Internal contour foam mattress

Abstract

Disclosed is a mattress for supporting a reclining body with low body pressure and in alignment. The mattress, extends in a lateral direction from side to side and extends in a longitudinal direction from a mattress head to a mattress foot where the mattress includes a head part, a shoulder part, a waist part, a hip part and a leg part. The reclining body has a displacement profile that causes the mattress to undergo differing vertical displacements when supporting the reclining body. The mattress core has displacement parameters established by internal contour interfaces varying to match the displacement profile of the reclining body while supporting the reclining body with low body pressure. The core has a plurality of regions where the vertical displacement in one or more of the regions varies to match the displacement profile of the reclining body to maintain the reclining body in alignment.

1 . A mattress, extending in a lateral direction from side to side and extending in a longitudinal direction from a mattress head to a mattress foot, for supporting a reclining body, said mattress including a head part, a shoulder part, a waist part, a hip part and a leg part, said reclining body having a displacement profile, said mattress comprising, 
 core means extending in said longitudinal direction and in said lateral direction, said core means for undergoing differing vertical displacements when supporting the reclining body, 
 said core means having displacement parameters varying to match the displacement profile of the reclining body whereby the reclining body is supported by low body pressure,  
 said core means having a plurality of regions where the vertical displacement in one or more of the regions varies to match the displacement profile of the reclining body to maintain the reclining body in alignment,  
 said core means including a foam member having contour-cut structural modification where the foam member at different longitudinal positions exhibits different displacement parameters to support the reclining body with low body pressure and exhibits different vertical displacements to maintain the reclining body in alignment.  
   
   
   
       2 . A mattress, extending in a lateral direction from side to side and extending in a longitudinal direction from a mattress head to a mattress foot, for supporting a reclining body, said mattress including a head part, a shoulder part, a waist part, a hip part and a leg part, said reclining body having a displacement profile, said mattress comprising, 
 core means extending in said longitudinal direction and in said lateral direction, said core means for undergoing differing vertical displacements when supporting the reclining body, 
 said core means having displacement parameters varying to match the displacement profile of the reclining body whereby the reclining body is supported by low body pressure,  
 said core means having a plurality of regions where the vertical displacement in one or more of the regions varies to match the displacement profile of the reclining body to maintain the reclining body in alignment,  
 said core means including a foam member having structural modification formed by contour-cuts forming slots in the foam member where the foam member at different longitudinal positions exhibits different displacement parameters to support the reclining body with low body pressure and exhibits different vertical displacements to maintain the reclining body in alignment.  
   
   
   
       3 . The mattress as in  claim 2  wherein said core means includes first and second foam members having contour-cuts where said contour cuts mate to form a uniform interface.  
   
   
       4 . A mattress, extending in a lateral direction from side to side and extending in a longitudinal direction from a mattress head to a mattress foot, for supporting a reclining body, said mattress including a head part, a shoulder part, a waist part, a hip part and a leg part, said reclining body having a displacement profile, said mattress comprising, 
 core means extending in said longitudinal direction and in said lateral direction, said core means for undergoing differing vertical displacements when supporting the reclining body, 
 said core means having displacement parameters varying to match the displacement profile of the reclining body whereby the reclining body is supported by low body pressure,  
 said core means having a plurality of regions where the vertical displacement in one or more of the regions varies to match the displacement profile of the reclining body to maintain the reclining body in alignment,  
 said core means including a foam member having structural modification formed by continuous wave contour-cuts in the foam member where the foam member at different longitudinal positions exhibits different displacement parameters to support the reclining body with low body pressure and exhibits different vertical displacements to maintain the reclining body in alignment.  
   
   
   
       5 . The mattress as in  claim 4  wherein said core means includes first and second foam members having contour-cuts where said contour cuts mate to form a uniform interface.  
   
   
       6 . The mattress as in  claim 1 ,  2  or  4  wherein said core means includes head, center and leg regions wherein said head region is for establishing head vertical elevations for supporting said head part, said center region is for establishing center vertical elevations for supporting said shoulder part, waist part and hip part, and said leg region is for establishing leg vertical elevations for supporting said leg part and wherein said center vertical elevations vary relative to said head vertical elevations and said leg vertical elevations to establish body alignment.  
   
   
       7 . The mattress as in  claim 6  wherein said core means has a flat top in the absence of a reclining body.  
   
   
       8 . The mattress as in  claim 6  wherein a high gradient exists in a body profile between said head part and said shoulder part and wherein said core means has a change in displacement parameters between said head region and said shoulder region that accommodates said high gradient to maintain low body pressure and body alignment.  
   
   
       9 . The mattress as in  claim 6  wherein said core means includes a first core beside a second core for supporting side-by-side reclining bodies.  
   
   
       10 . The mattress as in  claim 6  wherein said body alignment is substantially straight.  
   
   
       11 . The mattress as in  claim 6  wherein said low body pressure is below a low pressure threshold.  
   
   
       12 . The mattress as in  claim 11  wherein said threshold is below an ischemic pressure threshold.  
   
   
       13 . mattress as in  claim 1 ,  2  or wherein said core means includes head, center and leg regions wherein said head region is for establishing head vertical elevations, said center region is for establishing center vertical elevations, and said leg region is for establishing leg vertical elevations, said center region including a shoulder region, a waist region and a hip region.  
   
   
       14 . The mattress as in  claim 13  wherein said head region includes a first foam member having a first ILD displacement parameter and includes a second foam member having a second ILD displacement parameter, said first foam member above said second foam member with the first ILD displacement parameter greater than said second ILD displacement parameter.  
   
   
       15 . The mattress as in  claim 13  wherein said center region includes a first foam member having a first ILD displacement parameter and includes a second foam member having a second ILD displacement parameter, said first foam member above said second foam member with the first ILD displacement parameter greater than said second ILD displacement parameter.  
   
   
       16 . The mattress as in  claim 13  wherein said center region includes a first foam member above a second foam member and wherein said leg region includes a foam member that has an ILD displacement parameter greater than ILD displacement parameters for said first foam member and for said second foam member.  
   
   
       17 . The mattress as in  claim 13  wherein said core means includes a foam member having structural modification where the foam member at different longitudinal positions exhibits different displacement parameters to support the reclining body with low body pressure and exhibits different vertical displacements to maintain the reclining body in alignment.  
   
   
       18 . The mattress as in  claim 13  wherein said core means includes one or more tension relief slots for avoiding tension forces in said foam members as a result of displacement caused by said reclining body.  
   
   
       19 . A method of manufacturing a core for a mattress comprising, 
 storing contour-cutting parameters into a database, said contour-cutting parameters defining the internal contour surfaces of foam members with vertical displacements in one or more of regions of a core to match the displacement profile of a reclining body on the mattress,    accessing the contour-cutting parameters from the database to control a contour controller to cut a foam bun to produce the core.    
   
   
       20 . The method of  claim 19  wherein said contour-cutting parameters are stored in pairs whereby core members are cut in pairs.