Mattress assemblies including an orthotic layer and processes for forming the same
A mattress assembly generally includes an orthotic layer generated from a deformation map associated with a particular end user and process of manufacturing he mattress assembly. The orthotic layer is rigid and flexible and minimizes pressure points relative the mattress assembly without the orthotic layer.
1 . A process for manufacturing a mattress assembly comprising:
generating a deformation map from a particular end user, wherein generating the deformation map comprises measuring deformation corresponding to the particular end user on a test mattress including a plurality of pressure sensors;
forming an orthotic layer from the deformation map, wherein the orthotic layer has a contoured upper surface minimizing pressure points associated with the deformation map, a planar bottom surface and vertical sidewalls extending from the planar bottom surface to the contoured upper surface, and wherein the orthotic layer has a width and/or length dimension less than overall width and length dimensions of the mattress assembly, wherein the orthotic layer is positioned at a desired sleeping area in the mattress assembly; and
assembling the mattress assembly including the orthotic layer for the particular end user, wherein the mattress assembly comprises a plurality of comfort layers in addition to the orthotic layer, wherein the orthotic layer underlies at least one of the plurality of comfort layers conforming to the contoured surface of the orthotic layer, wherein the contoured upper surface is translatable to a sleeping surface of the mattress assembly,
wherein at least one of the plurality of comfort layers overlying the orthotic layer has a thickness and firmness such that, upon compression by the end user, the contoured surface of the orthotic layer is perceptible at the sleeping surface, thereby providing a personalized contoured sleeping surface with minimal pressure points for the particular end user, and
wherein the mattress assembly is dimensioned to simultaneously accommodate two end users, and comprises two orthotic layers arranged adjacent to one another, wherein each of the two orthotic layers are at a location to accommodate each respective end user, and wherein each of the two orthotic layers have different contouring.
2 . The process of claim 1 , wherein the orthotic layer has an indention load deflection of 7 to 45 pounds-force for non-viscoelastic foams and 7 to 16 pounds-force for viscoelastic foams.
3 . The process of claim 1 , wherein the orthotic layer comprises an elastomeric solid material.
4 . The process of claim 1 , wherein the orthotic layer comprises a foam.