Granted Patent B2

US 7,424,763 · App. 11/415,816 · Granted Sep 16, 2008

Abstract

Claims (18)

1. A mattress comprising:

a body made of foam having a mechanical characteristic, 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 and bottom surfaces including a plurality of channels extending into the body perpendicularly therefrom; and

a plurality of inserts, each insert having a mechanical characteristic different from the mechanical characteristic of the foam and affixed within one of the plurality of channels, each insert reinforcing the body.

2. The mattress of claim 1 wherein at least one of the inserts includes one or more springs.

3. The mattress of claim 1 wherein at least one of the inserts includes a row of pocket springs.

4. The mattress of claim 1 further comprising a material that covers at least one of the channels, the material securing at least one of the inserts within one of the channels.

5. The mattress of claim 4 further comprising a mattress cover surrounding the mattress.

6. The mattress of claim 1 , wherein at least one of the insert is substantially flush with the at least one of the top and bottom surfaces.

7. The mattress of claim 1 , wherein each channel extends to an opening in at least one of the surfaces adjacent to the channel surface.

8. A method of manufacturing a mattress comprising:

providing a plurality of rectangular foam pieces to form a body of foam shaped and sized for use as a mattress;

locating a region of the body where increased support is desired;

assembling the plurality of rectangular foam pieces to form the body having a channel in the region; and

affixing an insert into the channel, the insert having a different firmness than the body of foam.

9. The method of claim 8 wherein forming the channel comprises cutting foam out of the body.

10. The method of claim 8 wherein forming the channel comprises molding the channel into the foam.

11. The method of claim 8 further comprising covering the mattress with one or more conventional mattress covering materials.

12. The method of claim 8 , wherein the size of the insert is substantially equal to the size of the channel.

Assignments (22)