Field adjustable mattress system and method

Abstract

A field adjustable mattress system/method allowing a baseline mattress configuration to be ergonomically modified after initial installation is disclosed. The baseline system generally consists of an optional bottom mattress support (BMS) connected to a bottom mattress cover (BMC) that partially envelops a static mattress core (SMC) from the bottom. A top mattress cover (TMC) completes the encapsulation of the foam mattress core and is attached to the BMC using top/bottom mattress cover zippers (MCZ). Field adjustment of the mattress system is accomplished by inserting one or more mattress adjustment layers (MAL) between the top of the SMC and the TMC and inserting an adjustment border panel (ABP) via the MCZ between the TMC and the BMC. The MAL may comprise one or more layers and may be inserted using horizontally and/or split configurations to permit a variety of ergonomic combinations to be supported in a single mattress system.

What is claimed is: 
     
         1 . A field adjustable mattress system comprising:
 (a) static mattress core (SMC);   (b) top mattress cover (TMC);   (c) mattress adjustment layer (MAL);   (d) adjustment border panel (ABP);   (e) top zipper slider (TZS);   (f) bottom zipper slider (BZS); and   (g) bottom mattress cover (BMC);   wherein   said SMC comprises mattress material formed in the shape of a substantially rectangular prism having a top surface, a bottom surface, a vertical thickness, and a perimeter;   said MAL comprises mattress material formed in the shape of a substantially rectangular prism having a top surface, a bottom surface, a vertical thickness, and a perimeter;   said MAL vertical thickness is less than said SMC vertical thickness;   said MAL perimeter is substantially identical to said SMC perimeter;   said TMC comprises fabric configured to conform to said MAL top surface and to envelop said MAL perimeter;   said ABP comprises fabric configured in length to conform to said perimeter of said MAL and configured in height to conform to the thickness of said MAL;   said BMC comprises fabric configured to conform to said SMC bottom surface and to partially envelop said SMC perimeter;   said BMC comprises a bottom internal surface and internal peripheral surfaces contacting said SMC and a bottom external surface;   said TMC comprises a bottom peripheral edge comprising a bottom half zipper;   said ABP comprises a top peripheral edge comprising a top half zipper;   said ABP comprises a bottom peripheral edge comprising a bottom half zipper;   said BMC comprises a top peripheral edge comprising a top half zipper;   said TZS is configured to mate said TMC bottom half zipper and said ABP top half zipper; and   said BZS is configured to mate said ABP bottom half zipper and said BMC top half zipper.   
     
     
         2 . The field adjustable mattress system of  claim 1  wherein said MAL comprises a plurality of vertically stacked mattress adjustment layers. 
     
     
         3 . The field adjustable mattress system of  claim 1  wherein said MAL comprises a split mattress layer with each split mattress layer having a different firmness. 
     
     
         4 . The field adjustable mattress system of  claim 1  wherein said TMC comprises a fabric selected from a group consisting of: a hydrophobically treated fabric that repels fluid; and a water repellant fabric. 
     
     
         5 . The field adjustable mattress system of  claim 1  wherein at least one of said TMC, said ABP, said BMC, said SMC, and said MAL comprise flame-retardant materials. 
     
     
         6 . The field adjustable mattress system of  claim 1  wherein said SMC comprises a core material selected from a group consisting of: polyurethane foam mattress core; memory foam core; visco elastic foam core; gel foam core; spring core; pocket coil core; latex core; air bladder; and water bladder core. 
     
     
         7 . The field adjustable mattress system of  claim 1  wherein said MAL comprises a linear contoured surface structure. 
     
     
         8 . The field adjustable mattress system of  claim 1  wherein said MAL comprises a non-linear contoured surface structure. 
     
     
         9 . The field adjustable mattress system of  claim 1  wherein said TMC further comprises top edge peripheral piping. 
     
     
         10 . The field adjustable mattress system of  claim 1  wherein said BMC comprises a bottom mattress support (BMS) wherein:
 said BMS comprises a layer of non-skid fabric material substantially conforming to said bottom surface of said BMC; and 
 said BMS contacts and is attached to said bottom surface of said BMC. 
 
     
     
         11 . A field adjustable mattress method comprising:
 (1) forming a static mattress core (SMC) comprising a mattress material in the shape of a substantially rectangular prism having a top surface, a bottom surface, a vertical thickness, and a perimeter;   (2) forming a mattress adjustment layer (MAL) comprising mattress material in the shape of a substantially rectangular prism having a top surface, a bottom surface, a vertical thickness, and a perimeter;   (3) positioning said MAL on top of said SMC to form a mattress stack;   (4) enveloping said mattress stack on the bottom and on a portion of the sides with a unitary bottom mattress cover (BMC);   (5) enveloping said mattress stack on the top and on a portion of the sides with a unitary top mattress cover (TMC);   (6) enveloping said mattress stack on a portion of the sides between said BMC and said TMC with a unitary adjustment border panel (ABP);   (7) conjoining said TMC perimeter with said ABP top perimeter using a zipper and top zipper slider (TZS); and   (8) conjoining said BMC perimeter with said ABP bottom perimeter using a zipper and bottom zipper slider (BZS);   wherein   said MAL vertical thickness is less than said SMC vertical thickness;   said MAL perimeter is substantially identical to said SMC perimeter;   said TMC comprises fabric configured to conform to said MAL top surface and to envelop said MAL perimeter;   said ABP comprises fabric configured in length to conform to said perimeter of said MAL and configured in height to conform to the thickness of said MAL;   said BMC comprises fabric configured to conform to said SMC bottom surface and to partially envelop said SMC perimeter;   said BMC comprises a bottom internal surface and internal peripheral surfaces contacting said SMC and a bottom external surface;   said TMC comprises a bottom peripheral edge comprising a bottom half zipper;   said ABP comprises a top peripheral edge comprising a top half zipper;   said ABP comprises a bottom peripheral edge comprising a bottom half zipper;   said BMC comprises a top peripheral edge comprising a top half zipper;   said TZS is configured to mate said TMC bottom half zipper and said ABP top half zipper; and   said BZS is configured to mate said ABP bottom half zipper and said BMC top half zipper.   
     
     
         12 . The field adjustable mattress method of  claim 11  wherein said MAL comprises a plurality of vertically stacked mattress adjustment layers. 
     
     
         13 . The field adjustable mattress method of  claim 11  wherein said MAL comprises a split mattress layer with each split mattress layer having a different firmness. 
     
     
         14 . The field adjustable mattress method of  claim 11  wherein said TMC comprises a fabric selected from a group consisting of: a hydrophobically treated fabric that repels fluid; and a water repellant fabric. 
     
     
         15 . The field adjustable mattress method of  claim 11  wherein at least one of said TMC, said ABP, said BMC, said SMC, and said MAL comprise flame-retardant materials. 
     
     
         16 . The field adjustable mattress method of  claim 11  wherein said SMC comprises a core material selected from a group consisting of: polyurethane foam mattress core; memory foam core; visco elastic foam core; gel foam core; spring core; pocket coil core; latex core; air bladder; and water bladder core. 
     
     
         17 . The field adjustable mattress method of  claim 11  wherein said MAL comprises a linear contoured surface structure. 
     
     
         18 . The field adjustable mattress method of  claim 11  wherein said MAL comprises a non-linear contoured surface structure. 
     
     
         19 . The field adjustable mattress method of  claim 11  wherein said TMC further comprises top edge peripheral piping. 
     
     
         20 . The field adjustable mattress method of  claim 11  further comprising the step of:
 (9) supporting the bottom of said BMC with a bottom mattress support (BMS); 
 wherein: 
 said BMS comprises a layer of non-skid fabric material substantially conforming to said bottom surface of said BMC; and 
 said BMS contacts and is attached to said bottom surface of said BMC.