IP Library › Granted Patent US 12,137,816
Granted Patent B2
US 12,137,816 · App. 17/050,653 · Granted Nov 12, 2024

Rearrangeable mattress with covered layers

Inventors: Christopher E. Nolte (Milwaukee, WI); Thomas J. Metz (Milwaukee, WI); Kathy Thornton-Bias (Milwaukee, WI); Richard Feingold (Milwaukee, WI)
Assignee: Ahhfactor LLC
A47C27/15A47C27/002A47C27/148A47C31/001
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Quick Facts
Patent No.
US 12,137,816
App. No.
17/050,653
Granted
Nov 12, 2024
Kind
B2
Abstract

Systems and apparatuses include a mattress assembly including a tub including vertically extending rails and a base and defining an interior cavity bound by the rails and the base, a plurality of non-laminated and rearrangeable layers positioned within the interior cavity to provide both support and comfort levels within the mattress assembly, each layer including a layer cover and a layer foam, and a cover system that includes a removable cover allowing selective access to the plurality of layers and the interior cavity and selectively compressing the plurality of layers within the tub.

Claims (75)

1. A mattress assembly, comprising:

a tub including vertically extending rails defining a rail height and a rail width, and a base defining a base height, the tub defining an interior cavity bound by the rails and the base and defining a cavity height;

a plurality of non-laminated and rearrangeable layers positioned within the interior cavity to provide both support and comfort levels within the mattress assembly, each layer including a layer cover and a layer foam; and

a cover system that includes a removable cover allowing selective access to the plurality of layers and the interior cavity and selectively compressing the plurality of layers within the tub,

wherein a ratio of the rail height to the cavity height is between about 1.4 and about 1.8,

wherein a ratio of the rail width to the base height is between about 0.6 and about 0.8, and

wherein the cover system includes a first zipper and a second zipper coupling the removable cover to the tub, wherein the first zipper and the second zipper meet at a central portion of a front side of the mattress assembly, and wherein the first zipper and the second zipper are coupled to an inner perimeter of the rails.

2. The mattress assembly of claim 1 , wherein the tub defines a base height, and

wherein a ratio of the rail height to the base height is between about 2.5 and about 2.9.

3. The mattress assembly of claim 1 , wherein the plurality of layers includes:

a first layer foam being constructed of a first material,

a second layer foam being constructed of a second material,

a third layer foam being constructed of a third material,

a fourth layer foam being constructed of a fourth material, and

a fifth layer foam being constructed of the fourth material.

4. The mattress assembly of claim 3 , wherein the plurality of layers includes:

the first material is a gel memory foam with a density of about 4.0 pounds per cubic foot,

the second material is a polyurethane foam with a density of about 3.6 pounds per cubic foot and an indentation load deflection of between about 20 and about 26,

the third material is a polyurethane foam with density of about 1.8 pounds per cubic foot and an indentation load deflection of about 45, and

the fourth material is a polyurethane foam with a 1.8 pounds per cubic foot density and an indentation load deflection of about 33.

5. The mattress assembly of claim 1 , wherein the plurality of layers includes:

a first layer defining a thickness of between one and two inches,

a second layer defining a thickness of between one and two inches,

a third layer defining a thickness of between one and two inches,

a fourth layer defining a thickness of between one and two inches, and

a fifth layer defining a thickness of between one and two inches.

6. The mattress assembly of claim 1 , wherein each of the plurality of layer covers includes a layer identifier that aids an end user in identifying a characteristic of the layer.

7. The mattress assembly of claim 6 , wherein the plurality of layers includes

a first layer identifier including a first colored fabric,

a second layer identifier including a second colored fabric,

a third layer identifier including a third colored fabric,

a fourth layer identifier including a fourth colored fabric, and

a fifth layer identifier including the fourth colored fabric.

8. The mattress assembly of claim 1 , wherein the cover system further includes a fire retardant inner liner and a fire retardant top cover, wherein the top cover is not directly coupled to the inner liner.

9. The mattress assembly of claim 1 , wherein the cover system includes an outer liner including a pocket and a top cover zippered to the outer liner, the pocket holding recipe cards.

10. The mattress assembly of claim 1 , wherein the layer covers define a different material density than the layer foams.

11. The mattress assembly of claim 1 , wherein the layer covers are removable from the layer foams.

12. The mattress assembly of claim 1 , wherein the cover system includes

an inner liner surrounding the tub and fully covering a top surface of the tub,

an inner cover zipped to the inner liner to compress the plurality of layers within the interior cavity, and

an outer liner surrounding the inner liner and zipped to the removable cover at a periphery of the tub.

13. The mattress assembly of claim 12 , wherein the outer liner includes a pocket sized to hold recipe cards for instructing an end user of potential arrangements of the plurality of layers.

14. A mattress assembly, comprising:

a first layer defining a thickness of between one and two inches and including a first layer cover and a first layer foam being constructed of a first material;

a second layer defining a thickness of between one and two inches and including a second layer cover and a second layer foam being constructed of a second material;

a third layer defining a thickness of between one and two inches and including a third layer cover and a third layer foam being constructed of a third material;

a fourth layer defining a thickness of between one and two inches and including a fourth layer cover and a fourth layer foam being constructed of a fourth material;

a fifth layer defining a thickness of between one and two inches and including a fifth layer cover and a fifth layer foam being constructed of the fourth material;

a tub including rails and a base and defining an interior cavity sized to receive the first layer, the second layer, the third layer, the fourth layer, and the fifth layer;

an inner liner surrounding the tub, the first layer, the second layer, the third layer, the fourth layer, and the fifth layer, the inner liner fully covering a top surface of the tub;

an inner cover coupled to the inner liner with a first inner zipper and a second inner zipper;

an outer liner surrounding the inner liner and including a pocket holding recipe cards; and

a top cover coupled to the outer liner with a first outer zipper and a second outer zipper at a periphery of the tub,

wherein the first layer, the second layer, the third layer, the fourth layer, and the fifth layer are not laminated and are rearrangeable by an end user,

wherein the tub defines a rail height and a base height,

wherein a ratio of the rail height to the base height is between about 2.5 and about 2.9, and

wherein the cover system includes a first zipper and a second zipper coupling the removable cover to the tub, wherein the first zipper and the second zipper meet at a central portion of a front side of the mattress assembly, and wherein the first zipper and the second zipper are coupled to an inner perimeter of the rails.

15. The mattress assembly of claim 14 , wherein the first layer cover includes a first layer identifier, the second layer cover includes a second layer identifier, the third layer cover includes a third layer identifier, the fourth layer cover includes a fourth layer identifier, and the fifth layer cover includes a fifth layer identifier.

16. The mattress assembly of claim 15 , wherein

the first layer identifier includes a first colored fabric,

the second layer identifier includes a second colored fabric,

the third layer identifier includes a third colored fabric,

the fourth layer identifier includes a fourth colored fabric, and

the fifth layer identifier includes the fourth colored fabric.

17. The mattress assembly of claim 14 , wherein the fourth layer and the fifth layer are substantially identical.

18. The mattress assembly of claim 14 , wherein the first material is a gel memory foam with a density of about 4.0 pounds per cubic foot, the second material is a polyurethane foam with a density of about 3.6 pounds per cubic foot and an indentation load deflection of between about 20 and about 26, the third material is a polyurethane foam with density of about 1.8 pounds per cubic foot and an indentation load deflection of about 45, and the fourth material is a polyurethane foam with a 1.8 pounds per cubic foot density and an indentation load deflection of about 33.

19. A mattress assembly, comprising:

a tub including vertically extending rails defining a rail width and a rail height, and a base defining a base height, the tub defining an interior cavity bound by the rails and the base and defining a cavity height;

a plurality of non-laminated and rearrangeable layers positioned within the interior cavity to provide both support and comfort levels within the mattress assembly, each layer including a layer cover and a layer foam; and

a cover system that includes:

a removable cover zippered to an outer liner and allowing selective access to the plurality of layers and the interior cavity and selectively compressing the plurality of layers within the tub, and

an inner liner positioned within the outer liner and fully covering a top surface of the tub,

wherein a ratio of the rail width to the base height is between about 0.6 and about 0.8,

wherein a ratio of the rail height to the cavity height is between about 1.4 and about 1.8, and

wherein the cover system includes a first zipper and a second zipper coupling the removable cover to the tub, wherein the first zipper and the second zipper meet at a central portion of a front side of the mattress assembly, and wherein the first zipper and the second zipper are coupled to an inner perimeter of the rails.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 26, 2020
From: NOLTE, CHRISTOPHER E.; METZ, THOMAS J.; THORNTON-BIAS, KATHY; FEINGOLD, RICHARD
To: AHHFACTOR LLC
Reel/Frame 054167/0086 →
Continuity (5)
Continuation In Part 15965533 · Apr 27, 2018
Continuation In Part 15965520 · Apr 27, 2018
Continuation In Part 29645690 · Apr 27, 2018
Continuation In Part 29645691 · Apr 27, 2018
Related Publication 20210235884A1 · Aug 5, 2021
Cited By (4)
US 1,145,416 US 12,315,000 US 12,635,809 US 12,642,363