US2012304392A1PendingUtilityA1

Mattress system

47
Individually held — no corporate assignee on recordPriority: May 31, 2011Filed: May 30, 2012Published: Dec 6, 2012
Est. expiryMay 31, 2031(~4.9 yrs left)· nominal 20-yr term from priority
Inventors:Surendra Khambete
A47C 27/001A47C 27/12A47C 23/04A47C 27/22
47
PatentIndex Score
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Claims

Abstract

Disclosed is a mattress including a plurality of springs arranged in rows to provide an innerspring, and at least one polymer fiber rail including polymer fibers interlinked with one another. The at least one polymer fiber rail has a face adjoining one of the rows of springs. The at least one polymer fiber rail can be tuned to provide desired characteristics, and, together with the springs, the rail provides a comprehensive mattress system.

Claims

exact text as granted — not AI-modified
1 . A mattress comprising:
 a plurality of springs arranged in rows to provide an innerspring; and   at least one polymer fiber rail including polymer fibers interlinked with one another, the at least one polymer fiber rail having a face adjoining one of the rows of springs.   
     
     
         2 . The mattress as recited in  claim 1 , wherein the at least one polymer fiber rail is an external rail, and wherein the face of the external rail adjoins springs from an outer perimeter of the innerspring. 
     
     
         3 . The mattress as recited in  claim 2 , wherein the external rail includes a smooth, planar face opposite the face adjoining the springs from the outer perimeter of the innerspring. 
     
     
         4 . The mattress as recited in  claim 3 , wherein the face includes engagement features engaged with at least some of the plurality of springs, and wherein the engagement features are clips. 
     
     
         5 . The mattress as recited in  claim 1 , wherein the at least one polymer fiber rail is an internal rail positioned between adjacent rows of springs, and wherein the internal rail includes two opposing faces, each of the two opposing faces including engagement features partially receiving springs from a respective one of the adjacent rows of springs. 
     
     
         6 . The mattress as recited in  claim 1 , wherein the at least one polymer fiber rail includes at least one internal rail and at least one external rail. 
     
     
         7 . The mattress as recited in  claim 6 , wherein the at least one polymer fiber rail includes four external rails provided about a perimeter of the innerspring. 
     
     
         8 . The mattress as recited in  claim 6 , wherein a plurality of internal rails are positioned adjacent one another to provide a zone of increased support. 
     
     
         9 . The mattress as recited in  claim 8 , wherein the plurality of internal rails provide a lumbar support zone. 
     
     
         10 . The mattress as recited in  claim 1 , wherein the face includes engagement features engaged with at least some of the plurality of springs, and wherein the engagement features are one of slits, vertically-spaced slots, and a spring-shaped cross sectional profile, the springs are at least partially received within the engagement features. 
     
     
         11 . The mattress as recited in  claim 1 , wherein the springs are steel coil springs providing a first spring rate, the internal rails provide a second spring rate, and the external rails provide a third spring rate, wherein the first, second and third spring rates are different from one another. 
     
     
         12 . The mattress as recited in  claim 11 , where the first, second, and third spring rates are tuned to meet customer requirements. 
     
     
         13 . The mattress as recited in  claim 12 , wherein the third spring rate is greater than the second spring rate. 
     
     
         14 . The mattress as recited in  claim 1 , wherein the polymer fiber rail is wholly polyester and includes polyester fibers interlinked by a polyester binder. 
     
     
         15 . The mattress as recited in  claim 1 , wherein a batt of material providing the polymer fiber rail exhibits an ILD of 88.56 lbs. reduced in height by 25%, and an ILD of 92.70 lbs. reduced in height by 65%. 
     
     
         16 . A mattress comprising:
 a quilting layer;   at least one first topper pad adjacent the quilting layer;   an insulator pad adjacent the first topper pad;   a plurality of springs arranged in rows to provide an innerspring; and   at least one polymer fiber rail including polymer fibers interlinked with one another, the at least one polymer fiber rail having a face adjoining one of the rows of springs, the face provided with a plurality of engagement features engaged with at least some of the plurality of springs.   
     
     
         17 . The mattress as recited in  claim 16 , wherein the at least one polymer fiber rail includes four external rails positioned about the outer perimeter of the innerspring, and at least one internal rail positioned between adjacent rows of springs. 
     
     
         18 . The mattress as recited in  claim 16 , wherein the at least one polymer fiber rail is an internal rail including two opposing faces, each of the two opposing faces including engagement features partially receiving springs from adjacent rows of springs. 
     
     
         19 . The mattress as recited in  claim 16 , wherein the at least one first topper pad includes a plush topper pad and a firm topper pad, the firm topper pad being firmer than the plush topper pad. 
     
     
         20 . A mattress comprising:
 a plurality of springs arranged in rows to provide an innerspring; and   at least one polymer fiber rail including polymer fibers interlinked with one another, the at least one polymer fiber rail having a face adjoining one of the rows of springs, the face provided with a plurality of engagement features engaged with at least some of the plurality of springs.

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