COMPOSITE CUSHIONING SYSTEM

Description

TECHNICAL FIELD

Embodiments of the disclosure relate generally to cushioning apparatuses. Specific embodiments relate to spring-coil and elastomeric foam mattresses with cushioning fabrics.

BACKGROUND ART

Cushioning systems may serve as a utilitarian means for promoting health by providing structural support while enhancing a user's comfort. Cushioning technology has evolved over time to include coiled springs, foam, and elastomeric components. Such synthetic materials reduce the need for animal cushioning products like goose down or similar fill material thereby providing environmentally conscious alternative products to consumers.

Coiled spring cushioning systems may be comprised of any number of metallics or plastics. Despite providing strong structural support coiled cushioning systems have drawbacks. Coils may be uncomfortable when in close contact to a user's skin. Coils observable through an outer covering may be unsightly. Coils may be heavy therefore difficult for some users to reposition.

Foam cushioning systems provide users with a soft means for structural support. Foam has special durability due to its quality of returning to a decompressed state after a user provided pressure is removed. However, lightweight foam may provide insufficient support to a user. Strongly supportive foam is heavy and shares drawbacks with spring coils.

Elastomeric materials, also known as “gel elastomers,” or “gels” are one way to bridge the gap between coils and foam. Rigid gels provide strong support much like coil springs. Other malleable gels share the benefits and drawbacks of foam. Such gels can be made from various polymer materials as might be known now or in the future.

SUMMARY OF INVENTION

Technical Problem

Composite cushioning systems comprised of spring coils, foam, and gel materials may provide a user with aesthetically pleasing support in a user-friendly package. However, such composite systems may be expensive to manufacture due to complicated designs and costly materials making them inaccessible to much of the market. A need exists for user friendly yet cost effective composite cushioning systems.

Accordingly, there is a need for composite cushioning systems that combine the benefits of individual coil spring, foam, and/or gel cushion systems. When combined as described herein, such composite cushioning systems use the benefits of single material systems to resolve drawbacks, improve performance, and present a cost-effective solution. The present invention fulfills these needs and provides other related advantages.

Technical Solution

The present invention is directed to an apparatus satisfying the need for cost effective eco and user-friendly cushioning systems. A composite cushioning system having features of the present invention generally includes a base, a lower foam layer supporting the base, and an upper foam layer above said base on which a topper is disposed. The topper may have different configurations across various embodiments. A cover encloses the base, foam layers, and topper, with such cover preferably having a padded cushioning quality, as in quilted or knitted layers enclosing cushioning material.

The present invention is directed to a composite cushioning system, which includes a spring coil base layer, a topper layer, and an outer cover. The spring base layer has an array of coil springs surrounded by a border of cushioning foam and covered by an upper foam layer. The topper layer is disposed on the upper foam layer and coextensive with the spring base layer, said topper layer having an elastomeric layer coupled to a foam layer. The outer cover encloses both the spring base layer and the topper layer.

In one embodiment, the foam layer of the topper layer may include an inferior cushioning layer, the elastomeric layer may include a median elastomeric layer disposed on the inferior cushioning layer, and the topper layer may further include a superior fabric layer disposed on the median elastomeric layer. The topper layer may further include a plurality of buttons connecting the superior fabric layer to the inferior cushioning layer through the median elastomeric layer, creating a tufted look and feel. The outer cover may include a padded cushioning material, such as a quilted fabric or a formed unitary fabric enclosing a cushioning material.

In another embodiment, the elastomeric layer of the topper layer may include a median elastomeric layer disposed on the upper foam layer, the median elastomeric layer covering an area that is less than an area of the spring base layer. Stated another way, the median elastomeric layer is configured having a surface area that is less than a surface area of the spring base layer. In this embodiment, the foam layer of the topper layer includes a border cushion layer and a superior cushion layer. The border cushion layer surrounds the median elastomeric layer so as to have edges coterminous with edges of the upper foam layer. The superior cushion layer is disposed on the median elastomeric layer and the border cushion layer having edges coterminous with edges of the superior cushion layer. The topper layer further includes a fabric layer disposed between and fixed to the median elastomeric layer and the superior cushion layer, with the fabric layer is fixed to the superior cushion layer by an adhesive. The fabric layer may also be fixed to the median elastomeric layer by the adhesive, or preferably by melting, either with the fabric layer being in the mold during the injection molding process or by applying heat to the elastomeric layer when in contact with the fabric layer.

In yet another embodiment, the elastomeric layer of the topper layer may include an elastomeric cushion enclosed within a fabric cover, which is preferably resilient, but not necessarily stretchy. The fabric cover is preferably fixed to the upper foam layer by an adhesive. In an alternate embodiment, the topper layer may include a foam layer possibly designated as an inferior cushion layer, where both the elastomeric cushion and inferior cushion layer are coextensive with the upper foam layer of the coil spring layer. In this alternate embodiment, the fabric cover is preferably fixed to the inferior cushion layer by an adhesive.

In a further embodiment, the elastomeric layer of the topper layer may be an elastomeric cushion substantially co-extensive with the upper foam layer of the spring base layer. The topper layer may further comprise a supplemental cushion layer, with the elastomeric cushion and the supplemental cushion layer integrally formed at a melting interface. The elastomeric layer may further include an edge support structure around a perimeter of the melting interface. The supplemental cushion layer is preferably co-extensive with said upper foam layer of the spring base layer.

In a still further embodiment, the elastomeric layer of the topper layer may include a first elastomeric cushion disposed over a second elastomeric cushion, with a positioning fabric disposed and fixed therebetween. The first elastomeric cushion and the second elastomeric cushion are preferably co-extensive with each other, but both have a surface area that is less than the surface area of the upper foam layer of the spring base layer.

The elastomeric layer may further include a first foam border surrounding the first elastomeric cushion and a second foam border surrounding the second elastomeric cushion. The positioning fabric is disposed and fixed between the first foam border and the second foam board such that the topper layer is coextensive with the upper foam layer of the spring base layer. The first foam border and first elastomeric layer each have a uniform first thickness, and the second foam border and second elastomeric layer each have a uniform second thickness. The second thickness is preferably greater than the first thickness.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

DESCRIPTION OF DRAWINGS

These and other features and advantages of the present invention will become appreciated, as the same becomes better understood with reference to the specification, claims and drawings herein:

FIG. 1A shows a plan view of an assembled embodiment displaying features of the inventive composite cushioning system.

FIG. 1B shows a cutaway view of the system of FIG. 1 displaying features of the present invention for a composite cushioning system.

FIG. 2 shows a perspective view of the system of FIG. 1 displaying relative layer positioning and a topper of an embodiment of the inventive composite cushioning system.

FIG. 3 shows an exploded view of the system of FIG. 1 displaying upper layers of an embodiment of the inventive composite cushioning system.

FIG. 4 shows a sectional view of the system of FIG. 1 displaying a plurality of buttons interfacing with upper layers of an embodiment of the inventive composite cushioning system.

FIG. 5 shows a cutaway top view of another version of the system embodying features of the present invention for a composite cushioning system.

FIG. 6 shows a front view exploded-in-part of the system of FIG. 5 displaying upper layers and topper of an embodiment of the inventive composite cushioning system.

FIG. 7 shows a plan view of another version of the system embodying features of the present invention for a composite cushioning system.

FIG. 8 shows a perspective view of the system of FIG. 7 displaying a topper disposed over a base of an embodiment of the inventive composite cushioning system.

FIG. 9 shows a close-up cutaway view of the system of FIG. 7 displaying relative layer positioning and topper of an embodiment of the inventive composite cushioning system.

FIG. 10 shows a close-up view of the system of FIG. 7 displaying connection between layers of an embodiment of the inventive composite cushioning system.

FIG. 11 shows a perspective view of another version of the system embodying features of the present invention for a composite cushioning system.

FIG. 12 shows a close-up sectional view of the system of FIG. 11 displaying relative layer positioning and layer connection of an embodiment of the inventive composite cushioning system.

FIG. 13 shows a perspective view of another version of the system embodying features of the present invention for a composite cushioning system.

FIG. 14 shows an exploded view of the system of FIG. 13 displaying layer orientation within a topper of an embodiment of the inventive composite cushioning system.

FIG. 15 shows a close-up sectional view of the system of FIG. 13 displaying interfacing between topper layers of an embodiment of the inventive composite cushioning system.

MODE FOR INVENTION

The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present there between. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section.

As used herein, the singular forms “a,” “an,” and “the,” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” “includes” and/or “including,” and “have” and/or “having,” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

Furthermore, relative terms, such as “lower” or “bottom,” and “upper” or “top,” and “inner” or “outer,” may be used herein to describe one element's relationship to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures.

Unless otherwise defined, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Exemplary embodiments of the present invention are described herein with reference to idealized embodiments of the present invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the present invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

The present invention is directed to a composite cushioning system, in particular a cushion or mattress, generally referred to by reference numeral 1 in FIGS. 1A-15. At a minimum, composite cushioning system 1 includes a base layer 11 and a topper layer 19. Other cushioning materials can be added to the topper layer 19, either in one or more layers, consisting of soft polyurethane foam, foamed latex, or padding placed in a fabric sleeve. The padding in the fabric sleeve can be selected from buckwheat hulls, cotton, wool, down, foam particles, or segmented polyethylene tubes. The fabric sleeve can be a single cavity or the sleeve can be sewn together using yarn to form multiple cavities filled with filling material. While the detailed description is based upon the following description and drawings depicting an illustrated size and shape, the inventive composite cushion system 1 may be provided in any size and shape, including but not limited to twin, full, queen, or king size mattresses, or cushions, pads, or mattresses of any desired size.

As shown in FIG. 1B a composite cushioning system 1 comprises a base 11 housing a plurality of coil springs 13, a lower foam layer 15 and an upper foam layer 17 oppositely disposed about said base 11 and a topper 19 coextensive with and supported by said base 11. The plurality of coil springs 13 take different forms, including link springs, one-wire steel springs, independent cartridge springs, partitioned springs. A linked spring is a coil of thicker wire diameter springs that are fixed with a steel wire link. A wire spring is a continuous stream of steel wire that is wrapped around each part of the mattress from the end of the bed to the end of the bed and then linked in parallel. The independent cartridge spring is a steel spring in a separate shell, which is a separate bag made of non-woven fabric or cloth that is ultrasonically bonded or glued together.

Independent cartridge springs can be laid out in many forms, either in parallel pairs or in a honeycomb layout to provide different contact areas. A zoned spring is an improvement on the independent cartridge spring, adjusting the spring's elasticity according to the different support needed for different areas on the entire mattress. A coil spring mattress may be divided into multiple zone, preferably 5-7 zones. The implementation solution can be to use a spring with high support in the hip, back area where the weight is higher and a spring with low support in the head of the legs. Separate designs are also made according to the different support requirements at the edges and in the middle. It is also possible to change the coil diameter of the spring to adjust the number of springs used per unit area, preferably using a smaller coil diameter spring at the edge of the mattress and a larger coil diameter spring in the middle area.

The spring layer 13 can also use an airbag as an alternative. The airbag can be adjusted by an air pump to adjust the amount of air pressure in the airbag to achieve the adjustment of the support force. Multiple airbags can be used to accommodate the need for different support forces in different zones. In addition, the air pressure in the airbag can be controlled to change at different times according to the needs of use. The spring layer 13 can also use air fibers as an alternative. Air fibers are a polyolefin elastomer extruded by melting in a porous die, injected into cooling water, cooled, and formed into an interlaced web of fibers with high elasticity, breathability, and washability. The spring layer 13 can also use as an alternative a palm mat, which is made using plant fibers such as mountain palm silk or coconut silk. The spring layer 13 can also use polyurethane foam as an alternative. The polyurethane foam can be shaped and processed to change the local material density of the polyurethane foam by cutting or molding it to change the support force and stress-strain curve according to the functional requirements.

As shown in FIGS. 2-4 said topper 19 comprises an inferior cushioning layer 21 supporting a median elastomeric layer 23 supporting a superior fabric layer 25. A plurality of buttons 27 connects said inferior cushioning layer 21 to said superior fabric layer 25 through said median elastomeric layer 23. While illustrated with a particular number and spacing, the buttons 27 may be distributed across the topper 19 in any frequency and spacing. For example, larger toppers 19 as found on mattresses of different sizes might have buttons 27 less frequently (i.e., every ten grids on the elastomer layer 23) or more frequently (i.e., every grid or every other grid).

As shown in FIG. 1A an outer cover 29 encloses said base 11 and said topper 19. Said outer cover 29 may comprise a cushioning material 30 as shown in FIG. 1A. Said outer cover 29 preferably has a top fabric, a side fabric and a bottom fabric. The three parts of the fabric can be the same material or different materials. One combination scheme has the junction of the top fabric and the side fabric generally on the side, which can be in the form of zipper or stitched. The combination of the side fabric and the bottom fabric is generally on the bottom. Another combination scheme is to have only a top fabric and a bottom fabric, with the top fabric being made to wrap around the top and sides, and the bottom fabric being made to wrap around the bottom and sides, with the top and bottom fabrics being joined either on the bottom or the sides, by a zipper or stitching. The top fabric, side fabric and bottom fabric can be one or more of knitted, woven or quilted fabrics.

Knitted fabric is formed by the process of yarn sequence bending into loops, while the loops are set in series with each other and form the fabric, while the yarn forms the loops. Knitted fabric organizations are weft knitting flat knitting, ribbed organization, double reverse organization, warp knitting chain organization, warp flat organization, warp satin organization, etc. Such knitted fabric can also use the fabric described in patent GB1577399, a knitted fabric to provide a set of loops, the top surface knitted fabric and the bottom surface knitted fabric by stacking needles or loops (tuck stitches or loops) between said knitted fabric together, the spacing between said stitches positioned to define the free space between said top surface fabric and bottom surface fabric to fill the yarn, can be textured synthetic long yarns. The disclosure of foreign patent GB1577399 is hereby incorporated by reference.

Woven fabric is a fabric made of two or more sets of mutually perpendicular yarns, interwoven at an angle of 90 degrees for warp and weft. Woven fabrics are divided into plain weave, twill weave, and satin weave. It is also possible to use double-woven fabric that has warp yarns of two systems of surface warp, and inner warp, and can adopt a variety of structural methods to interlace the weft yarns of two systems of surface weft inner weft. It is also possible to use a multi-layer fabric where each layer of warp yarn is interlaced with its weft yarn respectively, and the layers are connected by warp yarn to form a whole. Quilted fabrics are interlayered textiles sewn with long needles, said textiles can be knitted fabrics, woven fabrics, or non-woven fabrics, and said interlayers can be filament yarns, cotton fibers, wool fibers, hemp fibers, etc. The interlayer can also be knitted fabric, woven fabric, polymer film, polyurethane foam, latex foam, etc.

The cover 30 can also be provided with a window for the consumer to view the internal structure of the mattress, the window can be square, L-shaped, monogram. Inside the outer sleeve can also be provided with an inner sleeve, the inner sleeve can be one or more of knitted fabric, woven fabric or quilted fabric. The inner sleeve can use functional fabrics, such as flame-retardant fabrics, waterproof fabrics, blackout fabrics, etc.

Said elastomeric layer 23 (in this and across other embodiments described herein) can be any thermoplastic rubber, which is formed using a plastic injection molding machine, i.e., heated, melted, injected into the mold, and formed after cooling. Said thermoplastic rubber can be one or more of styrene (SBS, SIS, SEBS, SEPS), olefin (TPO, TPV), diene (TPB, TPI), vinyl chloride (TPVC, TCPE), ammonia ester (TPU), ester (TPEE), amide (TPAE), organofluorine (TPF), silicone, and ethylene, etc.

An adhesive 35 may fix foam to fabric, foam to foam, and foam to elastomeric material. Said adhesive 35 may fix said lower foam layer 15 to said base 11 and to said plurality of springs 13. Another adhesive 35 may fix said upper foam layer 17 to the opposite side of said base 11 and to the opposite side of said plurality of springs 13. In some embodiments, such adhesive 35 may fix the inferior cushioning layer 21 to the median elastomeric layer 23 and the median elastomeric layer 23 to the superior fabric layer 25. In a preferred embodiment, as described below, the inferior cushioning layer 21 is fixed by each button 33 to the median elastomeric layer 23, with each button 33 also being fixed to the superior fabric layer 25, which superior fabric layer 25 is preferably fixed to the median elastomeric layer 23 by melting.

In many embodiments, polymer foam material, particularly open cell foams, may comprise said lower foam layer 15, said upper foam layer 17, and said inferior cushioning layer 21. Such open-cell, polymer foam material has a reduced density compared to other materials, which reduces the overall weight of the cushioning system while providing sufficient structural support. Such foam materials may also serve as a surface for adhesive between layers of the system. In other embodiments, such foam may serve as a site for heat fixation between layers.

Such foam material preferably surrounds said plurality of coil springs 13 as shown in FIGS. 1B-3. The presence of such foam material as described insulates a user from the sight and feel of said plurality of coil springs 13. This insulation is provided inferiorly by said lower foam layer 15, superiorly by said upper foam layer 17, and at the sides in part by said base 11 and a cover foam 31. Said cover foam 31 may be of the same composition of said base 11. The lower foam layer 15, the upper foam layer 17, and the cover foam 31 in the base layer 11 can be one or more of polyurethane foam, foam latex, 3D spacer fabric, and air fiber. The cushioning layer 21 can be one or more of polyurethane foam, foam latex, and 3D spacer fabric. The 3D spacer fabric or 3d mesh fabric refers to a high elasticity and high density three-dimensional hollow structure, preferably having upper and lower mesh six-sided shapes, which are preferably breathable. The middle is preferably made of functional polyester fiber material, which is X-90° a soft material for support.

As shown in FIGS. 1B-3, said plurality of springs 13 provides structural support to the composite cushioning system. Said plurality of springs 13 are preferably disposed in adjacent cylindrical fashion within optional fabric sheathes. Their vertical orientation maximally resists pressure applied by a user along a vertical axis of the apparatus perpendicular to said lower foam layer 15 as shown in FIG. 2.

As shown in FIG. 3, said plurality of buttons 27 is comprised of a button 33 in series. Each button 33 mechanically connects said inferior cushioning layer 21 to said superior fabric layer 25 through the median elastomeric layer 23 as shown in FIGS. 2B and 3. The median elastomeric layer 23 may bend and compress in response to the pressure supplied by a button 33, as shown in FIG. 4 creating an overall tufting configuration about the topper 19 across the plurality of buttons 27. Similarly, the median elastomeric layer 23 may also bend and compress in response to pressure supplied by a user thereby providing a cushioning quality to the topper 19 in the overall composite cushioning system 1.

As shown in FIGS. 5-6, another embodiment of the present invention comprises a second embodiment of topper 40 combined with said base 11, upper foam layer 17, lower foam layer, 15, plurality of springs 13 and cover foam 31 configured as shown in FIG. 1B.

As shown in FIG. 6, said second topper 40 comprises a superior cushioning layer 45 coextensive with said base 11 that is disposed over an elastomeric layer 41 preferably having an area less extensive than said base 11. Said elastomeric layer 41 is surrounded by a lateral foam layer 43 about the border forming an elastomeric-foam junction 49 (FIG. 5) adjoined to the upper foam layer 17 and superior cushioning layer 45 by adhesive 35. As shown in FIG. 6, an intermediate fabric layer 47 is preferably disposed between said superior cushioning layer 45 and said elastomeric layer 41, affixed by adhesive 35 or similar securing structure. The superior cushioning layer 45 can be one or more of polyurethane foam, foam latex, and 3D spacer fabric. Preferably, the fabric layer 47 is affixed to the elastomeric layer 41 by melting, either with the fabric layer 47 being in the mold during the injection molding process or by applying heat to the elastomeric layer 41 when in contact with the fabric layer 47.

Elastomeric materials comprise a substantial part of the weight of the type of composite cushioning systems described herein. As shown in FIGS. 5 and 6, said elastomeric layer 41 having a smaller surface area than the base 11, provides users with a lighter weight system than other systems incorporating an elastomeric layer coextensive with the base 11.

As shown in FIGS. 7-10, another embodiment of the composite cushioning system may include a third topper 51 enclosed by a fabric cover 55 as shown in FIGS. 8 and 9. Said third embodiment of topper 51 includes an elastomeric mat 53 coextensive with said base 11 resting upon said upper foam layer 17 and base 11-all enclosed by an outer cover 29 as shown in FIG. 7. Said fabric cover 55 and enclosed elastomeric mat 53 is fixed to said upper foam layer 17 by an adhesive 35 as shown in FIG. 10. The fabric cover 55 is also preferably attached to the elastomeric mat 53 by one of either injection molding with the fabric in the mold or by melting adherence. The fabric cover 55 is readily connected to the upper foam layer 17 by the adhesive 35. The adhesive 35 may also join the upper foam layer 17 to the tops of the coil springs 13, preferably including an intervening fabric layer (not shown). Said base 11, upper foam layer 17, lower foam layer 15, plurality of springs 13 and cover foam 31 are configured as shown in FIG. 1B.

Foam may be absent from said third topper 51 otherwise comprised of said elastomeric mat 53 enclosed in fabric cover 55. While an elastomeric mat 53 having a surface area co-extensive with the base 11 increases the overall weight of the system 1, it also maximizes flexibility and thus comfort for a user. This comfort is due to the flexible bending and support qualities of elastomeric materials defined by elastomeric grid walls 41 throughout a given topper.

FIGS. 11-12 show another embodiment of the composite cushioning system 1 including a fourth embodiment of topper 61 disposed directly upon said base 11. Said fourth topper 61 includes an elastomeric pad 63 substantially coextensive with said base 11 and a supplemental foam layer 65. The supplemental foam layer 65 may be attached to the upper foam layer 17 of the base 11 by an adhesive 35. Said supplemental foam layer 65 may optionally have a higher melting point than said elastomeric pad 63. Said supplemental foam layer 65 and elastomeric pad 63 intersect at a melting interface 69 where heat may be applied to facilitate adhesion. In a particularly preferred embodiment, the elastomeric pad 63 may be formed with the supplemental foam layer 65 positioned in a form mold, such as during a process of injection molding the elastomeric pad 63. As shown in FIG. 12, the edge borders of the melting interface 69 of the elastomeric pad 63 and supplemental foam layer 65 may include a quarter-round piece 69a or similar edge support structure to provide increased support and securing surface to the edge borders of the melting interface 69. The edges of the elastomeric pad 63 may also curve toward the quarter-round piece 69a so as to provide a more comfortable transition (as opposed to a corner edge) for a user when in contact with the edge. This edge support structure 69a can be provided in other shapes as may fit the needs of the user.

FIGS. 13-15 illustrate yet another embodiment of the composite cushioning system including a fifth embodiment of topper 81 with said base 11, upper foam layer 17, lower foam layer 15, plurality of springs 13 and cover foam 31 configured as shown in FIG. 1B. As shown in FIG. 14, said fifth topper 81 includes a first foam border 87 as a perimeter around a first elastomeric layer 83 disposed over a positioning fabric 91. The positioning fabric 91 is preferably coextensive with the base 11, whereas the first elastomeric layer 83 has a smaller surface area. Said positioning fabric 91 is disposed on top of a second elastomeric layer 85 and a second foam border 89. Said second elastomeric layer 85 and second foam border 89 may optionally be of greater thickness than said first elastomeric layer 83 and first foam border 87.

The first elastomeric layer 83, second elastomeric layer 85, and intervening positioning fabric 91 are preferably formed integrally as with the positioning fabric 91 being included in a form mold during a process of forming the elastomeric layers 83, 85 by injection molding. In this way, the elastomer material from the elastomeric layers 83, 85 may melt or ooze through the fabric 91. As shown in FIG. 15, since the positioning fabric 91 is co-extensive with the base 11, but the elastomeric layers 83, 85 are not, the portion of the positioning fabric 91 extending beyond is contained between the first foam border 87 and second foam border 89. By using adhesive 35 or similar securing methods, the elastomeric layers 83, 85, positioning fabric 91, and foam borders 87, 89 may ultimately be formed as a unitary piece, separable only by destructive means. This fifth topper 81 preferably rests directly on the upper foam layer 17. Due to their respective textures and friction coefficients, the second foam border 89 and second elastomeric layer 85 on top of the upper foam layer 17 may tend to remain as positioned, particularly when enclosed in an outer cover 29. An adhesive 35 may be used between the upper foam layer 17 and second foam borders 89 to more securely maintain this positioning.

In any of the foregoing embodiments, the polyurethane foam is preferably flexible and selected according to mattress design features such as super soft foam, normal foam, high resilience foam, high load bearing soft foam, slow spring-back foam sponge (slow spring-back sponge), and polyurethane foam with added gel particles. Polyurethane foam can be processed in shape, and the local material density of polyurethane foam can be changed by cutting or molding according to the functional requirements. The support force and stress-strain curve can also be altered. Wave undulations, pyramid undulations, wedge undulations, etc. can be formed on the surface of polyurethane foam. It is also possible to cut the part in the middle between the top and the bottom to optimize the stress-strain curve of the polyurethane foam.

Foamed latex is formed by foaming the latex of the ingredients into latex foam, and then injected into the mold, gelled, vulcanized, removed from the mold, washed and dried. It can be prepared by using natural latex or synthetic latex as raw material, with high elasticity. It has the characteristics of shock absorption, compression fatigue resistance, good load-bearing capacity, comfort and durable characteristics.

The mattress 1 may comprise one, two or more of the topper layers 19, 40, 51, 61, and 81 described above. The topper layers 19, 40, 51, 61, and 81 can be made into any size mattress, with the length and width of the topper layers 19, 40, 51, 61, and 81 being the length and width of the mattress. The mattress 1 may also consist of two topper layers 19, 40, 51, 61, and 81, which may be separately constructed with different properties, such as firmness, elasticity, ventilation capacity, etc., according to user needs. The two topper layers 19, 40, 51, 61, and 81 can be provided with linking devices on the cover 29 to connect the pad systems to each other.

The mattress 1 may further comprise a plurality of topper layers 19, 40, 51, 61, and 81, and the plurality of the same may be set differently according to the different mechanical response of different areas of the body to the topper layers 19, 40, 51, 61, and 81. For example, the weight of the waist-hip can increase the support force, and the weight of the legs can be reduced by the small weight of the support force. The plurality of topper layers 19, 40, 51, 61, and 81 can be provided with linking devices on the outer cover 29 to connect the plurality of topper layers 19, 40, 51, 61, and 81 to each other.

Mattresses 1 can be packaged and shipped in a variety of ways, compressed and rolled, split and packed directly. Compression roll pack method, put the constructed mattress into a sealed bag, compress the mattress on the press to the right thickness, then send it into the roll pack machine and roll it into a cylindrical shape. Put the rolled mattress into a packaging bag. Outside the bag can also use woven bags, cartons or plastic film packaging for logistics and transportation. Said sealed bags can be selected with polyethylene film or polypropylene film. Said bag can choose PVC material, PVC fabric composite material, PE material and other polymer film, but also can choose knitted fabric, woven fabric or quilted fabric, polymer composite fabric, etc., made into a cylindrical bag. The bag can be zipper closure for easy removal of the mattress. Said carton can be fitted with wheels and handles for easy transfer. When the mattress 1 consists of a plurality of topper layers 19, 40, 51, 61, and 81, it can be packaged using a split method, where a plurality of topper layers 19, 40, 51, 61, and 81 are stacked together and placed in a bag or carton for shipping.

Although several embodiments have been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention.