Perimeter stiffening system for a foam mattress
View Patent ↗A stiffening system for the perimeter edges of a foam core mattress comprising a coil spring (or other spring-based) structure disposed along one or more perimeter edges (e.g., one or both side edges, the foot, the head, or a combinations thereof including the foot and both side edges) of a mattress having a foam sleeping area. The perimeter spring structure is rectangular or square in cross-section and provides sufficient stiffness for comfortable seating on the edges of the mattress and is joined to the foam core by planar fabric elements that span the joint between them and are attached to both. The sleep area provides the softness and other salutary effects of a foam sleeping surface while the stiffer spring perimeter element provides the rigidity need for comfortable seating and wear resistance.
1. A bedding product, comprising:
a generally rectangular foam core having a sleeping area and a first width, said foam core including four perimeter sides having a first height, the sides extending along a perimeter of the sleeping area and downwardly therefrom;
a perimeter element having a second width less than the first width, and a second height approximately equal to said first height arranged in abutment with a plurality of said perimeter sides of said foam core and comprising a plurality of springs arranged in an array; and
one or more border wires securing said array of springs;
said perimeter element being joined to said foam core by one or more planar elements secured to both said foam core and said perimeter element.
2. The bedding product of claim 1 , wherein said plurality of springs comprises one or more pocketed springs.
3. The bedding product of claim 1 , further comprising a topper attached to the top surface of said bedding product.
4. The bedding product of claim 3 , wherein said topper comprises a latex foam layer.
5. The bedding product of claim 1 , wherein said one or more planar elements each comprise a fusible fabric.
6. The bedding product of claim 1 , wherein said one or more planar elements each comprise a webbing.
7. The bedding product of claim 1 , wherein said foam core comprises a monolithic resilient foam element.
8. The bedding product of claim 1 , wherein the one or more planar elements each includes one or more webbing members spanning the interface between the perimeter element and the foam core.
9. The bedding product of claim 1 , the one or more planar elements each includes an adhesive.
10. A method of manufacturing a bedding product, comprising:
furnishing a generally rectangular foam core having a sleeping area and a first width, said foam core including four perimeter sides having a first height, the sides extending along a perimeter of the sleeping area and downwardly therefrom;
placing a perimeter element in abutment with said foam core on a plurality of perimeter sides, said perimeter element having a second width less than the first width, and a second height approximately equal to said first height and comprising a plurality of springs arranged in an array with one or more border wires securing said array of springs; and
joining said perimeter element to said foam core to form said bedding product with one or more planar elements disposed perpendicular to said sides and securing each said one or more planar elements to both said foam core and said perimeter element.
11. The method of claim 10 , wherein said plurality of springs comprises one or more pocketed springs.
12. The method of claim 10 , further comprising attaching a topper to the top surface of said bedding product.
13. The method of claim 12 , wherein said topper comprises a latex foam layer.
14. The method of claim 10 , wherein said one or more planar elements each comprise a fusible fabric.
15. The method of claim 10 , wherein said one or more planar elements each comprise a webbing.
16. The method of claim 10 , wherein said foam core comprises a monolithic resilient foam element.