Channel-cut cushion supports
View Patent ↗The support characteristics within a foam mattress body may be varied by inserting reinforcements into channels cut or otherwise formed within the foam.
1. A mattress comprising:
a body made of foam, the body having a top surface, a bottom surface, a first and second side surfaces and a first and second end surfaces, at least one of the surfaces being a channel surface that includes a channel extending into the body perpendicularly therefrom; and
an insert including one or more springs affixed within the channel, the insert reinforcing the body; and
further comprising a plurality of channels, each channel having affixed therein an insert that reinforces the body of the mattress.
2. The mattress of claim 1 wherein the insert includes a row of pocket springs.
3. The mattress of claim 1 further comprising a material that covers the channel, the material securing the insert within the channel.
4. The mattress of claim 3 further comprising a mattress cover surrounding the mattress.
5. A method of manufacturing a mattress comprising:
providing a body of foam shaped and sized for use as a mattress;
locating a region of the body where increased support is desired;
forming a channel into the body within the region; and
affixing an insert into the channel, the insert having a greater firmness than the body of foam;
wherein forming the channel comprises assembling a plurality of rectangular foam pieces into a mattress that includes the channel.
6. The method of claim 5 wherein forming the channel further comprises cutting foam out of the body.
7. The method of claim 5 wherein forming the channel further comprises molding the channel into the foam.
8. The method of claim 5 further comprising covering the mattress with one or more conventional mattress covering materials.
9. A mattress comprising:
a body made of foam, the body having a top surface, a bottom surface, a first and second side surfaces and a first and second end surfaces, at least one of the top, bottom, first end, or second end surfaces being a channel surface that includes a channel extending into the body perpendicularly therefrom; and
an insert includinn one or more springs affixed within the channel, the insert reinforcing the body; and
further comprising a plurality of channels, each channel having affixed therein an insert that reinforces the body of the mattress.
10. The mattress of claim 9 wherein the insert includes a row of pocket springs.
11. The mattress of claim 9 further comprising a material that covers the channel, the material securing the insert within the channel.
12. The mattress of claim 11 further comprising a mattress cover surrounding the mattress.