ADJUSTABLE MATTRESS TOPPER

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Patent Application Ser. Nos. 61/880,258 (SINO0007USL), filed Sep. 20, 2013, and 62/036,216 (SINO0007USL02), filed Aug. 12, 2014, which are herein incorporated by reference.

BACKGROUND

1. Field

Embodiments described herein relate to body support products formed from foam materials. In particular, embodiments described herein relate to an adjustable, foam-based mattress topper and methods for forming such mattress topper.

2. Description of the Related Art

Conventional body supports can be found in a wide variety of shapes and sizes, and are often adapted for supporting one or more parts of a user's body. Examples of body supports include mattresses, pillows, and other cushion-type products. Many body supports are generally constructed out of foam materials, such as polyurethane foam. The foam materials may include visco-elastic properties, such foam materials being known in the art as “memory foam,” which provides the body support with an increased ability to conform to a user and thereby distribute the weight of the user.

Although there are a multitude of foam materials that exhibit specific properties and different degrees of support, e.g. some foam materials being soft and others firm, many body supports are constructed entirely out of a single foam material. A single conventional body support product is thus not adjustable for use by multiple users who have a different needed or desired amount or quality of support. Based on the limitations of existing products and the high consumer demand for body supports, there is a continuous need for new and improved adjustable body support type products and for methods for forming such adjustable body support type products.

SUMMARY

Embodiments described herein include a body support system comprising a housing having a first chamber and a second chamber, a first support member having a first foam layer secured to a second foam layer. The first and second foam layers have different support characteristics. The body support system further comprises a second support member having a third foam layer secured to a fourth foam layer, and the third and fourth foam layers have different support characteristics. The first and second support members are removable from and securable in the first and second chambers, respectively.

In another embodiment, a body support system includes a foam layer; and a gel layer disposed on the foam layer, wherein the gel layer is applied in liquid form and allowed to cure on the foam layer.

In another embodiment, a method for forming a foam apparatus includes forming a plurality of holes in a foam layer, depositing a layer of liquid gel on a surface of the foam layer, and curing the layer of liquid gel to form a layer of solid gel on the foam layer.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

FIG. 1 illustrates a body support system according to one embodiment.

FIG. 2 illustrates a side view of an embodiment of a foam layer having a gel layer disposed thereon according to one embodiment.

FIG. 3 illustrates a process flow chart showing a method for forming a layer of solid gel on the foam layer according to one embodiment.

FIG. 4 is a top view of an embodiment of a foam layer having holes formed therein.

FIG. 5 is a top view of another embodiment of a foam layer having holes formed therein

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one implementation may be beneficially utilized on other implementations without specific recitation.

DETAILED DESCRIPTION

Embodiments described herein relate to a mattress topper, also known as a pillow top mattress pad. A mattress topper is generally placed on top of an existing bed or mattress for additional comfort. The mattress topper may be covered with the same or different sheets as the existing bed or mattress. Although described herein as a mattress topper, embodiments described herein are not limited to mattress toppers, but may include mattresses and other body support type products.

FIG. 1 illustrates a body support system 100, such as a mattress topper, according to one embodiment. The body support system 100 includes a first support member 10, a second support member 20, and an enclosure 30 for housing the first and second support members 10, 20. A user may easily insert and remove the support members 10, 20 to and from the enclosure 30 to adjust the body support system 100 as further described herein. The system 100 may be placed on top of an existing bed or mattress to provide additional comfort and/or support.

The first support member 10 may be positioned in a first chamber 32 of the enclosure, and the second support member 20 may be positioned in a second chamber 34 of the enclosure. The first and second chambers 32, 34 may be separated by a wall or partition 33 to provide a physical barrier between the support members 10, 20 when disposed in the enclosure 30. The first and second chambers 32, 34, may each have an access side 31, 35, respectively, that can be opened and closed for inserting, removing, and securing the support members 10, 20 therein. The access sides 31, 35 may be disposed on opposite sides of the enclosure 30. The access sides 31, 35 may be opened and closed using a zipper arrangement or other similar fastening mechanisms.

When the support members 10, 20 are secured in the respective chambers 32, 34 of the enclosure 30, the support members 10, 20 are disposed adjacent to each other such that they jointly form a substantially flat and continuous top and bottom surface for positioning on a bed or mattress for supporting one or more users. Although the enclosure 30 is illustrated in FIG. 1 as a rigid, rectangular housing, the entire enclosure 30 or one or more portions thereof may be formed from a flexible cloth or sheet-type material, a woven fabric material, and/or a pre-shrunk quilted fabric material. The enclosure 30 may be formed from other types of bedding materials known in the art.

The enclosure 30 may conform to the shapes of the support members 10, 20. The support members 10, 20 may be formed in numerous shapes and sizes. In one embodiment, the support members 10, 20 may have a rectangular shape. In one embodiment, the support members 10, 20 when placed adjacent to each other may substantially form the size of a full, queen, and/or king size mattress.

The first support member 10 may be formed by a first foam layer 12 that is secured to a second foam layer 14 using an adhesive 13, such as glue. Similarly, the second support member 20 may be formed by a third foam layer 22 that is secured to a fourth foam layer 24 using an adhesive 23, such as glue. The foam layers 12, 14, 22, 24 may be made out of “memory foam” or polyurethane foam having visco-elastic properties. One or more of the foam layers 12, 14, 22, 24 may have a density of about 1-5 lbs/ft³. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may have a density that is different or the same as the density of one or more of the other layers 12, 14, 22, 24. One or more of the foam layers 12, 14, 22, 24 may have a thickness of about 1-5 inches. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may have a thickness that is different or the same as the thickness of one or more of the other layers 12, 14, 22, 24.

One or more of the foam layers 12, 14, 22, 24 may have an indention load deflection (“ILD”) rating of about 1-25 lbs. In one embodiment, one or more of the foam layers, 12, 14, 22, 24 may have an ILD rating of about 1-4 lbs, about 1-15 lbs, about 4-15 lbs, about 4-20 lbs, and about 20-25 lbs. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may have an ILD rating of about 11 lbs, an ILD rating less than about 11 lbs, or an ILD rating greater than about 11 lbs. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may have an ILD rating that is about 2-3 lbs greater than or less than the ILD rating of one or more of the other foam layers 12, 14, 22, 24. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may have an ILD rating that is different or the same as the ILD rating of one or more of the other layers 12, 14, 22, 24.

In one embodiment, the foam layer 24 of the second support member 20 may be infused with a gel material 25, such as a polyurethane based gel. The gel material 25 may comprise polyether or polyol. In one embodiment, the gel material 25 may be formed by reacting a polyol with an isocyanate in the presence of a catalyst. The gel material 25 may be in the form of particles or beads embedded in the foam layer 24. The gel material 25 may be a polymer such as elastomeric polymers, thermosetting polymers, thermoplastic elastomers, and combinations thereof. Suitable gels include polyurethane gels, silicone gels, PVC gels, polyorganosiloxane gels, polyol gels, polyisocyanate gels, and combinations thereof. The gel material 25 may provide additional support and/or increase the thermal conductivity of the foam layer 24 to effectively remove or absorb the body heat of a user, thereby providing a cool or colder temperature support than a non-gel-infused layer. The opposite foam layer 22 of the second support member 20 may be a non-gel-infused layer. Although the gel-infused layer is illustrated as foam layer 24 in FIG. 1, embodiments described herein include one or more of the foam layers 12, 14, 22, 24 having a gel component. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may have a thermal conductivity that is different or the same as the thermal conductivity of one or more of the other foam layers 12, 14, 22, 24. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may include a layer of gel material laminated or disposed across substantially all or a portion of the upper surfaces of the foam layers. In one embodiment, one or more of the foam layers 12, 14, 22, 24 may include one or more gel discs or squares spaced across the upper surfaces of the foam layers.

In another embodiment, the gel material may be applied on a surface of one or more of the foam layers 12, 14, 22, 24 in liquid form and allowed to cure. For example, the gel material may be applied in liquid form on top of the first foam layer 12 using a brush or other tool suitable for applying the gel material in liquid form. In another example, the gel material may be applied using a device for spraying liquid. The applied gel material may adhere to the foam layer without the use of any additional adhesives such as glue, although an adhesive may optionally be used to enhance attachment between the gel material and the foam layer. After curing, the gel material forms a solid gel layer 41 above the foam layer 12, as shown in FIG. 2. Multiple applications of the liquid gel may be performed to increase the height of the gel layer above the first foam layer 12. In one embodiment, after curing, the height of the gel layer is from about 0.003 inches to about 2 inches. In another embodiment, the height of the gel layer is from about 0.004 to about 0.5 inches. In yet another embodiment, the height of the gel material is from about 0.004 to about 0.2 inches. An exemplary process of forming the foam layer 12 having the solid gel layer 41 is described below with reference to FIG. 3.

In one embodiment, the foam layers of the support members 10, 20 may have different support characteristics, including different material properties, so that a user may lie on one of the foam layers for a specific degree of comfort or support, and may flip or adjust the support member 10, 20 to lie on the opposite foam layer for a different degree of comfort or support. In one example, the first foam layer 12 of the first support member 10 may be relatively soft and have an ILD rating of about 7 lbs, while the second foam layer 14 may be relatively firm and have an ILD rating of about 14 lbs. In one embodiment, the first foam layer 12 may have an ILD rating that is about 2-3 lbs greater than or less than the ILD rating of the second foam layer 14. The foam layers of the second support member 20 may be similarly situated. In this manner, when the support members 10, 20 are secured adjacent to each other in the enclosure 30, a user may position or adjust one of the support members 10, 20 with the softer foam layer facing up, while positioning or adjusting the other support member 10, 20 with the firmer foam layer facing up for another user. In another example, the support members 10, 20 may each have one gel-infused foam layer, and an opposite non-gel-infused foam layer, so that one user may lie on a gel-infused foam layer, while another user may lie on a non-gel-infused layer of the same body support system 100. In yet another example, the support members 10, 20 may each have one gel-infused foam layer, and an opposite foam layer having a gel layer formed thereon, so that one user may lie on a gel-infused foam layer, while another user may lie on a gel layer above a foam layer of the same body support system 100. In a further example, the gel layer is formed by applying a gel material in liquid form on the foam layer. Since the support members 10, 20 can be readily inserted and removed to and from the enclosure 30, the body support system 100 is adjustable to accommodate multiple comfort and support preferences of one or more users.

FIG. 1 illustrates the first foam layer 12 of the first support member 10 as the top layer disposed in the first chamber 32, and the fourth foam layer 24 of the second support member 20 as the top layer disposed in the second chamber 34. As described above, one or both of the support members 10, 20 may be adjusted so that that the second foam layer 14 and/or the third foam layer 22 form the top layers for supporting a user. Embodiments described herein include multiple variations of the above recited foam layer characteristics and materials.

In another embodiment, at least one of the support members 10, 20 may contain only one foam layer. For example, the first support member 10 may include a gel infused foam layer and the second support member 20 may include a foam layer having a different ILD rating than the foam layer of the first support member 10. In yet another embodiment, the foam layer of the second support member 20 may include a gel layer formed by a gel material applied in liquid form on the foam layer.

FIG. 3 illustrates an exemplary process flow chart 300 showing a method for forming the foam layer having a gel layer disposed thereon. At block 302, a plurality of holes is formed in a foam layer, such as the foam layer 12. The foam layer 12 may be made of any suitable material described herein. The plurality of holes may be in any suitable pattern. In one embodiment, the holes form a plurality of straight lines that are parallel to each other, and the corresponding holes in adjacent lines may be aligned or staggered, as illustrated in FIGS. 4 and 5. In FIG. 4, the holes in line 410 are aligned with the holes in line 420 of the foam layer 441. In FIG. 5, the holes in line 510 are staggered with the holes in line 520 of the foam layer 541. The holes in the same line or the adjacent line may be spaced at about 1 inch to about 10 inches apart from each other; preferably, at about 1.5 inches to about 6 inches apart; more preferably, at about 2 inches to about 5 inches apart. In one embodiment, the holes are through holes, which extend from a first surface of the foam layer to a second surface of the foam layer that is opposite the first surface, such as from the top surface to the bottom surface. The holes may have different cross sectional shapes. In one embodiment, the holes have a circular cross sectional shape. The holes have a diameter from about 0.25 inches to about 3 inches; preferably, from about 0.3 inches to about 1.5 inches. The holes may be formed in any suitable manner, such as forming each hole individually or forming multiples holes at one time. In another embodiment, a line of holes or multiple lines of holes are formed simultaneously. For example, the foam layer 12 may be positioned on a conveyor belt, and the holes may be formed as the foam layer 12 passes through a hole punch machine. In one embodiment, the holes are formed to increase ventilation through the foam layer 12.

At block 304, a first layer of gel is deposited on the top surface of the foam layer. Suitable gels for the first layer of gel include polyurethane gels, silicone gels, PVC gels, polyorganosiloxane gels, polyol gels, polyisocyanate gels, polyether gels and combinations thereof. The first layer of gel may be deposited by passing the foam layer 12 under a roller. The roller may be heated and coated with the gel in liquid form. In one embodiment, the roller may be part of a top coating machine, gluing machine, or other machine suitable for applying a liquid layer on the upper surface of the foam layer. As the foam layer is passed under the roller, the roller contacts the top surface of the foam layer, and as the roller spins, the upper surface of the foam layer is coated with the liquid gel. In one embodiment, the roller spins stationarily and the foam layer is placed on a conveyor, which moves the foam layer under the stationary spinning roller. Because the holes in the foam layer 12 were already formed, the roller does not contact holes, and thereby does not deposit the liquid gel inside the holes. Also, because the amount of liquid gel deposited on the top surface is small, the liquid gel does not substantially deposit inside the plurality of holes of the foam layer or on the side surfaces of the foam layer.

At block 306, the liquid gel is cured to form a thin layer of solid gel. For example, the curing may be performed at room temperature. The layer of solid gel may have a height between about 0.003 inches to about 2 inches. In another embodiment, the height of the gel layer is from about 0.004 inches to about 0.5 inches. In yet another embodiment, the height of the gel material is from about 0.004 to about 0.2 inches.

At block 308, multiple gel layers may be optionally be deposited to increase the height of the solid gel layer. For example, blocks 304 and 306 may be repeated to increase the height of the solid gel layer. For example, blocks 304 and 306 are repeated one time to double the height. In another example, multiple gel layers are deposited to achieve a total gel height from about 0.003 inches to about 2 inches; preferably, from about 0.004 inches to about 0.2 inches. In another embodiment, the additional gel layers deposited may be at the same or different height as the first gel layer or other gel layers. In one embodiment, two, three, four, five, or more gel layers may be deposited on the foam layer. The use of multiple gel layers to achieve a predetermined height may ensure the plurality of holes formed in the foam layer remain substantially free of gel, thus improving ventilation.

At block 309, after the layer of solid gel having a predetermined height is formed on the top surface of the foam layer, an optional powder may be applied to the surface of the layer of solid gel to improve the surface of the layer of solid gel. The powder prevents the surface of the layer of solid gel from sticking to other surfaces that may come in contact with the surface of the layer of solid gel.

In one embodiment, a body support system includes an enclosure having a first chamber and a second chamber; a first support member having a first foam layer secured to a second foam layer, wherein the first and second foam layers have different support characteristics; and a second support member having a third foam layer secured to a fourth foam layer, wherein the third and fourth foam layers have different support characteristics, and wherein the first and second support members are removable from and securable in the first and second chambers, respectively.

In one or more of the embodiments described herein, the support characteristics include at least one of density, indention load deflection, thermal conductivity, firmness, softness, and material type.

In one or more of the embodiments described herein, the first foam layer includes an indention load deflection rating that is about 2-3 lbs greater than an indention load deflection rating of the second foam layer.

In one or more of the embodiments described herein, the third foam layer includes an indention load deflection rating that is about 2-3 lbs greater than an indention load deflection rating of the fourth foam layer.

In one or more of the embodiments described herein, one of the foam layers of the first and second support members includes a gel-infused foam layer, and wherein the other one of the foam layers of the first and second support members includes a non-gel-infused foam layer.

In one or more of the embodiments described herein, one of the foam layers of the first and second support members is softer than the other one of the foam layers of the first and second support members.

In one or more of the embodiments described herein, one of the foam layers of the first and second support members is firmer than the other one of the foam layers of the first and second support members.

In one or more of the embodiments described herein, the first and second support members are disposed in the enclosure such that the first foam layer and the third foam layer jointly form a substantially continuous upper support surface, and wherein the first foam layer has different support characteristics than the third foam layer.

In one or more of the embodiments described herein, one of the foam layers includes a gel disposed on a top surface.

In one or more of the embodiments described herein, the gel is applied on the top surface in liquid form.

In one or more of the embodiments described herein, the gel is applied using a brush or a spray device.

In another embodiment, a body support system includes a foam layer; and a gel layer disposed on the foam layer, wherein the gel layer is applied in liquid form and allowed to cure on the foam layer.

In one or more of the embodiments described herein, the foam layer comprises a polyurethane foam having viscoelastic properties.

In one or more of the embodiments described herein, the gel layer comprises a polyurethane gel.

In one or more of the embodiments described herein, the gel layer has a height of about 0.004 inches to about 0.5 inches.

In another embodiment, a method for forming a foam apparatus includes forming a plurality of holes in a foam layer, depositing a layer of liquid gel on a surface of the foam layer, and curing the layer of liquid gel to form a layer of solid gel.

In one or more of the embodiments described herein, the method further includes repeating the depositing step and the curing step until a total height of the layer of solid gel reaches a predetermined height.

In one or more of the embodiments described herein, the method further includes applying a powder on a top surface of the layer of solid gel.

In one or more of the embodiments described herein, the plurality of holes are through holes.

In one or more of the embodiments described herein, the layer of liquid gel is cured at room temperature.

While the foregoing is directed to embodiments of the present disclosure, other and further embodiments may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.