Air flow mattress constructions and variable density mattress cores

Abstract

The present disclosure and related inventions includes various mattress constructions with improved air flow characteristics, and in particular mattress constructions which induce or control air flow when force is applied to the mattress support surface.

What is claimed: 
     
         1 . An air flow mattress comprising:
 a mattress core comprising two or more layers of foam material, air, springs or a combination thereof;   an intermediate layer having a plurality of openings adapted to receive an insert;   a plurality of inserts in extruded form inserted into each of the plurality of transverse openings;   an air flow passage formed in each of the plurality of inserts; and   each air flow passage having at least one intake and an exhaust, the exhaust having a valve which operates as a one-way valve to allow air to escape the air flow passage.   
     
     
         2 . The air flow mattress of  claim 1 , wherein the plurality of openings transverse a width of the mattress core. 
     
     
         3 . The air flow mattress of  claim 1 , wherein the plurality of openings extend longitudinally along the length of the mattress core. 
     
     
         4 . The air flow mattress of  claim 1 , wherein the plurality of inserts have a circular cross-section. 
     
     
         5 . The air flow mattress of  claim 1 , wherein the plurality of inserts have a triangular cross-section. 
     
     
         6 . The air flow mattress of  claim 1 , wherein the plurality of inserts extend an entire cross-sectional width of the mattress core. 
     
     
         7 . The air flow mattress of  claim 1 , wherein the plurality of inserts include both right and left half inserts. 
     
     
         8 . An air flow mattress comprising:
 a mattress core comprising two or more layers of foam material, air, springs or a combination thereof;   an intermediate layer having a plurality of openings adapted to receive an insert;   a plurality of inserts in extruded form inserted into each of the plurality of transverse openings;   an air flow passage formed in each of the plurality of inserts; and   a valve in fluid communication with at least one of the air flow passages, wherein the valve is operative to allow air to escape the air flow passage.   
     
     
         9 . The air flow mattress of  claim 8 , wherein the plurality of openings transverse a width of the mattress core. 
     
     
         10 . The air flow mattress of  claim 8 , wherein the plurality of openings extend longitudinally along the length of the mattress core. 
     
     
         11 . The air flow mattress of  claim 8 , wherein the plurality of inserts have a circular cross-section. 
     
     
         12 . The air flow mattress of  claim 8 , wherein the plurality of inserts have a triangular cross-section. 
     
     
         13 . The air flow mattress of  claim 8 , wherein the plurality of inserts extend an entire cross-sectional width of the mattress core. 
     
     
         14 . The air flow mattress of  claim 8 , wherein the plurality of inserts include both right and left half inserts. 
     
     
         15 . The air flow mattress of  claim 8 , wherein each air flow passage has at least one intake and an exhaust.