Independent foam spring mattress

Abstract

Embodiments of an independent foam spring mattress are disclosed. The independent foam spring mattress typically includes a sculpted layer of foam which has a plurality of foam pillars separated by a grid pattern of grooves. These foam pillars may be positioned and oriented in the mattress with respect to one or more additional foam layers to serve as independent foam springs. Accordingly, disclosed mattress embodiments typically would be all-foam mattresses, without any metal springs.

What is claimed is: 
     
         1 . A mattress comprising a sculpted foam layer with a sculpted surface having a grid pattern of grooves thereon forming a plurality of foam pillars projecting outward from a common, integral base of foam;
 wherein the sculpted surface with the grid pattern of grooves is not the mattress sleep surface; and   wherein the mattress does not include springs.   
     
     
         2 . The mattress of  claim 1  wherein the sculpted foam layer comprises an integral base portion of uniform thickness and a pillar portion comprising the plurality of independent foam pillars separated from each other by one or more grooves of the grid pattern; and wherein a surface of the sculpted foam layer opposite the sculpted surface is substantially flat. 
     
     
         3 . The mattress of  claim 1  further comprising a cover, and wherein the mattress is an all-foam mattress. 
     
     
         4 . The mattress of  claim 3  further comprising one or more additional layers of foam underlying the sculpted foam layer. 
     
     
         5 . The mattress of  claim 4  wherein the sculpted foam layer is located as the uppermost layer of foam within the mattress and is oriented with the sculpted surface having the grid of grooves facing downward. 
     
     
         6 . The mattress of  claim 1  further comprising an upper foam layer, and wherein the sculpted foam layer is located beneath the upper foam layer and is oriented so that the sculpted surface having the grid of grooves faces upward. 
     
     
         7 . The mattress of  claim 6  further comprising a base foam layer underlying the sculpted foam layer, wherein the upper foam layer has a uniform thickness and has a flat upper surface. 
     
     
         8 . The mattress of  claim 1  further comprising at least one additional layer of foam, wherein the uppermost foam layer is formed of gel memory foam or latex. 
     
     
         9 . The mattress of  claim 1  wherein the grooves in the sculpted layer of foam are about ⅜-1 inch wide and about 1-2 inches deep. 
     
     
         10 . The mattress of  claim 1  wherein the plurality of foam pillars in the sculpted foam layer are each uniform in size and shape. 
     
     
         11 . The mattress of  claim 1  wherein each of the plurality of foam pillars have a rectangular cross-section. 
     
     
         12 . The mattress of  claim 10  wherein each of the plurality of foam pillars have horizontal cross-section sides each ranging from 2-6 inches. 
     
     
         13 . The mattress of  claim 10  wherein each of the plurality of foam pillars have a rectangular cross-section, and wherein each of the plurality of pillars of foam have cross-section sides each ranging from about 3 and ⅝ inches to about 4 and ⅝ inches. 
     
     
         14 . The mattress of  claim 3  wherein the cover comprises one or more mesh panels located to improve airflow through the grooves in the sculpted layer of foam. 
     
     
         15 . The mattress of  claim 1  wherein the sculpted foam layer has a thickness of 2-4 inches. 
     
     
         16 . The mattress of  claim 1  wherein the sculpted foam layer has a thickness of about 2-4 inches, and wherein the grooves in the sculpted foam layer are about ⅜-1 inch wide and extend downward through about half to two-thirds of the total thickness of the sculpted foam layer. 
     
     
         17 . A mattress comprising:
 a sculpted foam layer with a sculpted surface having a grid pattern of grooves thereon forming a plurality of foam pillars projecting outward from a common, integral base of foam;   one or more additional layers of foam underlying the sculpted foam layer; and   a cover;   wherein the sculpted foam layer is located within the mattress above the one or more additional layers of foam and is oriented with the sculpted surface having the grid of grooves facing downward;   wherein a surface of the sculpted foam layer opposite the sculpted surface is substantially flat;   wherein the sculpted surface with the grid pattern of grooves is not the mattress sleep surface;   wherein the foam layers are all laminated together into an integrated whole; and   wherein the mattress does not include springs.   
     
     
         18 . The mattress of  claim 17  wherein the sculpted foam layer is formed of gel memory foam, and wherein the cover comprises one or more mesh panels located to improve airflow through the grooves in the sculpted layer of foam. 
     
     
         19 . The mattress of  claim 17  wherein the plurality of foam pillars in the sculpted foam layer are each uniform in size and shape and each have a rectangular cross-section; and wherein the flat surface of the sculpted foam layer opposite the sculpted surface faces upward to serve as a sleep surface for the mattress. 
     
     
         20 . The mattress of  claim 19  wherein each of the foam pillars have a square cross-section, and wherein each of the plurality of foam pillars have cross-section sides ranging from about 3 and ⅝ inches to about 4 and ⅝ inches.