Memory Foam Mattress and Method of Construction

Abstract

The present invention is directed toward an improved foam mattress. In one embodiment, the mattress has a base layer coupled to rectangular side sections each having a top surface. The top surfaces of the side sections extend above the top surface of the base layer and define a periphery of a space. The base layer and side sections are made of a material having a first resiliency. A central core layer is configured to fit entirely within the space defined by the side sections and is made of a material having a second resiliency, where the second resiliency is lower than said first resiliency. A top layer rests on the top surface of the central core layer and the top surface of the side sections. The top layer is made of a material of having a resiliency equal to or less than the second resiliency.

1 . A mattress comprising:
 a base layer, having a top surface, coupled to a plurality of rectangular side sections each having a top surface, wherein the top surfaces of said side sections extend above the top surface of the base layer and define a periphery of a space and wherein said base layer and side sections are made of a material having a first resiliency;   a central core layer, having a top surface, configured to fit entirely within the space defined by the side sections, said central core layer being made of a material having a second resiliency, wherein said second resiliency is lower than said first resiliency; and   a top layer that rests on the top surface of the central core layer and the top surface of the side sections, said top layer being made of a material of having a resiliency equal to or less than the second resiliency.   
     
     
         2 . The mattress of  claim 1 , wherein the side sections provide support at the edges of the mattress. 
     
     
         3 . The mattress of  claim 1 , wherein said side sections are individual members bonded to said base layer. 
     
     
         4 . The mattress of  claim 1 , wherein the side sections and said base layer are shaped from a single contiguous unit of material. 
     
     
         5 . The mattress of  claim 1  further comprising an air foam layer placed between the top layer and the central core layer. 
     
     
         6 . The mattress of  claim 1  further comprising an air foam layer placed between the central core layer and the base layer. 
     
     
         7 . The mattress of  claim 1 , wherein the mattress is encased with at least one fire retardant fabric cover. 
     
     
         8 . The mattress of  claim 1 , wherein the ILD for the material of the base layer and the side sections is in the range of 20 to 40. 
     
     
         9 . The mattress of  claim 1 , wherein the ILD for the material of the central core layer and the top layer is in the range of 12 to 16. 
     
     
         10 . The mattress of  claim 1 , wherein the material used for the base layer, side sections, central core layer and the top layer is a visco-elastic polyurethane foam. 
     
     
         11 . The mattress of  claim 1 , wherein the overall thickness of the mattress is in the range of 7 to 13 inches. 
     
     
         12 . A mattress comprising:
 a base layer, having a top surface, coupled to four rectangular side sections each having a top surface, wherein the top surfaces of said side sections extend above the top surface of the base layer and define a periphery of a space and wherein said base layer and side sections are made of a material having a first resiliency;   a central core layer, having a top surface, configured to fit entirely within the space defined by the four side sections, said central core layer being made of a material having a second resiliency, wherein said second resiliency is lower than said first resiliency; and   a top layer that rests on the top surface of the central core layer and the top surface of the side sections, said top layer being made of a material of having a resiliency equal to or less than the second resiliency.   
     
     
         13 . The mattress of  claim 12 , wherein the thickness of each of said four side sections is in the range of 1 to 4 inches, and wherein the width of said side sections is in the range of 2 to 4 inches. 
     
     
         14 . The mattress of  claim 12 , wherein the thickness and width of side sections at the foot and head of the mattress is less than that of the side sections at the sides of the mattress. 
     
     
         15 . The mattress of  claim 12 , wherein said side sections are individual members bonded to said base layer. 
     
     
         16 . The mattress of  claim 12 , wherein the side sections and said base layer are shaped from a single contiguous unit of material. 
     
     
         17 . The mattress of  claim 12 , wherein the ILD for the material of the base layer and the side sections is in the range of 20 to 40. 
     
     
         18 . The mattress of  claim 12 , wherein the ILD for the material of the central core layer and the top layer is in the range of 12 to 16. 
     
     
         19 . The mattress of  claim 12 , wherein the material used for the base layer, side sections, central core layer and the top layer is visco-elastic polyurethane foam.