Mattress including a pressure relief and methods of manufacturing the same

Abstract

A mattress includes a base layer, the top layer, and a pressure relief layer. The top layer is disposed above the base layer. The pressure relief layer is disposed between the base layer and the top layer and includes a tray and one or more pods. The tray defines a first channel that extends the width of the tray and extends downward through a top surface to a depth of 50 percent to 80 percent of a thickness of the tray. The tray has a monolithic construction and is formed of a foam. The one or more pods are disposed within the first channel of the tray and have a rectangular base and extend upward from the base while remaining in contact with the side walls defining the channel for at least 25 percent of the height of the one or more pods.

What is claimed: 
     
         1 . A mattress comprising:
 a base layer defining a base length and a base width;   a top layer disposed above the base layer and having a top length and a top width the same as the base length and the base width; and   a pressure relief layer disposed between the base layer and the top layer, the pressure relief layer comprising:
 a tray having a top surface and a bottom surface, a thickness of the pressure relief layer defined as the distance between the top surface to the bottom surface, the bottom surface defining a tray length and a tray width, the tray length and the tray width the same as the base length and the base width, the tray defining a first channel extending the width of the tray and extending downward through the top surface to a depth of 50 percent to 80 percent of the thickness of the tray, the tray having monolithic construction and formed of a foam having a first firmness; and 
 one or more pods disposed within the first channel, the one or more pods having a rectangular base and extending upward from the rectangular base while remaining in contact with sidewalls defining the channel for at least 25 percent of a height of the one or more pods. 
   
     
     
         2 . The mattress according to  claim 1 , wherein a bottom surface of the pressure relief layer is secured to a top surface of the base layer. 
     
     
         3 . The mattress according to  claim 1 , wherein a top surface of the tray is secured to a bottom surface of the top layer. 
     
     
         4 . The mattress according to  claim 3 , wherein a top surface of the one or more pods is unsecured to the bottom surface of the top layer. 
     
     
         5 . The mattress according to  claim 4 , wherein a top surface of the one or more pods is in contact with the bottom surface of the top layer. 
     
     
         6 . The mattress according to  claim 1 , wherein the one or more pods are formed of a memory foam. 
     
     
         7 . The mattress according to  claim 6 , wherein the tray is formed of polyurethane foam. 
     
     
         8 . The mattress according to  claim 1 , further comprising a secondary layer disposed between the top layer and the pressure relief layer. 
     
     
         9 . The mattress according to  claim 1 , wherein the base layer is formed of foam. 
     
     
         10 . The mattress according to  claim 1 , wherein the base layer includes pocketed springs. 
     
     
         11 . The mattress according to  claim 1 , wherein the tray defines a second channel and a third channel that each extend the width of the tray and extend downward through the top surface of the tray, each of the first channel, the second channel, and the third channel spaced apart from one another along the length of the pressure relief layer, one or more pods disposed within each of the second channel and the third channel. 
     
     
         12 . The mattress according to  claim 1 , further comprising a side cap extending the entire length of the pressure relief layer and having a thickness equal to or greater than a thickness of the tray, the side cap covering ends of the first channel. 
     
     
         13 . The mattress according to  claim 12 , wherein the side cap defines a total thickness of the mattress and is disposed along each side of the mattress. 
     
     
         14 . A mattress comprising:
 a base layer defining a base length and a base width;   a top layer disposed above the base layer and having a top length and a top width the same as the base length and the base width; and   a pressure relief layer disposed between the base layer and the top layer, the pressure relief layer defining a plurality of zones along the length of the pressure relief layer with each of zone of the plurality of zones extending across the entire width of the pressure relief layer, the plurality of zones, in order, including a first support zone, a first pressure relief zone, a second support zone, a second pressure relief zone, a third support zone, a third pressure relief zone, and a fourth support zone, the pressure relief layer including a tray, the tray defining at least one channel in each of the pressure relief zones that extend the width of the tray, the second support zone and the third support zone having a length of at least 10 inches on either side of the second pressure relief zone.   
     
     
         15 . The mattress according to  claim 14 , wherein the pressure relief layer includes one or more pods disposed in each of the at least one channels. 
     
     
         16 . The mattress according to  claim 15 , wherein the one or more pods are formed of at least one of memory foam, an air bladder, a water bladder, copper foam, gel foam, or combinations thereof. 
     
     
         17 . The mattress according to  claim 14 , wherein each of the at least one channels extend from a top surface of the tray to a depth in a range of 50 percent to 80 percent of the thickness of the tray. 
     
     
         18 . The mattress according to  claim 14 , wherein the first pressure relief zone includes four channels spaced apart from one another. 
     
     
         19 . The mattress according to  claim 14 , wherein a top surface of the tray is secured to a bottom surface of the top layer. 
     
     
         20 . A pressure relief structure comprising:
 a tray having a top surface and a bottom surface, a thickness of the pressure relief layer defined as the distance between the top surface and the bottom surface, the bottom surface defining a tray length and a tray width, the tray length, the tray defining a first channel extending the width of the tray and extending downward through the top surface to a depth of 50 percent to 80 percent of the thickness of the tray, the tray having monolithic construction and formed of a foam having a first firmness; and   one or more pods disposed within the first channel, the one or more pods having a rectangular base and extending upward from the rectangular base while remaining in contact with sidewalls defining the channel for at least 25 percent of a height of the one or more pods.