support for a person lying on the mattress. The comfort layer is designed to allow the body to sink into the comfort layer, distributing pressure more evenly across the person's body, while still retaining support from the underlying support layer.

Mattress elements that are formed of latex or foam materials are generally of a uniform thickness and uniform material. Accordingly, such mattress elements provide a uniform support across their extent. The human body, however, does not have such a uniform structure with the mass distribution varying across the length of the body and the shape of the body also varying. Accordingly, different parts of the body have different support requirements, and uniform mattress structures typically result in various pressure points along the body. The individual needs of users may also vary over time, as their body shape and size changes.

It would thus be desirable to be able to customize the support characteristics of a mattress along its length.

Object of the Invention It is the object of the present invention to at least substantially satisfy the above desire.

Summary of the Invention In a first aspect, the present invention provides a mattress comprising a support element formed of a latex or flexible foam material, said support element having a pair of laterally opposing side walls, a pair of longitudinally opposing end walls and a pair of opposing faces each extending longitudinally between said end walls and extending laterally between said side walls; AH22(2440826 1):PRW 581941 2 wherein a plurality of longitudinally spaced apertures extend laterally across said support element from one of said side walls in between said opposing faces; said mattress further comprising a plurality of rods that are each removably receivable in a respective one of said apertures.

Typically, each of said apertures extends to the other of said side walls.

Typically, each said rod has a higher resilience than that of said latex or flexible foam material.

Typically, said apertures and said rods each have a substantially circular cross-section.

In a preferred form, at least some of said apertures are located in a shoulder zone of said support element.

The apertures may vary in diameter.

Each of said rods may be formed of, for example, polyethylene or high density polyurethane foam material.

Each of said rods will typically have a diameter substantially identical to that of the respective said aperture, although it is also envisaged that some (or all) of said rods may have a diameter smaller than that of the respective said aperture.

Brief Description of the Drawings Preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings wherein: Figure 1 is a perspective view of a mattress.

Figure 2 is a side elevation view of the mattress of Figure 1.

Figure 3 is a side elevation view of an alternate mattress.

Detailed Description of the Preferred Embodiments Referring to Figures 1 and 2 of the accompanying drawings, a mattress 1 comprises a support element 2 with a comfort element 3 located on the support element 2. The support element 2 is of a generally rectangular prismatic form, and has a pair of laterally opposing side walls 4, 5, a pair of longitudinally opposing end walls 6, 7 and a pair of opposing upper and lower faces 8, 9. The faces 8, 9 extend longitudinally between the end walls 6, 7 and laterally between the side walls 4, 5. The support element 2 is formed of a latex or flexible foam material. Typical flexible foam materials include open cell polyurethane foams. In the arrangement depicted, a lower resilience comfort element 3 is located on, and typically bonded to, the upper face 8 of the support element 2.

AH22C2440826 1):PRW 581941 3 A plurality of longitudinally spaced apertures 11 are formed in the support element 2, extending laterally across the support element 2 from one of the side walls 4 in between the opposing faces 8, 9 of the support element 2. The apertures 11 will typically extend through the entire width of the support element 2 through to the opposing side wall 5, 5 however it is envisaged that the apertures 11 might only open onto one of the side walls 4. The apertures 11 typically have a substantially circular cross-section, although other cross-sections are envisaged. The apertures 11 may be of equal diameter, or may vary in diameter. Diameters of the order of 25 mm would be typical. The apertures 11 may be equally spaced or the spacing of the apertures 11 may vary along the length of the support 10 element 2.

At least some of the apertures 11 are typically located in a shoulder zone 12 of the support element 2, being a zone on which the shoulders of a user would typically be located.

A plurality of rods 13 are provided, each being removably receivable in a respective 15 one of the apertures 11. Each of the rods 13 typically has a higher resilience to that of the latex or flexible foam material from which the support element 2 is formed. The rods 13 are typically flexible. Some examples of typical materials for forming the rods 13 include polyethylene or higher density polyurethane foam material. As depicted in Figure 2, each of the rods 13 may have a diameter that is substantially identical to that of the respective 20 aperture 11 in which it is received. In the arrangement depicted in Figure 3, however, the rods 13 have a diameter smaller than that of the respective aperture 11. It is also envisaged that some rods may have a diameter substantially identical to that of the respective aperture 11, whilst others have a smaller diameter.

In embodiments where the support element 2 is formed of latex, the apertures 11 are 25 typically formed during the vulcanization process that forms the latex, with fixed rods forming part of the mould in which the support element 2 is formed forming the apertures 11. As a result, the walls of the apertures 11 are effectively formed with a skin during the vulcanization process which aids in preventing any flaking or other damage to the support element 2 as the rods 13 are inserted or removed. In embodiments where the support 30 element 2 is formed of a foam material, it is envisaged that the apertures 11 may be lined so as to reduce any potential damage to the support element 2 during insertion and removal of the rods 13.

The mattress 1 is typically provided with a removable cover that might be secured to the edge of the lower face line with a zipper or other suitable means so as to enable AH22C2440826 1):PRW 581941 4 easy partial removal of the cover for access to the apertures 11 for insertion and removal of the rods 13.

The rods 13 serve to vary the resilience and support characteristics of the mattress 1 along its length so as to meet the particular needs and desires of persons using the 5 mattress 1. To achieve the desired support characteristics, a user might insert rods 13 in each of the apertures 11 or only in selected apertures, depending upon their body characteristics and desires. Known body pressure mapping techniques may be utilized to identify pressure points when a user is lying on the mattress 1 to better identify the preferred resilience characteristics along the length of the mattress 1 to alleviate the 10 pressure points. It is also envisaged that various rods 13 of differing resilience characteristics might be provided, potentially colour-coded, with more resilient rods 13 being provided in areas of the mattress where particularly high resilience is desired, lower resilience rods 13 being provided in other zones where intermediate resilience is desired, and no rods being utilized in areas where lower resilience is desired. is For configurations as depicted in Figure 3 where the rods 13 have a diameter smaller than that of the corresponding aperture 11 in which it is received, the mattress in these areas will be characterized by allowing lower resilience compression of the mattress to some degree until the aperture 11 is deformed sufficiently to contact the upper surface of the rods 13, upon which the resilience of the mattress is increased in that area. 20 Over time as the desired needs of the user of the mattress change, which may result from changes in body shape and/or mass or the user's age, the characteristics of the mattress 1 may be readily adjusted by adjusting the distribution and usage of the rods 13.

AH22Q440826 1):PRW

Claims (10)

The claims: 581941 5

1. A mattress comprising a support element formed of a latex or flexible foam material, said support element having a pair of laterally opposing side walls, a pair of longitudinally opposing end walls and a pair of opposing faces each extending longitudinally between said end walls and extending laterally between said side walls; wherein a plurality of longitudinally spaced apertures extend laterally across said support element from one of said side walls in between said opposing faces; said mattress further comprising a plurality of rods that are each removably receivable in a respective one of said apertures.

2. The mattress of claim 1, wherein each of said apertures extends to the other of said side walls.

3. The mattress of either one of claims 1 and 2, wherein each said rod has a higher resilience than that of said latex or flexible foam material.

4. The mattress of any one of claims 1 to 3, wherein said apertures and said rods each have a substantially circular cross-section.

5. The mattress of any one of claims 1 to 4, wherein at least some of said apertures are located in a shoulder zone of said support element.

6. The mattress of any one of claims 1 to 5, wherein said apertures vary in diameter.

7. The mattress of any one of claims 1 to 6, wherein each of said rods is formed of polyethylene or high density polyurethane foam material.

8. The mattress of any one of claims 1 to 7, wherein at least some of said rods has a diameter substantially identical to that of the respective said aperture.

9. The mattress of any one of claims 1 to 8, wherein at least some of said rods has a diameter smaller than that of the respective said aperture. AH22(2440826 1);PRW 581941 6

10. A mattress substantially as hereinbefore described with reference to Figures 1 and 2 or Figures 1 and 3 of the accompanying drawings. A. H. Beard Pty Ltd By the Attorneys for the Applicant SPRUSON & FERGUSON Per: AH22(244Q826 1):PRW