Multi-layer multi-material foam mattresses

Abstract

The multi-layer multi-material foam mattresses of the present disclosure and related inventions provide novel combinations of multiple layer, multiple material foam layers or stacks which provide unexpected and improved support characteristics and pressure relief and distribution. By combining multiple layers of visco-elastic or latex foam as the top structure of a mattress supported by underlying layers of a laminated urethane foam core, the conformance properties of visco-elastic or latex foam are achieved along with structural support from the underlying core. The multi-layer multi-material foam mattresses of the present disclosure and related inventions include in the various embodiments two or three layers of a first type of foam such as visco-elastic foam or latex foam, in combination with a multi-layer foam support core of a second type of foam such as urethane foam. The disclosed multi-layer/multi-material foam combinations provide superior comfort and conformance, pressure relief, orthopedic support and dampen motion transfer. The multiple layers of the first type of foam preferably have differing density and mass and/or thickness to provide relative gradation between layers and a aggregate performance of support and conformance to body contours and resulting pressure distribution, i.e., avoidance of pressure concentrations. The multiple layers of the second type of foam preferably have differing density and mass and/or thickness to provide relative gradation between layers and aggregate performance of softness and support for the overlying layers of the first type of foam.

1 . A quick-response multi-layer foam mattress comprising:
 at least two layers of visco-elastic foam arranged in a stacked arrangement;   at least one layer of polyurethane foam located beneath the at least two layers of visco-elastic foam and having a substantially planar top surface and a substantially planar bottom surface opposite the substantially planar top surface;   a support core located beneath the at least two layers of visco-elastic foam and at least one layer of polyurethane foam, the support core comprising at least three foam layers that are not visco-elastic;   wherein the thickness of the first or top layer of the at least two layers of visco-elastic foam is less than the thickness of the second layer of the at least two layers of visco-elastic foam and the thickness of the at least one layer of polyurethane foam;   wherein the density of the second layer of the at least two layers of visco-elastic foam is greater than the density of the first or top layer of the at least two layers of visco-elastic foam and the density of the at least one layer of polyurethane foam.   
     
     
         2 . The mattress of  claim 1 , wherein the at least three foam layers of the support core include one generally planar foam layer sandwiched between two extracted foam layers. 
     
     
         3 . The mattress of  claim 2 , wherein each of the two extracted foam layers contains one generally planar surface and one convoluted surface opposite the generally planar surface. 
     
     
         4 . The mattress of  claim 3 , wherein the one convoluted surface of each of the two extracted foam layers is in contact with the one generally planar layer of the support core. 
     
     
         5 . The mattress of  claim 1 , wherein an Indentation Force Deflection (IFD) of each of the at least two layers of visco elastic foam is approximately 12 lbs.@25% indentation. 
     
     
         6 . The mattress of  claim 1 , wherein one of the at least two layers of visco elastic foam has a thickness of approximately 0.5 inches and a density of approximately 2.5 lb/ft3 and is positioned closest to a user lying prone on the mattress. 
     
     
         7 . The mattress of  claim 1 , wherein an Indentation Force Deflection (IFD) of the at least one polyurethane layer is approximately 33 lbs.@25% indentation. 
     
     
         8 . The mattress of  claim 1 , wherein an Indentation Load Deflection (ILD) of the top and bottom layers of the at least three foam layers of the support core is less than an ILD of the middle layer of the at least three foam layers of the support core. 
     
     
         9 . The mattress of  claim 1 , wherein the density of each the at least three foam layers of the support core is approximately 1.8 lb/ft 3 . 
     
     
         10 . A quick-response multi-layer foam mattress comprising:
 a first layer of visco-elastic foam;   a second layer of polyurethane foam located beneath the first layer;   a support core, located beneath the first and second layers, comprising at least three layers of foam.   
     
     
         11 . The mattress of  claim 10 , wherein the first layer of visco-elastic foam is hole punched. 
     
     
         12 . The mattress of  claim 11  further including a spacer fabric located between the first and second layers. 
     
     
         13 . The mattress of  claim 12 , wherein the spacer fabric has a length that is less than a length of the first and second layers and wherein the spacer fabric is centered lengthwise between the first and second layers. 
     
     
         14 . The mattress of  claim 10 , wherein the first layer of visco-elastic foam has a first zone proximate to a head region of the mattress, a second zone proximate to a middle region of the mattress, and a third zone proximate to a foot region of the mattress, the first and third zones having a density that is less than the density of the second zone. 
     
     
         15 . The mattress of  claim 10  wherein the first layer of visco-elastic foam contains a generally planar top surface and a non-planar bottom surface opposite the generally planar top surface, the non-planar bottom surface being in contact with the second layer of polyurethane foam. 
     
     
         16 . The mattress of  claim 10 , wherein the first layer of visco-elastic foam and the second layer of polyurethane foam each have a substantially planar top surface and a substantially planar bottom surface opposite the substantially planar top surface. 
     
     
         17 . The mattress of  claim 10 , wherein the first layer of visco elastic foam has a thickness of approximately 3 inches and a density of approximately 5 lb/ft 3 . 
     
     
         18 . The mattress of  claim 10 , wherein the second layer of polyurethane foam has a thickness of approximately 1 inch and a density of approximately 1.45 lb/ft 3 . 
     
     
         19 . A quick response multi-layer foam mattress comprising:
 at least one layer of latex foam; and   a support core comprising at least two layers of non-latex foam located beneath the at least one layer of latex foam;   the at least one layer of latex foam having a density that is greater than the density of the support core.   
     
     
         20 . The mattress of  claim 19 , wherein the at least one layer of latex foam is approximately 3 inches thick with a density of approximately 3.5 lb/ft 3 . 
     
     
         21 . The mattress of  claim 19  further including two additional layers of latex foam in a stacked arrangement with the at least one layer of latex foam and located above the support core. 
     
     
         22 . The mattress of  claim 21 , wherein the support core comprises three layers of non-latex foam. 
     
     
         23 . The mattress of  claim 19 , wherein the mattress comprises two layers of latex foam and the support core comprises three layers of non-latex foam. 
     
     
         24 . A quick response multi-layer foam mattress comprising:
 at least two layers of visco-elastic foam in a stacked arrangement; and   a support core, located beneath the at least two layers of visco-elastic foam, having at least two urethane foam layers.   
     
     
         25 . The mattress of  claim 24 , wherein one of the at least two layers of visco elastic foam has a thickness of 0.5 inches and the other layer of visco elastic foam has a thickness of approximately 2.5 inches. 
     
     
         26 . The mattress of  claim 24 , wherein one of the at least two layers of visco elastic foam has a density of 2.5 lb/ft 3  and the other layer of visco elastic foam has a density of 5.0 lb/ft 3 . 
     
     
         27 . The mattress of  claim 24 , wherein one of the at least two urethane foam layers has a thickness of approximately 2.0 inches and the other urethane foam layer has a thickness of approximately 5.0 inches. 
     
     
         28 . The mattress of  claim 24 , wherein one of the at least two urethane foam layers has a density of 1.5 lb/ft 3  and the other urethane foam layer has a density of approximately 1.45 lb/ft 3 . 
     
     
         29 . The mattress of  claim 24 , having four layers of visco-elastic foam and the support core having three layers of urethane foam. 
     
     
         30 . A quick response multi-layer foam mattress comprising:
 a pillowtop having at least two layers of visco elastic foam;   at least two layers of visco-elastic foam in a stacked arrangement beneath the pillowtop;   a support core, located beneath the at least two layers of visco elastic foam comprising at least three layers of urethane foam.   
     
     
         31 . The mattress of  claim 30 , wherein one of the at least two layers of visco elastic foam in the pillowtop is hole punched. 
     
     
         32 . The mattress of  claim 31 , wherein the hole-punched layer of visco elastic foam is the top layer. 
     
     
         33 . The mattress of  claim 30 , wherein one of the at least two layers of visco elastic foam of the pillowtop has a thickness of approximately 0.5 inches and the other layer of visco elastic foam of the pillowtop has a thickness of approximately 2.0 inches. 
     
     
         34 . The mattress of  claim 30 , wherein one of the at least two layers of visco elastic foam of the pillowtop has a density of approximately 2.5 lb/ft 3  and the other layer of visco elastic foam of the pillowtop has a density of approximately 5.0 lb/ft 3 . 
     
     
         35 . The mattress of  claim 30 , wherein both of the at least two layers of visco elastic foam beneath the pillowtop have a thickness of approximately 2.0 inches. 
     
     
         36 . The mattress of  claim 30 , wherein one of the at least two layers of visco elastic foam beneath the pillowtop has a density of approximately 7.5 lb/ft 3  and the other layer of visco elastic foam beneath the pillowtop has a density of approximately 5.0 lb/ft 2 .