Knock down foam bed

Abstract

A mattress system that can be readily broken down into components sized for shipment by common carrier. The system may include a top layer, bottom and sides, for capturing foam blocks in the body of the mattress. The top layer may be a foam and silicone rubber or viscoelastic PVC laminate, or it may be wholly foam, wholly silicone rubber, wholly viscoelastic PVC, or fabric enclosed foam particulates. If desired magnets may be glued or otherwise affixed to the top layer. Various components of the system may be made fire retardant.

1 . A mattress system comprising: 
 a pair of foam side members to form the side of a cavity;    a head foam member and a foot foam member to form the head and foot of said cavity;    a bottom of said cavity connected to said side members and said head and foot members;    a set of at least two separable foam blocks sized so that the set of foam blocks fits within and substantially fills said cavity;    a relatively flat layer dimensioned to cover the top of said cavity and to be disposed at least partially over said side members, said head member and said foot member; and    a fastening system directly connected to the flat layer, the head foam member, the foot foam member and the side foam members to prevent relative movement of the flat layer with respect to the side members, the head member and the foot member.    
   
   
       2 . The mattress system as set forth in  claim 1  wherein the bottom of the cavity is formed of foldable sheets.  
   
   
       3 . The mattress system as set forth in  claim 1  wherein the set of foam blocks includes at least separable three foam blocks, at least one of said foam blocks of the set having a load responsive characteristic value different from the load responsive characteristic value of one of the other foam blocks of the set.  
   
   
       4 . The mattress system as set forth in  claim 1  wherein the flat layer is dimensioned to substantially cover the tops of the side members and the tops of the head member and the foot member when fastened thereto.  
   
   
       5 . The mattress system as set forth in  claim 1  wherein the fastening system is hidden from view when the flat layer is fastened to the head member, the foot member, and the side members.  
   
   
       6 . The mattress system as set forth in  claim 1  wherein the flat layer is latex foam.  
   
   
       7 . The mattress system as set forth in  claim 1  wherein the flat layer is memory foam.  
   
   
       8 . The mattress system as set forth in  claim 1  wherein the foam blocks are all substantially the same size.  
   
   
       9 . The mattress system as set forth in  claim 1  wherein the flat layer is sculpted.  
   
   
       10 . The mattress system as set forth in  claim 1  wherein the flat layer is unsculpted.  
   
   
       11 . The mattress system as set forth in  claim 1  wherein the flat layer is dimensioned to capture the foam blocks in the cavity when fastened to the side members, the head member and the foot member.  
   
   
       12 . The mattress system as set forth in  claim 1  further including a mattress cover with an opening sized to accept said members, said blocks, and said flat layer in assembled form, said mattress cover further including an openable top for covering said opening.  
   
   
       13 . The mattress system as set forth in  claim 12  wherein the mattress cover is quilted.  
   
   
       14 . The mattress system as set forth in  claim 12  wherein the mattress cover is unquilted.  
   
   
       15 . The mattress system as set forth in  claim 1  wherein all the components of the system are fire retardant.  
   
   
       16 . The mattress system as set forth in  claim 1  wherein at least some of the components of the system are fire retardant.  
   
   
       17 . The mattress system as set forth in  claim 1  wherein the flat layer is a single sheet of silicone rubber or viscoelastic PVC material.  
   
   
       18 . The mattress system as set forth in  claim 1  wherein the flat layer is composed of multiple sections of silicone rubber or viscoelastic PVC material.  
   
   
       19 . The mattress system as set forth in  claim 18  wherein at least two of the multiple sections have different durometers.  
   
   
       20 . The mattress system as set forth in  claim 1  wherein the flat layer is composed of a foam and silicone rubber or viscoelastic PVC laminate.  
   
   
       21 . The mattress system as set form in  claim 20  wherein the silicone rubber or viscoelastic PVC forms the top of the flat layer.  
   
   
       22 . The mattress system as set forth in  claim 21  wherein the silicone rubber or viscoelastic PVC is formed in sections having at least two different durometers.  
   
   
       23 . The mattress system as set forth in  claim 1  further including magnets affixed to the flat layer.  
   
   
       24 . The mattress system as set forth in  claim 23  wherein the magnets are bipolar.  
   
   
       25 . The mattress system as set forth in  claim 23  wherein the magnets are unipolar.  
   
   
       26 . The mattress system as set forth in  claim 1  wherein the flat layer is composed of foam particulates enclosed in a fabric covering.  
   
   
       27 . The mattress system as set forth in  claim 26  wherein the fabric covering is elastic.  
   
   
       28 . The mattress system as set forth in  claim 26  wherein the fabric covering has a plurality of separate enclosures, at least some of which enclosures contain foam particulates.  
   
   
       29 . A mattress system comprising: 
 separable foam members defining a cavity;    a bottom of said cavity;    at least two separable foam blocks sized to fit within and substantially fill the cavity;    a separable relatively flat layer dimensioned to cover the cavity;    said members, bottom, foam blocks and flat layer being compressible so that they fit in one or more boxes each having a shipping dimension, obtained by adding the length and the girth of said box, of no more than 130 inches.    
   
   
       30 . The mattress system as set forth in  claim 29  wherein the bottom of the cavity is formed of foldable sheets, said bottom being secured to the members.  
   
   
       31 . The mattress system as set forth in  claim 29  wherein the set of foam blocks includes at least separable three foam blocks, at least one of said foam blocks of the set having a load responsive characteristic value different from the load responsive characteristic value of one of the other foam blocks of the set.  
   
   
       32 . The mattress system as set forth in  claim 29  wherein the flat layer is dimensioned to substantially cover the tops of the members in addition to covering the cavity.  
   
   
       33 . The mattress system as set forth in  claim 29  further including a fastening system adapted to fasten the flat layer to the members defining the cavity.  
   
   
       34 . The mattress system as set forth in  claim 33  wherein the fastening system is hidden from view when the flat layer is fastened to the members.  
   
   
       35 . The mattress system as set forth in  claim 33  wherein the fastening system is a hook and pile fastening system.  
   
   
       36 . The mattress system as set forth in  claim 29  wherein the flat layer is latex foam.  
   
   
       37 . The mattress system as set forth in  claim 29  wherein the flat layer is memory foam.  
   
   
       38 . The mattress system as set forth in  claim 29  wherein the flat layer is dimensioned to capture the foam blocks in the cavity when fastened to the members.  
   
   
       39 . The mattress system as set forth in  claim 29  further including a mattress cover with an opening sized to accept said members, said blocks, and said flat layer in assembled form, said mattress cover further including an openable top for covering said opening.  
   
   
       40 . The mattress system as set forth in  claim 29  wherein all the components of the system are fire retardant.  
   
   
       41 . The mattress system as set forth in  claim 29  wherein at least some of the components of the system are fire retardant.  
   
   
       42 . A mattress system comprising: 
 a pair of foam side members connected by a first foldable sheet, said first foldable sheet being disposed substantially at the bottom of said foam side members;    a head foam member and a foot foam member connected by a second foldable sheet, said second foldable sheet being disposed substantially at the bottom of said head foam member and at the bottom of said foot foam member, said side members, head member and foot member being disposable with said first and second foldable sheets adjacent each other to form a cavity whose bottom is defined by the foldable sheets and whose sides are defined by the side, head and foot members;    a set of at least two separable foam blocks sized so that the set fits within said cavity;    a relatively flat layer dimensioned to cover the top of said cavity; and    a fastening system directly connected to the flat layer, the head foam member, the foot foam member and the side foam members to fasten the flat layer to the side members and to the head and foot members so that the separable foam blocks are captured in the cavity.    
   
   
       43 . The mattress system as set forth in  claim 42  wherein the fastening system prevents movement of the flat layer with respect to the members.  
   
   
       44 . The mattress system as set forth in  claim 42  wherein the set of foam blocks includes at least separable three foam blocks, at least one of said foam blocks of the set having a load responsive characteristic value different from the load responsive characteristic value of one of the other foam blocks of the set.  
   
   
       45 . The mattress system as set forth in  claim 42  wherein the flat layer is dimensioned to substantially cover the tops of the side members and the tops of the head member and the foot member when fastened thereto.  
   
   
       46 . The mattress system as set forth in  claim 42  wherein the fastening system is hidden from view when the flat layer is fastened to the head member, the foot member, and the side members.  
   
   
       47 . The mattress system as set forth in  claim 46  wherein the fastening system is a hook and pile fastening system.  
   
   
       48 . The mattress system as set forth in  claim 42  wherein the foam blocks are all substantially the same size.  
   
   
       49 . The mattress system as set forth in  claim 42  wherein the flat layer is sculpted.  
   
   
       50 . The mattress system as set forth in  claim 42  wherein the flat layer is unsculpted.  
   
   
       51 . The mattress system as set forth in  claim 42  further including a mattress cover with an opening sized to accept said members, said blocks, and said flat layer in assembled form, said mattress cover further including an openable top for covering said opening.  
   
   
       52 . The mattress system as set forth in  claim 42  wherein all the components of the system are fire retardant.  
   
   
       53 . The mattress system as set forth in  claim 42  wherein at least some of the components of the system are fire retardant.  
   
   
       54 . A mattress component for a mattress for a human user comprising: 
 a layer of foam having a top and a bottom;    a layer of silicone rubber or viscoelastic PVC secured to the top of the foam layer;    said foam layer and said silicone rubber or viscoelastic PVC layer being sized to receive at least a portion of a human body, and having in combination a resilience and a resistance to deformation selected to support a human body in comfort.    
   
   
       55 . The mattress component as set forth in  claim 54  wherein the silicone rubber or viscoelastic PVC layer is generally from ¼″ to 6″ thick.  
   
   
       56 . The mattress component as set forth in  claim 54  wherein the foam layer constitutes a first layer of foam, further including a second layer of foam secured to the silicone rubber or viscoelastic PVC layer opposite the first layer of foam.  
   
   
       57 . The mattress component as set forth in  claim 56  wherein the second foam layer is at least approximately ¼″ thick and the silicone rubber or viscoelastic PVC layer is generally from ¼″ to 6″ thick.  
   
   
       58 . The mattress component as set forth in  claim 54  wherein the silicone rubber or viscoelastic PVC layer has a Shore 00 durometer of no greater than 75.  
   
   
       59 . The mattress component as set forth in  claim 58  wherein the silicone rubber or viscoelastic PVC layer has a Shore 00 durometer of no greater than 50.  
   
   
       60 . The mattress component as set forth in  claim 59  wherein the silicone rubber or viscoelastic PVC layer has a Shore 00 durometer of no greater than 40.  
   
   
       61 . The mattress component as set forth in  claim 54  wherein the silicone rubber or viscoelastic PVC layer has a rebound percentage of less than 50.  
   
   
       62 . The mattress component as set forth in  claim 61  wherein the silicone rubber or viscoelastic PVC layer has a rebound percentage of less than 20.  
   
   
       63 . The mattress component as set forth in  claim 54  wherein the silicone rubber or viscoelastic PVC layer includes embedded bubbles.  
   
   
       64 . The mattress component as set forth in  claim 54  wherein the silicone rubber or viscoelastic PVC layer constitutes two separate layers.  
   
   
       65 . The mattress component as set forth in  claim 54  wherein the silicone rubber or viscoelastic PVC layer is solid.  
   
   
       66 . The mattress component as set forth in  claim 54  wherein the silicone rubber or viscoelastic PVC layer is porous.  
   
   
       67 . The mattress component as set forth in  claim 54  wherein foam layer and the silicone rubber or viscoelastic PVC layer both extend horizontally substantially the entire extent of the mattress.  
   
   
       68 . The mattress component as set forth in  claim 54  wherein at least the silicone rubber or viscoelastic PVC layer is disposed only in a lumbar section of the mattress.  
   
   
       69 . The mattress component as set forth in  claim 54  wherein the foam layer is viscoelastic foam, said silicone rubber or viscoelastic PVC layer being laminated to the viscoelastic foam.  
   
   
       70 . The mattress component as set forth in  claim 54  wherein the foam layer is polyurethane foam, said silicone rubber or viscoelastic PVC layer being laminated to the polyurethane foam.  
   
   
       71 . The mattress component as set forth in  claim 54  wherein the foam layer is latex foam, said silicone rubber or viscoelastic PVC layer being laminated to the latex foam.  
   
   
       72 . The mattress component as set forth in  claim 54  wherein silicone rubber or viscoelastic PVC layer is laminated to the foam layer.  
   
   
       73 . The mattress component as set forth in  claim 54  further including a heating device.  
   
   
       74 . The mattress component as set forth in  claim 54  which is fire retardant.