A Hybrid Mattress

Abstract

A mattress has an upper foam panel and a lower foam panel. The panels are molded out of a foam material with integrally preferably molded side walls, and there is an assembly of a plurality of spring units placed and secured on or within the lower foam panel. The upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly forms the mattress.

1 . A mattress comprises an upper foam panel and a lower foam panel, said panels having integrally produced side walls, and an assembly of a plurality of spring units placed and secured on or within the lower foam panel, wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly forms the mattress. 
     
     
         2 . A mattress according to  claim 1  having an upper foam panel and a lower foam panel, said panels molded out of a foam material with integrally molded side walls, and an assembly of a plurality of spring units placed and secured on or within the lower foam panel, wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly forms the mattress. 
     
     
         3 . A mattress according to  claim 1  having an upper foam panel and a lower foam panel, said panels produced out of a foam material in a continuous quadrilateral shape with integrally produced side walls, and an assembly of a plurality of spring units placed and secured on surface of the lower foam panel, wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly, forms a box-type structure of the mattress, and wherein the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress, and provide a tight packed arrangement to the assembly of plurality of spring units when the upper foam panel is secured over the lower foam panel. 
     
     
         4 . The mattress in accordance with  claim 1 , whereby the upper and lower foam panels are identical either in shape and/or size and/or material. 
     
     
         5 . The mattress in accordance with  claim 1 , wherein the upper and lower foam panels are produced from a number of foam materials such as including and not limited to natural and synthetic latex foam material, polyurethane foam, and other synthetic foam material manufactured by crude oil, and the like including composite foams. 
     
     
         6 . The mattress in accordance with  claim 1 , wherein the foam panels are molded into a continuous rectangular, square, or any other suitable quadrilateral/geometrical shape. 
     
     
         7 . The mattress as claimed in  claim 1 , wherein each spring unit further comprises a coiled spring enclosed in a fabric cover and behaves independently of each other to provide resilience to the mattress. 
     
     
         8 . The mattress as claimed in  claim 7 , wherein the coiled spring may be helical or conical in shape. 
     
     
         9 . The mattress as claimed in  claim 1 , wherein the spring units are pocket springs. 
     
     
         10 . The mattress as claimed in  claim 1 , wherein the spring units are secured to the surface of the lower foam panel using a glue, or metallic stitches, or clips, or any other securing mechanism. 
     
     
         11 . The mattress as claimed in  claim 1 , wherein the upper foam panel and the lower foam panel are attached with each other, via a number of methods including and not limited to using a glue, metallic stitches, clips, or any other mechanical connections. 
     
     
         12 . A method of manufacturing a mattress, comprising producing an upper foam panel and a lower foam panel with integrally produced side walls, placing and securing an assembly of a plurality of spring units within the surface of the lower foam panel, and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units. 
     
     
         13 . A method of manufacturing a mattress according to  claim 12 , comprising:
 producing two identical foam panels, an upper foam panel and a lower foam panel, both produced out of a foam material from a mold, in a continuous quadrilateral shape with integrally produced side walls; placing and securing an assembly of a plurality of spring units on surface of the lower foam panel, and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units and form a box-type structure of the mattress,   wherein the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress, and provide a tight packed arrangement to the assembly of the plurality of spring units, when the upper foam panel is secured over the lower foam panel.   
     
     
         14 . The method as claimed in  claim 12  further comprises placing each spring unit within the surface of the lower foam panel, such that each spring unit is supported, in its respective position, by the adjacent ones and also supported and tightly packed by the side walls. 
     
     
         15 . The method as claimed in  claim 12 , wherein the foam panels may be molded into a rectangular, square or any other suitable quadrilateral/geometrical shape and wherein the foam is selected from a number of foam materials such as including and not limited to natural and synthetic latex foam material, polyurethane foam, and other synthetic foam material manufactured by crude oil, and the like including composite foams, the foam panels being identical in either shape and/or size and/or material. Said foam panels optionally independently comprise perforations and/or profiles.