Mattress and a method of manufacturing a mattress

Abstract

The present disclosure envisages a mattress that comprises a resiliently compressible foam shell defining a plurality of pockets along the breadth of the mattress, a bottom layer, a plurality of resiliently compressible block elements receivable in the plurality of pockets having predetermined varying compressibility values, and a flexible top layer. In one aspect of the present disclosure, the plurality of pockets is configured in the form of an array of rows and columns, wherein the rows are in parallel to a width of mattress and preferably seven in numbers and the columns are in parallel to length of mattress and number of columns varies with the width of the mattress. In another aspect of the present disclosure, the plurality of pockets is in the form of horizontal slots along the breadth of the mattress.

We claim: 
     
         1 . A mattress comprising,
 i. a resiliently compressible foam shell defining a plurality of pockets along the breadth of said mattress;   ii. a bottom layer;   iii. a plurality of resiliently compressible block elements receivable in said plurality of pockets and having predetermined varying compressibility values; and   iv. a flexible top layer.   
     
     
         2 . The mattress of  claim 1 , wherein said plurality of pockets are configured in an array of rows and columns, wherein said rows comprise seven rows, which are in parallel to a width of mattress, said columns are in parallel to a length of mattress, and wherein a number of columns varies with the width of the mattress. 
     
     
         3 . The mattress of  claim 1 , wherein said plurality of pockets is in the form of horizontal slots along the breadth of said mattress. 
     
     
         4 . The mattress as claimed in  claim 1 , wherein said shell, said bottom layer and said flexible top layer are of a material selected from the group consisting of latex foam, polyurethane foam, visco-elastic foam, coir foam and combinations thereof. 
     
     
         5 . The mattress as claimed in  claim 1 , wherein said plurality of block elements comprises at least one of latex foam, polyurethane foam, visco-elastic foam, coir foam, polyester wadding, cotton, springs made of steel wire or plastic, polyester fiber, wool, down, feathers, and combinations thereof. 
     
     
         6 . The mattress as claimed in  claim 1 , wherein said bottom layer is integral with said shell and said plurality of pockets are recessed in said shell. 
     
     
         7 . The mattress as claimed in  claim 1 , wherein said shell is configured with a plurality of slits through said shell; and said bottom layer is fixed to said shell and said plurality of pockets are defined by the walls of said slits and said bottom layer. 
     
     
         8 . The mattress as claimed in  claim 3 , wherein said plurality of horizontal slots are configured in rows along the breadth of said mattress such that the number of said rows is in a multiple of seven. 
     
     
         9 . The mattress as claimed in  claim 1 , wherein the upper surface of said flexible top layer is configured with a layer of gel pad. 
     
     
         10 . The mattress as claimed in  claim 1 , wherein an adhesive layer is provided between said plurality of block elements and an inner surface of said plurality of pockets in said shell, and wherein the adhesive layer is disposed on at least one of said block elements and the inner surface of said plurality of pockets in said shell. 
     
     
         11 . The mattress as claimed in  claim 1 , wherein the walls of said shell have perforations, enabling venting of air through said shell. 
     
     
         12 . The mattress as claimed in  claim 1 , wherein the cross-section of said pockets in said shell is selected from the group consisting of polygonal, quadrilateral, square, and combinations thereof; and the cross-section of said plurality of block elements is complementary to the cross-section of said pockets in said shell. 
     
     
         13 . The mattress as claimed in  claim 1 , wherein said mattress is enclosed within a mattress ticking. 
     
     
         14 . The mattress as claimed in  claim 1 , wherein said plurality of block elements are configured such that the upper surface of said plurality of block elements is flush with the upper surface of said shell. 
     
     
         15 . The mattress as claimed in  claim 1 , wherein said plurality of block elements are configured such that predetermined rows of block elements selected from said plurality of block elements are raised above the upper surface of said shell to define a pillow formation on said mattress. 
     
     
         16 . The mattress as claimed in  claim 1 , wherein in the plurality of block elements selected to be received in said pockets are such that the compressibility value of said plurality of block elements received in said pockets increases sequentially from the center of said shell towards the ends of said shell. 
     
     
         17 . The mattress as claimed in  claim 1 , wherein the compressibility of the plurality of block elements received in each of said plurality of pockets, varies along the width of the mattress. 
     
     
         18 . A method of manufacturing a mattress, said method comprising the following steps:
 i. fabricating a resiliently compressible foam shell defining a plurality of pockets configured along the breadth of said mattress;   ii. integrally providing or securing a bottom layer to said shell;   iii. fabricating a plurality of resiliently compressible block elements having shapes complementary to said plurality of pockets;   iv. receiving the plurality of block elements in said plurality of pockets in a predetermined varying arrangement by the shell; and   v. securing a flexible top layer to said shell.   
     
     
         19 . The method as claimed in  claim 18 , wherein an adhesive is applied between said plurality of block elements and the inner surface of said plurality of pockets in said shell either on said block elements or on said inner surface of said plurality of pockets in said shell, or on both. 
     
     
         20 . A method of manufacturing a mattress customized to requirement of at least one user depending on the need for orthopedic support of said at least one user, said method comprising the following steps:
 fabricating a resiliently compressible foam shell defining a plurality of pockets configured in rows along the breadth of said mattress;   integrally providing or securing a bottom layer to said shell;   determining an orthopedic need of said at least one user;   selecting a plurality of resiliently compressible block elements with shapes complementary to said plurality of pockets having predetermined compressibility values suited to said orthopedic needs of said at least one user;   receiving the plurality of block elements in said plurality of pockets in a predetermined varying arrangement by the shell; and   securing a flexible top layer to said shell.