US20160262552A1

US20160262552A1 - Chiral Zipper System For A Mattress

Info

Publication number: US20160262552A1
Application number: US14/790,976
Authority: US
Inventors: William John Scarleski
Original assignee: Levitation Sciences LLC
Current assignee: Levitation Sciences LLC
Priority date: 2015-03-10
Filing date: 2015-07-02
Publication date: 2016-09-15
Also published as: AU2016229096A1; WO2017004618A1; EP3291708A1; CA2982583A1; WO2016145148A1; AU2016287838A1; US20170007036A1

Abstract

A multiple layer mattress system is disclosed which addresses the issue of degradation of the elasticity of a foam mattress core. In one embodiment, the multiple layer mattress is formed with split layers; namely, one or more comfort layers and one or more support layers. Each layer is encased with an encasement which includes complementary chiral zippers to enable the comfort layer and the support layer to be removably secured together. The chiral zippers allow the various layers to be rotated 180° relative to each other and reconnected thereto. Layers can also be added to the mattress or replaced to suit a user's comfort level. Optionally, a separate cover may be selectively secured to the top of a comfort layer and/or the bottom of the support layer for accessories. The optional bottom accessory cover may be used to provide active or passive maneuvering of the support layer relative to a foundation. The optional top accessory layer may provide for various accessories including: a protective cover; a heating pad, a smart tech cover, for example, as illustrated at lunasleep.com; a launderable cover; a pillow top and other accessories. An aftermarket mattress encasement is also disclosed that includes a top cover and a bottom cover connectable together by way of a chiral zipper system that allows accessories to be secured on top of a conventional mattress.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/130,906, filed on Mar. 10, 2015, hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to a system and method for forming mattresses with multiple layers that are removably connected together by way of a chiral zipper system that provides functionality heretofore unknown, such as; replacing one or more layers with one or more user selected layers, repositioning layers vertically relative to other layers, rotating one or more layers 180°; and enabling a mattress to be custom configured with one or more user selectable support layers and one or more user selectable comfort layers.
2. Description of the Prior Art
Various mattress systems are known. FIGS. 1-6 illustrate known mattress systems. These mattress systems vary from each other by way of the materials used to form the mattress core. For example, some known mattresses are formed from foam mattress cores, inner spring mattress cores and hybrid mattress cores.
FIGS. 1 and 2 illustrate various known memory foam mattress cores. Such memory foam cores are known to be made from various materials, such as polyurethane foam, memory foam, and latex foam and may contain gel or other materials. The foam core can be made with various densities as well as various shapes and thicknesses as illustrated in FIGS. 1 and 2 to form one or more layers of a mattress core. U.S. Patent Application Publication US No. US 2015/0082549 A1, hereby incorporated by reference, describes an exemplary foam mattress in detail.
FIGS. 3 and 4 illustrate various known innerspring mattress cores. Such inner spring mattress cores include a steel coil support system. Various types of steel coil support systems are known. For example, FIG. 3 illustrates an example in which the coil springs are connected together and form a single unit. FIG. 4 illustrates an alternative embodiment in which the coil springs are received in pockets. An example of the latter type of coil spring core is disclosed in detail in U.S. Pat. No. 6,883,196, hereby incorporated by reference.
The coil springs are known to have various shapes and configurations. The steel gauge of the coils as well as the number of coils per mattress may vary. The steel core support system is covered with various types of padding, such as foam, fiber and one or more additional layers of smaller coil springs.
FIGS. 5 and 6 illustrate known mattresses formed with hybrid mattress cores. Such hybrid mattress cores are known to include a steel core support system with one or more layers of foam, such as polyurethane foam, memory foam, or latex foam. Such hybrid mattress cores are also known to include a layer of gel foam.
In addition to the foam and inner spring support layers, mattresses are known to include spacers. Various spacers are illustrated in FIGS. 7-10. As shown in FIGS. 7-9, these spacers are known to be disposed as layers between the various layers of the mattress core. These spacers include air channels that allow air to flow through. FIG. 10 illustrates a spacer used as a top layer. As shown, the spacer illustrated in FIG. 10 is formed from porous reticulated polyurethane foam. Such a spacer is used to wick away heat from the mattress.
Unfortunately, the elasticity of some foam materials, such as memory foam, is known to degrade over a period of use resulting in uneven support causing discomfort. Since the mattress cores are normally encased with an encasement that does not allow access to the mattress core, a user is left with a few choices in such a situation. For one, a user can keep using the mattress and suffer with the discomfort. Alternatively, a user can replace the mattress, which is normally relatively expensive.
Another option is the user can purchase a “pillow top” cover and install it over the mattress. An example of a pillow top cover is disclosed in US Patent Application Publication No. US 2007/0283497 A1. Pillow tops are also relatively expensive.
Another problem with known mattresses relates to the fact that the top cover is not removable. Thus, when the top cover becomes soiled, it cannot be laundered.
In order to solve these problems, various mattress systems have been developed. Examples of these systems are disclosed in: US Patent Application Publication No. US 2010/0000019 A1; European Patent Application No. EP 0 748 602 A1; Canadian Patent Application Nos. CA 2 290 164 A1 and CA 2 297 573 A1; and Canadian Patent No. 2,166,942.
US Patent Application Publication No. US 2010/0000019 A1 discloses a mattress with an encasement that has a removable cover. The removable cover is formed with multiple layers, such as a top layer of a breathable fabric, one layer forming a moisture barrier and a batting layer that are quilted together forming a comfort layer. Even though this mattress system allows for laundering of the top cover of the mattress encasement, it does not allow for access to the mattress core. As such, as the elasticity of a foam core mattress degrades, there is no way to remedy the situation.
European Patent Application No. EP 0 748 602 A1 discloses a mattress with an encasement with top and bottom covers that are removable for laundering. In this case, the mattress core is a set of inner springs covered by padding. Though the elasticity of the inner springs will remain fairly constant, the support provided by the springs is fixed. As such, a user is unable to alter the support level.
Canadian Patent No. 2,166,942 discloses a mattress system which includes a mattress encasement that permanently encases the mattress core and a removable top panel that is removably attached to the top panel of the mattress encasement. The removable top panel is quilted and provides added comfort. It can also be removed for cleaning.
Canadian Patent Application No. CA 2 290 164 A1 discloses a removable quilted top cover that can be removably attached to a top panel of a mattress encasement. An additional panel can be inserted between the top panel of the mattress encasement and the top quilted cover. The additional panel is for added comfort and can be removed for laundering.
Canadian Patent Application No. CA 2 297 573 A1 is similar to Canadian Patent Application No. CA 2 290 164 A1 but includes a cover that is split in a lengthwise direction defining two halves of a mattress. Each half of the cover is removably attached to the mattress to enable removable support panels to be inserted in each half of the cover.
The foam core mattresses discussed above do not address the issue of eliminating the effects of degrading elasticity of the mattress core. At best, the prior art teaches to add removable top covers on top of a mattress to adjust comfort level on top of the mattress but does not disclose or suggest addressing the problems associated with the mattress core. The various covers discussed above do not allow access to the mattress core and thus would provide unsatisfactory results in situations in which the elasticity of the mattress core is significantly degraded. Moreover, none of the prior art references allow the mattress cores to be replaced or custom configured by the user after the mattress is purchased.
Thus, there is a need for providing a mattress system which addresses the problems discussed above and addresses the issue of degradation of the elasticity of the foam mattress cores and allows a user to custom configure as mattress even after it is purchased.

SUMMARY OF THE INVENTION

Briefly, a multiple layer mattress system is disclosed which addresses the issue of degradation of the elasticity of a foam mattress core. In one embodiment, the multiple layer mattress is formed with split layers; namely, one or more comfort layers and one or more support layers. Each layer is encased with an encasement which includes complementary chiral zippers to enable the comfort layer and the support layer to be removably secured together. The chiral zippers allow the various layers to be rotated 180° relative to each other and reconnected thereto. Layers can also be added to the mattress or replaced to suit a user's comfort level. Optionally, a separate cover may be selectively secured to the top of a comfort layer and/or the bottom of the support layer for accessories. The optional bottom accessory cover may be used to provide active or passive maneuvering of the support layer relative to a foundation. The optional top accessory layer may provide for various accessories including: a protective cover; a heating pad, a smart tech cover, for example, as illustrated at lunasleep.com; a launderable cover; a pillow top and other accessories. An aftermarket mattress encasement is also disclosed that includes a top cover and a bottom cover connectable together by way of a chiral zipper system that allows accessories to be secured on top of a conventional mattress.

DESCRIPTION OF THE DRAWING

These and other advantages of the present invention will be readily understood with reference to the following specification and attached drawing wherein:

FIG. 1 is an isometric view of an exemplary mattress core, shown with the encasement removed, illustrating the core formed from multiple layers of foam.

FIG. 2 is an isometric view of an exemplary mattress core, shown with a top cover partially removed and a fire barrier inner cover.

FIG. 3 is an isometric view of an exemplary inner spring mattress, partially broken away, illustrating an embodiment in which the coil springs are connected together.

FIG. 4 is similar to FIG. 3 but illustrates an exemplary embodiment in which the coil springs are disposed in pockets.

FIG. 5 is an isometric view of an exemplary hybrid mattress which includes multiple layers of inner springs with a spacer therebetween and a foam layer, shown with the mattress encasement partially removed.

FIG. 6 is an isometric view of another exemplary hybrid mattress which includes a layer of pocketed inner springs and a plurality of foam layers.

FIG. 7 is a partial isometric view of an exemplary spacer formed from a quilted material that defines air channels for use as part of a mattress core.

FIG. 8 is a partial isometric view of an alternate exemplary spacer for use as part of a mattress core.

FIG. 9 is a partial isometric view of another alternate exemplary spacer for use as part of a mattress core.

FIG. 10 is a partial isometric view of an exemplary spacer material known to be used as a top layer of a mattress core.

FIG. 11 is a partial isometric view illustrating an exemplary mattress with a removable cover that is removably attached to the mattress by way of a chiral zipper system.

FIG. 12 is an isometric view of an exemplary two layer which includes a support layer and comfort layer removably attachable to each other by way of a chiral zipper system, shown with the top and bottom encasements partially removed.

FIG. 13A is an isometric view illustrating the two layer mattress illustrated in FIG. 12 shown attached together by way of the chiral zipper system in a first configuration.

FIG. 13B is an exploded isometric view illustrating the two layer mattress illustrated in FIG. 13A shown in a first configuration with the corners of each layer labeled.

FIG. 13C is an isometric view illustrating the two layer mattress illustrated in FIG. 13A shown in a second configuration rotated 180°.

FIG. 13D is an exploded isometric view illustrating the two layer mattress illustrated in FIG. 13B shown in a second configuration rotated 180° with the corners of each layer labeled.

FIG. 14 is an exploded isometric view of an exemplary three-layer mattress in which each layer is connectable to each other by way of a chiral zipper system.

FIG. 15 is similar to FIG. 14, shown with each layer partially broken away to illustrate that the multiple layer mattress system can be used with virtually any mattress core.

FIG. 16A is an exploded isometric view of a top accessory top removably attachable to a mattress by way of a chiral zipper system.

FIG. 16B is an exploded isometric view of a top accessory panel removably attachable to a mattress by way of a chiral zipper system.

FIG. 17 is an isometric view of a multiple layer mattress connectable together with a chiral zipper system, shown with a top accessory layer removed and connectable to a top comfort layer of the multiple layer mattress by way of a chiral zipper system.

FIG. 18 is similar to FIG. 17 but shown with both a top accessory panel and a bottom accessory boot removed.

FIG. 19 is an exploded isometric view illustrating an encased mattress core with removably connectable top and bottom covers by way of chiral zipper systems.

FIG. 20 is similar to FIG. 19 but shown with an active bottom cover.

FIG. 21 is an exploded isometric view of a slit level mattress shown with chiral zippers on the top and bottom peripheral edges of each layer.

FIGS. 22A-22D illustrate a method for rotating of a top comfort layer with respect to a support layer removably attached thereto by a chiral zipper system.

FIGS. 23A-23D illustrate a method of removal and replacement of a mattress layer in a multiple layer mattress.

FIGS. 24A-24D illustrate a method of adding an additional mattress layer to a multiple layer mattress.

FIGS. 25A-25D illustrate a method of rotating multiple layers of a three-layer mattress at one time.

FIG. 26A is a simplified diagram of a chiral zipper system as used herein.

FIGS. 26B-26D are alternative embodiments of the chiral zipper system illustrated in FIG. 26A.

FIG. 27 is an alternative to a chiral zipper system.

FIGS. 28-39 illustrate alternate embodiments of the chiral zipper system.

DETAILED DESCRIPTION

A multiple layer mattress system is disclosed which addresses the issue of degradation of the elasticity of a foam mattress core. In one embodiment, the multiple layer mattress is formed with split layers; namely, one or more comfort layers and one or more support layers. Each layer is encased with an encasement which includes complementary chiral zippers to enable the comfort layer and the support layer to be removably secured together. The chiral zippers allow the various layers to be rotated 180° relative to each other and reconnected thereto. Layers can also be added to the mattress or replaced to suit a user's comfort level. Optionally, a separate cover may be selectively secured to the top of a comfort layer and/or the bottom of the support layer for accessories. The optional bottom accessory cover may be used to provide active or passive maneuvering of the support layer relative to a foundation. The optional top accessory layer may provide for various accessories including: a protective cover; a heating pad, a smart tech cover, for example, as illustrated at lunasleep.com; a launderable cover; a pillow top and other accessories. An aftermarket mattress encasement is also disclosed that includes a top cover and a bottom cover connectable together by way of a chiral zipper system that allows accessories to be secured on top of a conventional mattress.
As used herein, a mattress layer means a layer formed from virtually any conventional or non-conventional mattress core materials and covered with a conventional or unconventional encasement. Conventional core materials include foam cores, innerspring mattress cores and hybrid mattress cores that include a combination of both foam and innerspring mattress core materials, as generally illustrated in FIGS. 1-6. The mattress cores may include spacers, such as the spacers illustrated in FIGS. 7-9. A porous spacer, as illustrated in FIG. 10 can be used as the top layer to wick heat away from the mattress core.
As shown in FIGS. 4-6, innerspring mattress cores formed from pocketed springs may be encased around the periphery with foam. Inner spring mattress cores formed with interlocking springs may be encased with various materials including organic cotton and wool, as generally shown in FIG. 3 and covered with cotton.
The mattress cores can also be encased with various materials, For example. FIGS. 2 and 6 illustrate a fire barrier encasement for a foam mattress core. FIG. 3 illustrates an exemplary wool encasement for an inner spring mattress core. Foam layers are used to cover innerspring mattress cores as illustrated in FIGS. 4-6.
An important aspect of the mattress system disclosed herein is a chiral zipper system. As used herein, a chiral system relates to a zipper system that includes two zippers that are used to attach a cover or encasement to a mattress core layer or to attach two (2) or more mattress core layers together. The system allows the cover or the encasement or the core mattress layer to be un-zipped from the other mattress core layer, rotated 180° and zipped back to the other mattress core layer.
In addition, the chiral zipper system allows a mattress core zipped to another mattress core to be unzipped flipped about a horizontal axis and re-zipped together for example, with a configuration as shown in FIG. 19. In particular, with reference to FIG. 19, the core may be formed with a firm layer on one side and a less firm layer on the other side. By enabling the mattress core to be flipped about a horizontal axis, the user can then configure the sleep surface of the top of the mattress to be either the firm side or the less firm side. The Chiral zipper system allows the mattress core to be reconnected to one or more covers, either a top cover and/or a bottom cover. As such the configuration illustrated in FIG. 19 creates a user selectable mattress comfort level.
In addition, the top cover 196 may include an integral comfort layer. This top cover 196 can be removably attached to the mattress core 191. In an alternate embodiment, the top cover 196 may include an integral comfort layer that is formed from a single layer of conventional or non-conventional mattress comfort material. Alternately, the top cover 196 may be formed from at least two layers of conventional or non-conventional mattress comfort material. For example, the top cover 196 may be formed with a comfort layer formed from one or more layers of conventional or non-conventional mattress comfort materials. In one embodiment, the top cover may include a comfort layer formed from 2 different materials such as a latex layer and a foam layer. This allows additional selectivity of the sleep surface by flipping the top layer about a horizontal axis with respect to the mattress core and reattaching the top cover to the mattress core 191 by way of the chiral zipper system. This also applies to the bottom cover 190 which provides addition user mattress comfort selectivity.
Each zipper of the chiral zipper system may include a zipper start, a zipper stop formed on a zipper backing material and one or more zipper pulls. Alternatively, each zipper may include two zipper starts and no zipper stop. The head and tail ends of the backing material may be at least partially formed from a stretchable material to account for shrinkage.
Various configurations of the chiral zipper system are contemplated. An exemplary embodiment of a chiral zipper system is illustrated in FIG. 26 and generally identified with the reference numeral 50. As shown, the chiral zipper system includes two zippers 52 and 54. Each zipper 52 and 54 includes a zipper start, a zipper pull and a zipper stop. Both zippers 52 and 54 are shown in the fully zipped up position. The zipper 52 includes a zipper pull 56 and a zipper stop 58. The zipper 54 includes a zipper pull 60 and a zipper stop 62.
Each zipper 52, 54 may be a conventional zipper and extend around a mattress layer, for example 180° or 360°. Both zippers 52, 54 need to have the same length and be disposed at the same height relative to the side of the mattress layer. The zippers 52, 54 need to be oriented so that the zipper starts and zipper stops line of the two zippers line up when the mattress core is rotated 180° or flipped or a cover or encasement is rotated. For example, the zippers 52, 54 may be configured so that one zipper extends around one half of the mattress layer and the other zipper extends around the other half of the mattress layer, as generally shown in FIG. 26. The zippers 52, 54 may be further configured so that the mattress pull 56, 60 of one zipper 52, 54 is adjacent the zipper stop 58, 62 of the other zipper 52, 54. Such a configuration results in the zippers 52, 54 zipping and unzipping in the same direction. As shown in FIG. 26, both zippers 52, 54 will unzip in a counterclockwise direction. Both zippers 52, 54 will zip up in a clockwise direction.
The location of the starting and stopping points around the periphery of the mattress layer is not critical and may vary. The zippers 52, 54 need only be configured to have the functionality as discussed above and have the same length and be at the height relative to the side of the mattress layer. FIGS. 26B-26D illustrate alternate embodiments of the chiral zipper system illustrated in FIG. 26A utilizing two zippers.
FIG. 27 illustrates an alternate embodiment of the chiral zipper system illustrated in FIG. 26A utilizing four zippers, generally identified with the reference numeral 64. The zipper system 64 includes four (4) zippers 66, 68, 70 and 72. Each opposing pair of these zippers must be the same length and the same height relative to the side of a mattress layer. The zippers 66 and 70 form one opposing pair and the zippers 68 and 72 form another opposing pair. The lengths and/or the heights of the opposing pairs may different with respect to each other. Each opposing pair must zip and unzip in the same direction. For example, the zippers 66 and 70, which form one opposing pair, zip in a clockwise direction and unzip in a counter clockwise direction. The zippers 68 and 72, which form the other opposing pair, must all zip and unzip in the same direction but opposite to the direction of the first opposing pair. For example, the zippers 68 and 72 zip in a counterclockwise direction and unzip in a clockwise direction-opposite the direction of zipping and unzipping the zippers 66 and 70. Each zipper in an opposing pair must be disposed on opposite corners as shown.
As used herein, a chiral zipper system refers to any of the embodiments illustrated in FIGS. 26A-26D and also includes the chiral zipper alternate system illustrated in FIG. 27. As will be discussed in more detail below, the chiral zipper system allows mattresses to be formed in multiple layers and maneuvered in a way not hereto known. In particular, all of the chiral zipper systems allow mattress layers to be rotated 180° in a horizontal plane and be re-secured to contiguous mattress layers. Rotation of a mattress layer reduces wear and extends the life of a mattress. The use of chiral zipper systems in connection with multiple layer mattresses also allows mattress layers to be added, replaced and moved to different vertical positions to obviate the need to completely replace a mattress.
As used herein a multiple layer mattress refers to a mattress that is separate from a box spring or platform (“foundation”) and is normally supported by a foundation. The multiple layer mattress may include a support layer on the bottom of the stack and one or more comfort layers on top of the support layer. Each mattress layer may be formed from virtually any mattress core material including those mattress core materials discussed above and illustrated herein.
Turning to FIGS. 12 and 13A-13D, a two-layer mattress is illustrated and identified with the reference numerals 80 and 82. The layer 82 functions as the support layer while the layer 80 functions as a comfort layer.
The support layer 82 may include virtually any mattress core materials including those discussed above. For example, the exemplary support layer 82 may include individual or a matrix of inner springs, comfort foam, natural or synthetic materials otherwise used in an upper or lower portion of a mattress plus any materials normally used for comfort layers.
The comfort layer 80 may include virtually any mattress core materials including those discussed above. For example, the comfort layer may include one or more layers of memory foam, gel foam, spacer material, cotton, wool, latex or any natural or synthetic material, that is breathable or not.
Each mattress layer 80, 82 is covered with an encasement or outer fabric cover 84, 86, respectively. Such encasements are known to include removable bottom panels to enable mattress core materials to be received therein. The layers 80 and 82 may be selectively and releasably secured together by way of a chiral zipper system. As discussed above, the chiral zipper system may include a pair of zippers 88 and 90. One half of each of the zippers 88 and 90 is secured to the support layer 82 while the complementary half of each of the zippers 88 and 90 is secured to the comfort layer 80. Each half of the zippers 88 and 90 must be oriented so that the zippers 88 and 90 can be zipped up to secure the comfort layer 80 to the support layer 82 and unzipped to disconnect the support layer 82 from the comfort layer 80.
FIGS. 13A-13D illustrate the ability of the chiral zipper system to enable one layer of the multiple layer mattress to be rotated 180° relative to a contiguous layer and reconnected thereto. Referring first to FIG. 13A, an exemplary two layer mattress is shown with the support layer 82 and the comfort layer 80 secured together by the zippers 88 and 90 in a first orientation.
FIG. 13B illustrates the comfort layer 180 separated from the support layer 182 with a first orientation of the comfort layer 180 with respect to the support layer 182, as shown in FIG. 13A. In this orientation, the corners labeled as B on the comfort layer 180 is aligned with the corner labeled A on the support layer 182. Similarly, the corner labeled D on the comfort layer 180 is aligned with the corner labeled C on the support layer 182.
Turning to FIG. 13C, the comfort layer 180 is shown rotated 180° relative to the support layer 182. As shown in FIG. 13D, in this orientation, the corner labeled B on the comfort layer 180 is now aligned with the corner labeled C on the support layer 182. Similarly, the corner labeled as D on the comfort layer 180 is aligned with the corner labeled A on the support layer 182. FIG. 13C thus indicates a 180° rotation of the comfort layer 180 with respect to the support layer 182.
The chiral zippers 88 and 90 enable the comfort layer 180 to be reconnected to the support layer 182 after the comfort layer 180 is rotated 180° relative to the support layer 182. One half of the zippers 88 and 90 on the support layer 182 remain in place. However, when the comfort layer 180 is rotated with respect to the support layer 182, the complementary halves of the zippers 88 and 90 are also rotated 1800.
As such, with reference to FIG. 13D, after the rotation, the zipper half of the zipper 88 on the comfort layer 180 will be paired with the zipper half of the zipper 90 on the support layer 182. Similarly, the zipper half of the zipper 90 on the support layer 182 will be paired with the zipper half 88 on the comfort layer 180.
FIGS. 14 and 15 illustrate a multiple layer mattress system 94 that includes a support layer 96, a first comfort layer 98 and a second comfort layer 100. One or more additional comfort layers are also contemplated. In this embodiment, a separate chiral zipper system is used to interconnect each of the contiguous layers 96, 98 and 100 to each other. In particular, one chiral zipper system consisting of the zippers 102 and 104 is used to interconnect the comfort layer 98 to 100. A separate chiral zipper system consisting of the zippers 106 and 108 is used to interconnect the comfort layer 98 to the support layer 96.
Each of the comfort layers 98 and 100 may be rotated 180°. In particular, the comfort layer 98 can be rotated 180° relative to the support layer 96. Similarly, the comfort layer 98 can also be rotated 180° relative to the support layer 96.
In addition to rotating the comfort layers 98 and 100, one or more of the comfort layers 98 and 100 as well as the support layer 96 can be removed and/or replaced. For example the comfort layer 98 can be removed to form a two-mattress system. Additional layers can be added to form a mattress system with four or more layers, for example.
Turning to FIG. 15, the three-layer mattress system consisting of the layers 96, 98 and 100, illustrated in FIG. 14 but without a bottom cover, is shown. The corners are broken away to emphasize the fact the mattress cores within these layers 96, 98 and 100 can be of virtually any mattress core material.
FIGS. 16A, 16B and 17 illustrate various types of accessory tops that can be secured to a top comfort layer of a mattress system. Referring first to FIG. 16A, a shoebox type accessory top is shown and generally identified with the reference numeral 120. The shoe box top includes a top panel 122 and four side panels 124. The shoe box top 120 is configured to be attached to a top comfort layer 126 by way of a chiral zipper system which includes the zippers 128 and 130. The shoe box top 120 allows a floating comfort layer (not shown) to be held in place between the underside of the shoe box top 120 and the top of a comfort layer 126 by way of the zippers 128 and 130. In this embodiment, the zippers 128 and 130 are secured to a top edge of the comfort layer 126 and a bottom edge of the side panels 124 of the shoe box top 120. The chiral zipper system allows the shoe box top 120 to be secured to the top comfort layer 126 in either a normal orientation or rotated 180° therefrom.
FIG. 16B illustrates an alternative top. The top 132 is formed as a panel that is connected to a top comfort layer 134 by way of a chiral zipper system that includes the zippers 138 and 140. The top 132 is an accessory top, for example, as discussed above. The chiral zipper system allows the panel 132 to be secured to the top comfort layer 126 in either a normal orientation or rotated 180° therefrom.
FIG. 17 illustrates a multiple layer mattress 150 which includes a support layer 152 and a comfort layer releasably secured together with a chiral zipper system which includes the zippers 151 and 153. Another set of chiral zippers 156 and 158 are attached to a top edge of the comfort layer 154 and an accessory panel 160 in order to releasably secure the accessory panel 160 to the comfort layer 154. The chiral zipper system may also be used to releasably secure an accessory panel to a conventional mattress.
FIG. 18 illustrates a split-level mattress 162 which includes a support layer 164 and a comfort layer 166. The support layer 164 and the comfort layer 166 are releasably secured together with a chiral zipper system which includes the zippers 168 and 170.
A top accessory panel 172 is shown separated from the multiple layer mattress. The top accessory panel 172 is releasably secured to the comfort layer 166 by a chiral zipper system which includes the zippers 174 and 176. The zippers 174 and 176 are secured to the accessory panel 172 and to a top edge of the comfort layer 166. As mentioned above the top accessory panel 172 can be used for various accessories, as discussed above.
A bottom accessory boot 178 is also shown separated from the mattress. The bottom accessory boot 178 is formed as an upside down shoe box top and is slipped over the bottom of the support layer 164 but connectable to the comfort layer 166 by way of a chiral zipper system which includes the zippers 180 and 182 to cover up the zippers 168 and 170.
An exemplary embodiment of an application of the accessory boot 178 is illustrated in FIG. 14. As shown, the accessory boot may incorporate active or passive mattress maneuvering. The accessory boot 178 may be secured to the support layer 164 by any conventional or non-conventional means including a chiral zipper system.
An exemplary embodiment of an active accessory boot is described in detail in US Patent Application Publication No. US 2013/0269108 A1 (“the '108 publication”) and illustrated in FIG. 139 B, hereby incorporated by reference.
Bottom accessory panels are also contemplated. These panels are releasably securable to the bottom of the support layer 164 by any way of any conventional or non-conventional means including a chiral zipper system, as described herein. The active mattress management system can also be configured as a panel. An exemplary embodiment of a bottom accessory panel is illustrated in FIG. 148 and described in the '108 publication, also incorporated by reference.
US Patent Application Publication No. US 2013/0212809 A1 (“the '809 publication”), hereby incorporated by reference, describes and illustrates in FIGS. 46-48 exemplary embodiments of a bottom accessory boot that can be used for passive mattress management. FIGS. 53, 56 and 57 of the '809 publication illustrate exemplary bottom accessory panels that can be used for passive mattress management.
FIGS. 19 and 20 illustrate a single layer mattress 184 (FIG. 20), for example, an inner spring mattress, which includes a mattress core (not shown) and encased by an inner encasement 186. The mattress 184 may include an optional center band 188 and include a pair of chiral zipper systems.
One chiral zipper system may be used to releasably secure a bottom cover 190 to the mattress 184. This chiral system includes the zippers 192 and 194. The zippers 192 and 194 are secured to a top edge of the bottom panel 190 and to the mattress 184. For those embodiments which include a center band 188, the zippers 192 and 194 are secured to a lower edge of the center band 188.
Another chiral zipper system is used to releasably secure a top cover 196 to the mattress 184. This chiral zipper system includes the zippers 198 and 200. These zippers are secured to a bottom edge of the top cover 196 and to the mattress 184. For embodiments that include a center band 188, the zippers 198 and 200 are secured to a top edge of the center band.
The bottom cover 190 may be configured for active mattress maneuvering for example as described in detail in US Patent Application Publication No. US 2013/0269108 A1 and illustrated in FIG. 139 B, hereby incorporated by reference. As part of the active mattress management system, the bottom cover 190 may include an adjustable air exit valve 202 to adjust the airflow out of an inflatable volume (not shown). Air is supplied to the inflatable volume by way of an air inlet 203 from an external air source, such as the external air pump 112, illustrated in FIG. 14.
The bottom cover 190 may also include an attachment point 204 which attaches the layers of the inflatable volume together. The inflatable volume is used to levitate or lift the mattress 184. The attachment point 204 stabilizes the levitation.
The bottom cover 190 may optionally be formed to provide passive mattress management in addition to or in lieu of the active mattress management discussed above. In particular, the bottom cover 190 may be formed with a panel 206 and sidewalls 208 forming an upside down shoe box top. An interior, i.e. top, side of the panel 206 may be formed with a slick surface. The sidewalls 208 may be formed to enable them to be selectively flipped down in a first mode of operation and releasably secured to a foundation (not shown). In a second mode of operation, the sidewalls 208 are releasably secured to the mattress 184. Such covers (without the chiral zippers) are described in detail in the '809 publication.
FIG. 21 illustrates an exemplary multiple layer mattress 210. This embodiment includes three layers 212, 214 and 216. In this embodiment, chiral zipper systems are used to releasably secure the layer 214 to the layer 216 and to releasably secure the layer 214 to the layer 212. An additional chiral zipper system, generally identified with the reference numeral 218, may be attached to the top layer to add accessories, as discussed above, or to interchange the vertical positions of the layers. For example, the vertical positions of the layers 214 and 216 can be flipped. In this case, the layer 216 is secured to the layer 212 and the layer 214 is secured as the top layer. Other configurations are contemplated.
FIG. 21 also illustrates the use of different mattress heights for the various layers. For example, the layer 212 is formed with a height of 2.25 units, while layer 214 is formed with a height of 1.5 units. Layer 216 is formed with a height of 1 unit. It is contemplated that the heights of the various layers may be the same or may all be different. In addition, in a three-layer mattress, two layers may be the same and one may be different.
FIGS. 22-25 illustrate exemplary methods of use of the chiral zipper system described herein. In each of the four examples, one or more layers of the multi-layer mattress are maneuvered without affecting a bed skirt that covers the foundation.
Referring first to FIGS. 22A-22D, these Figs. illustrate a method for rotating of a top comfort layer with respect to a support layer removably attached thereto by a chiral zipper system. In particular, FIG. 22A illustrates a bed 220 with a multiple layer mattress with a support layer 222 and a comfort layer 224 supported by a foundation (not shown) covered by a bed skirt 226. The support layer 222 and the comfort layer 224 are releasably secured together by a chiral zipper system, generally identified with the reference numeral 228. Initially, as shown in FIG. 22B, the chiral zipper system is unzipped, which disconnects the support layer 222 from the comfort layer 224. Next, as illustrated in FIG. 22C, the comfort layer 224 is rotated 180° with respect to the support layer 222. Finally, the comfort layer 224 is zipped to the support layer 222 by way of the chiral zipper system 228. The bed skirt 226 remains intact throughout the steps.
FIGS. 23A-23D illustrate a method of removal and replacement of a mattress layer in a multiple layer mattress. FIG. 23A illustrates a bed 320 with a multiple layer mattress with a support layer 322 and a comfort layer 324 supported by a foundation (not shown) covered by a bed skirt 326. The support layer 322 and the comfort layer 324 are releasably secured together by a chiral zipper system, generally identified with the reference numeral 328. Initially, as shown in FIG. 23B, the chiral zipper system 328 is unzipped, which disconnects the support layer 322 from the comfort layer 324. In the next step, as illustrated in FIG. 23C, the comfort layer 324 is removed. In the next step, as illustrated in FIG. 23D, a new comfort layer 324′ is releasably secured to the support layer 322.
24A-24D illustrate a method of adding an additional mattress layer to a multiple layer mattress. FIG. 24A illustrates a bed 420 with a multiple layer mattress with a support layer 422 and a comfort layer 424 supported by a foundation (not shown) covered by a bed skirt 426. The support layer 422 and the comfort layer 424 are releasably secured together by a chiral zipper system, generally identified with the reference numeral 428. Initially, as shown in FIG. 24B, the chiral zipper system 428 is unzipped, which disconnects the support layer 422 from the comfort layer 424. In the next step, as illustrated in FIG. 24C, the comfort layer 424 is removed. Next an additional comfort layer 423 is releasably secured to the support layer 422 by way of chiral zipper halves, generally identified with the reference numeral 428′, formed on the bottom edge of the comfort layer 423. These chiral zipper halves 428′ mate with the chiral zipper halves 428A on the top edge of the support layer 423. As such, the additional comfort layer 423 is able to be releasably secured to the support layer 422. The top of the additional comfort layer 423 includes chiral zipper halves 428″. These chiral zipper halves 428″ enable the original comfort layer 424 to be releasably secured to the additional comfort layer 423 by way of the chiral zipper halves 428″ and 428B, as shown in FIG. 24D.
FIGS. 25A-25D illustrate a method of rotating multiple layers of a three-layer mattress at one time. FIG. 25A illustrates a bed 520 with a multiple layer mattress with a support layer 522, a first comfort layer 524 supported by a foundation (not shown) covered by a bed skirt 526. The support layer 522 and the first comfort layer 524 are releasably secured together by a chiral zipper system, generally identified with the reference numeral 528. The second comfort layer 525 is releasably secured to the first comfort layer 524 by a chiral zipper system 529. Initially, as shown in FIG. 25B, the chiral zipper system 528 is unzipped, which disconnects the support layer 522 from the comfort layers 524 and 525. In the next step, as illustrated in FIG. 25C, the comfort layers 524 and 525, zipped together, are rotated 180° as a unit with respect to the support layer 522. Finally, the comfort layer 522 is re-zipped to the support layer 522 by way of the chiral zipper system 528.
FIGS. 28-39 illustrate different embodiments of a mattress cores having tops and or bottom covers. These covers are removably attached to the mattress core with zippers as described in U.S. Patent No. 62/130,906, hereby incorporated by reference. In alternate embodiments described in FIGS. 28-39 are chiral zippers as described herein.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.
What is claimed and desired to be secured by a Letters Patent of the United States is:

Claims

I claim:

1. A mattress comprising

a support layer;

one or more comfort layers; and

one or more chiral zipper systems for releasably securing said layers together.