Mattresses with reinforcement inserts and densified stitch zones

Abstract

Reinforced mattresses have a mattress core and one or more reinforcement pads located proximate to the mattress core, and corresponding higher density stitch patterns in a quilt package layer which are co-located with the reinforcement pads. The one or more reinforcement pads are located in higher load areas of the mattress such as the pelvic region or head and shoulders region to provide additional support and to resist or prevent permanent indentation of the mattress support surface and provide increased support. In one embodiment, the one or more reinforcement pads have a length that is less than the length of the mattress core and a width that is substantially the width of the mattress core, with corresponding areas in the quilt package layer of higher density stitching. The higher density stitching in those areas of the quilt package layer pattern provide a pre-compressed support structure in combination with the reinforcement pads which provides greater support and pressure distribution and resistance to permanent indentation of the support structure.

1 . A mattress comprising:
 a mattress core;   one or more reinforcement pads having a top surface, a bottom surface which is opposite the top surface and four side surfaces which extend between the top surface and the bottom surface, the bottom surface positioned proximate to the mattress core;   one or more upholstery layers in contact with the top surface of the one or more reinforcement pads;   a quilt package layer which substantially covers the upholstery layers and the mattress core;   a first reinforcement pad positioned to extend transverse of the mattress core proximate to a middle region of the mattress core of the mattress assembly, and   an area of the quilt package layer which overlies and substantially corresponds in location to the first reinforcement pad having a greater density of stitches than a stitch density of other areas of the quilt package layer.   
     
     
         2 . The mattress of  claim 1 , further comprising a second reinforcement pad positioned to extend transversely across a width of the mattress core and spaced from the first reinforcement pad, and a second area of the quilt package layer which overlies and substantially corresponds in location with the second reinforcement pad having a greater density of stitches than a stitch density of other areas of the quilt package layer and a substantially similar stitch density to the area of the quilt package layer which overlies the first reinforcement pad. 
     
     
         3 . The mattress of  claim 1 , wherein the quilt package layer on a top surface of the mattress assembly contains a stitch pattern over an area of the mattress where the first reinforcement pad is located that is different from a stitch pattern in a remainder of the quilt package layer. 
     
     
         4 . The mattress of  claim 2 , wherein the quilt package layer on a top surface of the mattress assembly contains a stitch pattern over areas of the mattress where the first and second reinforcement pads are located that is different than a stitch pattern in a remainder of the quilt package layer. 
     
     
         5 . The mattress of  claim 1 , wherein the one or more reinforcement pads have a thickness dimension in an approximate range of 0.5 to 0.75 inches. 
     
     
         6 . The mattress of  claim 1 , wherein the one or more reinforcement pads are made of visco-elastic foam. 
     
     
         7 . The mattress of  claim 6 , wherein the one or more reinforcement pads have a density of approximately 1.5 lb/in 2 . 
     
     
         8 . The mattress of  claim 1 , wherein the length of the first reinforcement pad is approximately 30 inches. 
     
     
         9 . The mattress of  claim 2 , wherein the height of the second reinforcement pad is approximately 10 inches. 
     
     
         10 . The mattress of  claim 1  wherein the mattress core is an innerspring assembly. 
     
     
         11 . The mattress of  claim 1  wherein the mattress core is comprised of foam. 
     
     
         12 . The mattress of  claim 1  further including an edge support system located along the perimeter of the mattress core. 
     
     
         13 . The mattress of  claim 10  further including one or more foam constructs located between the convolutions of one or more coils of the innerspring. 
     
     
         14 . The mattress of  claim 3 , wherein stitch pattern in the quilt package layer which overlies the first reinforcement pad is made with threat of a different color than in a remainder of the quilt package layer. 
     
     
         15 . The mattress of  claim 2  further comprising a third reinforcement pad positioned to extend laterally across a width of the mattress core and spaced from the first reinforcement pad and the second reinforcement pad. 
     
     
         16 . The mattress of  claim 15  further comprising a stitch pattern in an area of the quilt package layer which overlies the third reinforcement pad which is different than a stitch pattern in areas of the quilt package layer which do not overlie the first, second or third reinforcement pads. 
     
     
         17 . The mattress of  claim 16  wherein the stitch pattern in the areas of the quilt package layer which overlie the first, second and third reinforcement pads is in a common location. 
     
     
         18 . The mattress of  claim 1  further comprising a resilient pad which is aligned with and proximate to substantially the entire mattress core. 
     
     
         19 . The mattress of  claim 1  wherein the first reinforcement pad is positioned on top of or extends from a resilient pad which is aligned with substantially the entire mattress core. 
     
     
         20 . The mattress of  claim 1  wherein the first reinforcement pad is located on top of the mattress core. 
     
     
         21 . The mattress of  claim 1  wherein the first reinforcement pad is located under the mattress core. 
     
     
         22 . The mattress of  claim 1  further comprising a bottom pad which extends over substantially an entire bottom surface of the mattress core, and the first reinforcement pad located between the bottom pad and the mattress core. 
     
     
         23 . The mattress of  claim 2  wherein the second reinforcement pad is located on top of the mattress core. 
     
     
         24 . The mattress of  claim 2  wherein the second reinforcement pad is located under the mattress core. 
     
     
         25 . The mattress of  claim 2  wherein the second reinforcement pad is located at a head region of the mattress. 
     
     
         26 . The mattress of  claim 1  wherein the first reinforcement pad is located approximately one third of a length of the mattress from a foot end of the mattress, and approximately one third of the length of the mattress from a head end of the mattress. 
     
     
         27 . A mattress comprising:
 an innerspring having a top surface and a bottom surface;   a first reinforcement pad having a substantially planar top surface that is opposite a substantially planar bottom surface and four substantially planar side surfaces extending between the top surface and the bottom surface, the first reinforcement pad having a width dimension that is equal to or less than a width of the innerspring and a length dimension that is equal to or less than a length of the innerspring, the first reinforcement pad positioned proximate to the innerspring and spaced from a first end of the innerspring and a second end of the innerspring;   one or more upholstery layers positioned over a support surface of the innerspring;   a quilt package layer which extends over the one or more upholstery layers and the innerspring and the first reinforcement pad, the quilt package layer having a first stitch pattern and a second stitch pattern, the first stitch pattern having a greater density of stitches than the second stitch pattern, the first stitch pattern in an area of the quilt package layer which overlies the first reinforcement pad, and the second stitch pattern in areas of the quilt package layer which do not overlie the first reinforcement pad.   
     
     
         28 . The mattress of  claim 27  further comprising a second reinforcement pad having a substantially planar top surface that is opposite a substantially planar bottom surface and four substantially planar side surfaces extending between the top surface and the bottom surface, the second reinforcement pad having a width dimension less than or equal to a width of the innerspring and a length dimension that is less than a length of the innerspring and less than the length dimension of the first reinforcement pad, the second reinforcement pad positioned proximate to the innerspring and spaced from the first reinforcement pad;
 the first stitch pattern of the quilt package layer in an area of the quilt package layer which overlies the first reinforcement pad and the second reinforcement pad, and the second stitch pattern of the quilt package layer in areas of the quilt package layer which do not overlie the first reinforcement pad or the second reinforcement pad. 
 
     
     
         29 . The mattress of  claim 28 , wherein the first and second reinforcement pads are made of visco-elastic foam, polyurethane or latex. 
     
     
         30 . The mattress of  claim 27  wherein a the first reinforcement pad is located approximately one-third a length of the innerspring from a first end of the innerspring and approximately one-third a length of the innerspring from a second end of the innerspring which is opposite the first end of the innerspring. 
     
     
         31 . The mattress of  claim 27  wherein the first stitch pattern is a different color than the second stitch pattern. 
     
     
         32 . The mattress of  claim 27  wherein the quilt package layer is compressed by the first stitch pattern to a greater extent than by the second stitch pattern. 
     
     
         33 . The mattress of  claim 27  further comprising a foam edge supports positioned about a perimeter of the innerspring. 
     
     
         34 . A mattress comprising:
 a mattress core;   one or more upholstery layers proximate to the mattress core;   a quilt package layer positioned over the mattress core and the one or more upholstery layers;   at least one reinforcement pad positioned proximate to the mattress core;   the quilt package layer having an area of higher stitch density located over a support surface of the mattress wherein the are of higher stitch density is greater than a stitch density in a remainder of the quilt package layer,   and wherein the area of higher stitch density in the quilt package layer is located over the at least one reinforcement pad.   
     
     
         35 . The mattress of  claim 34  wherein the at least one reinforcement pad is located on a top surface of the mattress core. 
     
     
         36 . The mattress of  claim 34  wherein the at least one reinforcement pad is located under the mattress core. 
     
     
         37 . The mattress of  claim 34  wherein the at least one reinforcement pad is located between upholstery layers. 
     
     
         38 . The mattress of  claim 34  wherein the at least one reinforcement pad is located with the upholstery layer. 
     
     
         39 . The mattress of  claim 34  wherein the area of the quilt package layer which is located over the at least one reinforcement pad is of a different color than other areas of the quilt package layer. 
     
     
         40 . The mattress of  claim 34  in combination with a foundation which underlies and supports the mattress, and wherein the at least one reinforcement pad is proximate to the foundation. 
     
     
         41 . The mattress of  claim 34  wherein the higher stitch density in the quilt package layer is comprised of tufting. 
     
     
         42 . The mattress of  claim 41  wherein the tufting is comprised of tufting twine or tufting tape. 
     
     
         43 . The mattress of  claim 34  wherein at least one of the upholstery layers is made of foam which has been pre-compressed.