Self-inflating mattress with comfort adjustment

Abstract

Sealed foam, self-inflating mattress system includes a mattress core formed of open-cell foam. The mattress core includes first and second major sleeping surfaces on opposing sides of the mattress and at least one side wall which extends between the two major sleeping surfaces. An elastomeric coating encloses the mattress core to define an airtight mattress chamber. A vacuum pump is disposed in a recess of the mattress core and operatively coupled to the airtight mattress chamber. The vacuum pump is configured to selectively establish a negative PSIG internal operation pressure within the airtight mattress chamber. The negative PSIG internal operation pressure improves a comfort of the self-inflating mattress.

We claim: 
     
         1 . A sealed foam, self-inflating mattress system comprising:
 a mattress core formed of open-cell foam;   an elastomeric coating which encloses the mattress core to define an airtight mattress chamber;   a vacuum pump operatively coupled to the airtight mattress chamber and configured to selectively establish a negative PSIG internal operation pressure within the airtight mattress chamber, whereby the self-inflating mattress can be adjusted for improved comfort.   
     
     
         2 . The sealed foam, self-inflating mattress system according to  claim 2 , wherein an air inlet of the vacuum pump is coupled to the airtight mattress chamber through an airtight control chamber. 
     
     
         3 . The sealed foam, self-inflating mattress system according to  claim 2 , further comprising a check valve provided between the air inlet of the vacuum pump and the airtight control chamber, the check valve configured to create an airtight seal between the airtight control chamber and the air inlet of the vacuum pump when the vacuum pump is not activated. 
     
     
         4 . The sealed foam, self-inflating mattress system according to  claim 3 , further comprising an override valve configured to selectively allow air to enter or exit the airtight control chamber. 
     
     
         5 . The sealed foam, self-inflating mattress system according to  claim 3 , wherein a recess is formed in the mattress core, and the vacuum pump is disposed in the recess. 
     
     
         6 . The sealed foam, self-inflating mattress system according to  claim 5 , further comprising a three-dimensional construct which defines a complex geometry sealing membrane (CGSM), the CGSM formed from two or more panels of elastomeric material which are arranged to correspond with or replicate a panel geometry of the recess. 
     
     
         7 . The sealed foam, self-inflating mattress system according to  claim 6 , wherein the two or more panels are heat fused together at adjacent edges to define one or more seams of the CGSM. 
     
     
         8 . The sealed foam, self-inflating mattress system according to  claim 7  wherein the CGSM is heat fused within the recess, whereby corners of the recess are sealed to form the airtight mattress chamber. 
     
     
         9 . The sealed foam, self-inflating mattress system according to  claim 7 , wherein the mattress core is comprised of first and second major sleeping surfaces on opposing sides of the mattress and at least one side wall which extends between the two major sleeping surfaces, and wherein the recess is disposed in the at least one side wall. 
     
     
         10 . A method for controlling a comfort of a sealed foam, self-inflating mattress, comprising:
 causing an airtight mattress chamber which is formed of open-cell foam and enclosed by an elastomeric coating to automatically self-fill with air by utilizing a resilience associated with the open-cell foam to expand the airtight mattress chamber;   allowing the airtight mattress chamber to be filled with air to an ambient air pressure comprising 0 PSIG;   selectively operating a vacuum pump to establish a negative PSIG internal operation pressure within the airtight mattress chamber for improving a comfort of the self-inflating mattress; and   automatically sealing the airtight mattress chamber using a check valve after the negative PSIG internal operation pressure has been established.   
     
     
         11 . The method according to  claim 10  further comprising drawing air from the airtight mattress chamber through an airtight control chamber which is coupled to an air inlet of the vacuum pump. 
     
     
         12 . The method according to  claim 10 , further comprising automatically creating an airtight seal with the check valve to seal the airtight mattress chamber when the vacuum pump is not activated. 
     
     
         13 . The method according to  claim 12 , further comprising using an override valve coupled to the airtight control chamber to selectively allow air to enter or exit the airtight control chamber and the airtight mattress chamber. 
     
     
         14 . The method according to  claim 12 , further comprising position the vacuum pump and the airtight control chamber in a recess formed in the mattress core. 
     
     
         15 . A method for manufacturing a sealed foam, self-inflating mattress system, comprising:
 forming a mattress core comprised of open cell foam, the mattress core including first and second major sleeping surfaces on opposing sides of the mattress core and at least one side wall which extends between the two major sleeping surfaces;   forming a recess in the mattress core;   coating the entire mattress core with a layer of a first elastomeric coating material to form an enclosure around the mattress core and define a mattress air chamber;   assembling a three-dimensional construct which defines a complex geometry sealing membrane (CGSM) comprised of two or more panels of a second elastomeric material which are arranged to correspond with or replicate a panel geometry of the recess;   heat fusing the two or more panels together at adjacent edges to define one or more seams of the CGSM; and   heat fusing the CGSM within the recess to seal one or more corners of the recess, whereby the mattress air chamber is made airtight.   
     
     
         16 . The method according to  claim 15 , further comprising selecting the first and second elastomeric material to be the same type of elastomeric material. 
     
     
         17 . The method according to  claim 15 , forming the recess in the at least one side wall. 
     
     
         18 . The method according to  claim 15 , further comprising disposing with the recess a vacuum pump having at least one air inlet coupled to the mattress air chamber. 
     
     
         19 . The method according to  claim 18 , further comprising allowing the mattress air chamber to be filled with air to an ambient air pressure comprising 0 PSIG. 
     
     
         20 . The method according to  claim 19 , further comprising selectively operating the vacuum pump to establish a negative PSIG internal operation pressure within the airtight mattress chamber for improving a comfort of the self-inflating mattress. 
     
     
         21 . The method according to  claim 20 , further comprising automatically sealing the airtight mattress chamber using a check valve after the negative PSIG internal operation pressure has been established.