Systems and methods for hinged bedding assemblies

Abstract

In many aspects, the systems and methods described herein include mattress having a top sleeping layer disposed on top of a support layer. The support layer includes polyurethane foam having channels comprising one or more slits on both sides of a surface to act as hinges for articulation. The channels may be 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, comprising
 a top layer, and   a support foam layer disposed below the top layer, having a top surface, a bottom surface, a first side wall, a second side wall,   wherein the support foam layer includes a first channel extending from the first side wall to the second side wall along the bottom surface, and a second channel extending from the first side wall to the second side wall along the top surface.   
     
     
         2 . The mattress of  claim 1 , further comprising a third layer disposed between the support foam layer and the top layer. 
     
     
         3 . The mattress of  claim 1 , further comprising a plurality of layers disposed between the support foam layer and the top layer. 
     
     
         4 . The mattress of  claim 3 , wherein at least one of the layers includes at least one of foam or springs. 
     
     
         5 . The mattress of  claim 3 , wherein a layer includes a spring layer having foam disposed in between a plurality of coil springs. 
     
     
         6 . The mattress of  claim 5 , wherein the spring layer comprises wrapped coil spring. 
     
     
         7 . The mattress of  claim 3 , wherein at least one of the layers and support foam layer includes at least one of polyurethane, latex, and visco foam. 
     
     
         8 . The mattress of  claim 1 , wherein at least one of the first channel and the second channel comprise a plurality of parallel slits. 
     
     
         9 . The mattress of  claim 8 , wherein the plurality of slits are parallel to each other, spaced apart by about ⅓ inch to about ½ inch. 
     
     
         10 . The mattress of  claim 1 , wherein at least one of the first channel and the second channel has a width that allows for consistent firmness in the top layer. 
     
     
         11 . The mattress of  claim 10 , wherein at least one of the first channel and the second channel is about ⅓ inch to about ¾ inch wide. 
     
     
         12 . The mattress of  claim 1 , wherein at least one of the first channel and the second channel has a depth that extends partially into the thickness of the support foam layer. 
     
     
         13 . The mattress of  claim 12 , wherein the depth of at least one of the first and the second channel extends about ⅓ to about ½ of the thickness of the support foam layer. 
     
     
         14 . The mattress of  claim 8 , wherein at least one of the first channel and the second channel comprises a plurality of parallel slits having a depth that extends partially into the thickness of the support foam layer. 
     
     
         15 . The mattress of  claim 14 , wherein the depth of the parallel slits are the same as or different from each other. 
     
     
         16 . The mattress of  claim 12 , wherein the depth of at least one of the first channel and second channel extends perpendicular from the bottom and top surface, respectively, of the support foam layer. 
     
     
         17 . The mattress in  claim 1 , wherein the channel is sufficiently deep to allow flexing and reduce mechanical stress on the point of articulation of the mattress. 
     
     
         18 . The mattress in  claim 1 , wherein the support foam layer is sufficiently rigid/firm to accommodate the load of the top layers.