Systems and methods for hinged bedding assemblies
View Patent ↗In many aspects, the systems and methods described herein include a mattress having a top sleeping layer disposed on top of a support layer. The support layer includes a polyurethane foam having channels aligned with the joints of the articulated sections of the foundation or frame of the adjustable bedding assembly. When the sections articulate about the joints, the channels allow the overlying top layer to conform to the sections while reducing wear and tear therein.
1. A mattress having multiple flexure points for articulating the mattress into different positions, the mattress comprising:
a top layer having a top surface and a bottom surface, wherein the top layer comprises an innerspring,
a support foam layer disposed below the bottom surface of the top layer, having a top surface, a bottom surface, a first side wall, a second side wall, and a support layer thickness, wherein the support foam layer includes a first channel extending from the first side wall to the second side wall along the bottom surface of the support foam layer, and a second channel extending from the first side wall to the second side wall along the top surface of the support foam layer,
at least one additional layer disposed between the support foam layer and the top layer, wherein said at least one additional layer includes at least one of foam or springs,
wherein the first and second channels each comprise a first vertical wall and a second vertical wall, the vertical walls spaced a width apart by a bottom wall, and wherein the first channel has a first depth less than the support layer thickness and the second channel has a second depth less than the support layer thickness, the first and second channels defining the flexure points, and
wherein the top layer further comprises foam blocks disposed between a plurality of coil springs in the innerspring, wherein each of the foam blocks is aligned with a selected one of the first and second channels.
2. The mattress of claim 1 , wherein the innerspring top layer comprises wrapped coil springs.
3. The mattress of claim 1 , wherein at least one of the at least one additional layer and support foam layer includes at least one of polyurethane, latex, and visco foam.
4. The mattress of claim 1 , wherein the widths of the first channel and the second channels allow for consistent firmness in the top layer.
5. The mattress of claim 4 , wherein at least one of the first channel and the second channel is about ⅓ inch to about ¾ inch wide.
6. The mattress of claim 1 , wherein the depth of at least one of the first and the second channels extends about ⅓ to about ½ of the thickness of the support foam layer.
7. The mattress of claim 1 , wherein the depth of at least one of the first and second channels extends perpendicular from the bottom and top surface, respectively, of the support foam layer.
8. The mattress in claim 1 , wherein at least one of the first channel and the second channel is sufficiently deep to allow flexing and reduce mechanical stress on the point of articulation of the mattress.
9. The mattress in claim 1 , wherein the support foam layer is sufficiently rigid/firm to accommodate the load of the top layer.
10. A mattress having multiple flexure points for articulating the mattress into different positions, the mattress comprising:
a top layer having a top surface and a bottom surface, wherein the top layer comprises an innerspring, and
a support foam layer disposed below the bottom surface of the top layer, having a top surface, a bottom surface, a first side wall, a second side wall, and a support layer thickness, wherein the support foam layer includes a first channel extending from the first side wall to the second side wall along the bottom surface of the support foam layer, and a second channel extending from the first side wall to the second side wall along the top surface of the support foam layer, and wherein the first channel has a first depth less than the support layer thickness and the second channel has a second depth less than the support layer thickness, wherein the first and second channels each comprise a first vertical wall and a second vertical wall, the vertical walls spaced a width apart by a bottom wall, wherein the width is constant across the support foam layer and is within a range of about ⅛ inch to 1.5 inches, and wherein the first and second channels define the flexure points, and
at least one additional layer disposed between the support foam layer and the top layer, wherein said at least one additional layer includes at least one of foam or springs,
wherein the top layer further comprises foam blocks disposed between a plurality of coil springs in the innerspring, wherein each of the foam blocks is aligned with a selected one of the first and second channels.