Mattress Support Apparatus

Description

FIELD OF THE INVENTION

The present invention relates generally to a mattress support that is positioned under a mattress and on top of a slated bed base. More specifically, the present invention is a mattress support apparatus that is breathable, noise-minimizing, and moisture-resistant.

BACKGROUND OF THE INVENTION

With prolonged use, mattresses placed on a bed base often develop sagging areas, particularly in the center or along the sides, where the surface becomes overly soft or concave. While still functional, this loss of structural integrity significantly diminishes support and comfort during sleep.

Several existing solutions aim to provide mattress support to avoid such loss of structural integrity. However, there are drawbacks associated with these solutions. For example, traditional wooden bunkie boards, for instance, are susceptible to moisture absorption, leading to mold, mildew, and warping in humid conditions. Other solutions attempt to use metal or plastic slats, but these solutions are similarly unable to meet the needs of the industry because they can create noise and do not provide even weight distribution, leading to discomfort and mattress sagging. Still, other solutions seek to use thin, non-breathable boards, but these solutions also fail to meet industry needs because they do not offer sufficient ventilation, can cause heat buildup, and are not durable enough to provide long-term support.

Therefore, it is an objective of the present invention to provide a mattress support apparatus which overcomes the problems set forth above.

SUMMARY OF THE INVENTION

The present invention discloses a mattress support apparatus. It includes a top layer, a bottom layer, and at least one corrugated board. The top layer comprises an outer surface and an inner surface, and the bottom layer comprises an outer surface and an inner surface. The at least one corrugated board comprises a top sheet, a bottom sheet, and a flute layer sandwiched between the top sheet and the bottom sheet. An edge of the top layer is attached to an edge of the bottom layer to create at least one interior space. The at least one corrugated board is accommodated in the at least one interior space to form at least one support section.

In one embodiment, the top layer is made of moisture-resistant and breathable material.

In one embodiment, the top layer is made of Oxford fabric.

In one embodiment, the bottom layer is made of moisture-resistant and breathable material.

In one embodiment, the bottom layer is made of Oxford fabric.

In one embodiment, the outer surface of the bottom layer comprises an anti-slip member.

In one embodiment, the anti-slip member comprises a plurality of silicone honeycomb patterns.

In one embodiment, the inner surface of the top layer and the inner surface of the bottom layer are coated with polyurethane.

In one embodiment, the at least one corrugated board comprises a plurality of holes.

In one embodiment, the at least one support section comprises a plurality of support sections.

In one embodiment, the plurality of support sections is adapted to fold together.

In one embodiment, the plurality of support sections is formed by stitching between the support sections.

In one embodiment, the present invention further comprises a protective trim along the edge of the top layer and the edge of the bottom layer.

In one embodiment, the present invention further comprises a padding layer between the inner surface of the top layer and the top sheet of the corrugated board.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and together with the description serve to explain the principles of the invention. They are meant to be exemplary illustrations provided to enable persons skilled in the art to practice the disclosure and are not intended to limit the scope of the present invention. That is, the dimensions of the components of the present invention, independently and in relation to each other can be different. It should be noted that the drawings are schematic and not necessarily drawn to scale. Some drawings are enlarged or reduced to improve drawing legibility.

FIG. 1 depicts an exploded view of the present invention.

FIG. 2 depicts another exploded view of the present invention.

FIG. 3 depicts a top view the present invention.

FIG. 4 depicts a cross-sectional view of the present invention, taken along the line A-A in FIG. 3.

FIG. 5 depicts an enlarged view of the area B in FIG. 4.

FIG. 6 depicts a bottom view of the present invention.

FIG. 7 depicts a top view of the corrugated board of the present invention.

FIG. 8 depicts a perspective view of the corrugated board of the present invention.

FIG. 9 depicts another embodiment of the present invention, in which a plurality of support sections is included.

FIG. 10 depicts yet another embodiment of the present invention, in which two apparatuses of the present invention are used in tandem to form a complete mattress support.

DETAIL DESCRIPTIONS OF THE INVENTION

As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.

Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure and is made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself. Accordingly, it is intended that the scope of patent protection is to be defined by the issued claim(s) rather than the description set forth herein.

Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. When not explicitly defined herein, to the extent that the meaning of a term used herein—as understood by the ordinary artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.

Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.”

The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subject matter disclosed under the header.

Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description. It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

Unless otherwise indicated, the drawings are intended to be read together with the specification and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up”, “down” and the like, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, “radially”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly,” “outwardly” and “radially” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate. As used herein, the term “proximate” refers to positions that are situated close/near in relationship to a structure. As used in the following description, the term “distal” refers to positions that are situated away from positions.

The present disclosure includes many aspects and features. Moreover, while many aspects and features relate to, and are described in the context of mattress support apparatuses, embodiments of the present disclosure are not limited to use only in this context.

The present invention is a mattress support apparatus that can be placed between a mattress and a bed base. It is an aim of the present invention to provide a breathable and moisture-resistant mattress support apparatus. It is another aim of the present invention to provide a mattress support apparatus with reduced noise and enhanced support. It is yet another aim of the present invention to provide even weight distribution and maintain structural integrity of the mattress over time.

Referring now to the figures of the present disclosure. The mattress support apparatus of the present invention comprises a top layer 110, a bottom layer 120, and at least one corrugated board 130.

The top layer 110 and the bottom layer 120 are configured to encapsulate the at least one corrugated board 130. It should be noted that the top layer 110 and/or the bottom layer 120 can be of any shape, size, material, features, type or kind, orientation, location, quantity, components, and arrangements of components that would allow the present invention to fulfill the objectives and intents of the present invention. In one embodiment, the top layer 110 comprises an outer surface 111 and an inner surface 112, while the bottom layer 120 also comprises an outer surface 121 and an inner surface 122. An edge of the top layer 110 is attached to an edge of the bottom layer 120 to create at least one interior space 115. It should be noted that any suitable means may be used to attach the edge of the top layer 110 and the edge of the bottom layer 120, including but not limited to stitching, adhesive, zipper, loop and hook fasteners, snap buttons, etc. In a preferred embodiment, The present invention further comprises a protective trim 140 along the edge of the top layer 110 and the edge of the bottom layer 120 to provide enhanced durability and prevent fraying. Moreover, the edge of the top layer 110 and the edge of the bottom layer 120 can be reinforced by overlock stitches.

The top layer 110 and the bottom layer 120 may or may not be made of the same material. In one embodiment, the top layer 110 is made of moisture-resistant and breathable material. Preferably, the top layer 110 is made of Oxford fabric. In one embodiment, the bottom layer 120 is made of moisture-resistant and breathable material. Preferably, the bottom layer 120 is made of Oxford fabric. The Oxford fabric cover of the present invention effectively minimizes noise between the present invention's apparatus and bed slats, ensuring a quiet and undisturbed night's sleep free from creaks and other sounds. However, it should be noted that any other suitable material (e.g., non-woven fabric) may also be used. In one embodiment, the outer surface 121 of the bottom layer 120 comprises an anti-slip member 123. Preferably, the anti-slip member comprises a plurality of silicone honeycomb patterns, as best shown in FIG. 6, such that the present invention can grip the bed slats firmly to avoid any movement and offer long-lasting durability. In a preferred embodiment, the inner surface 112 of the top layer 110 and/or the inner surface 122 of the bottom layer 120 are coated with polyurethane. In another preferred embodiment, a handle may be attached to the outer surface 111 of the top layer 110 to facilitate installation and removal of the present invention. In one embodiment, various indicia, logos or graphic images may be applied to the outer surface of the top layer and/or bottom layer for personalization of the present invention or for promotional or advertising purposes.

The at least one corrugated board 130 is configured to provide uniform support to the mattress. It should be noted that the corrugated board 130 can be of any shape, size, material, features, type or kind, orientation, location, quantity, components, and arrangements of components that would allow the present invention to fulfill the objectives and intents of the present invention. In one embodiment, the at least one corrugated board 130 comprises a top sheet 131, a bottom sheet 132, and a flute layer 133 sandwiched between the top sheet 131 and the bottom sheet 132. In one embodiment, the at least one corrugated board 130 comprises a plurality of holes 134 that enhances air circulation and breathability.

Unlike traditional wooden bunkie boards, the corrugated board 130 resists moisture absorption from the air, helping to prevent mold and mildew growth and ensuring long-term durability, even in humid environments. In one embodiment, the at least one corrugated board 130, the top layer 110, and/or the bottom layer 120 may be treated with an antimicrobial agent to further prevent mold, mildew, and bacterial growth.

The at least one corrugated board 130 is accommodated in the at least one interior space 115 to form at least one support section 117. Preferably, the at least one support section 117 comprises a plurality of support sections 117. In one embodiment, the plurality of support sections 117 is adapted to fold together. For example, the plurality of support sections 117 may be folded in a “zig-zag” pattern. It should be noted that edges of the first and last corrugated board 130 in the zig-zag fold should be beveled to eliminate sharpness. In one embodiment, the plurality of support sections 117 is formed by stitching between the support sections. Other methods such as adhesive bonding or other fastening techniques can also be used to create multiple separate interior spaces, thereby forming the plurality of support sections 117. Multiple support sections enable the present invention to accommodate various bed sizes and allow for more compact packaging during transportation. Moreover, the size of the support sections can vary depending on design requirements. For example, the mattress support apparatus may comprise two support sections, each having a size of 20″ by 40″, and three such apparatuses would fit in a queen bed, as shown in FIG. 10. In another example, the mattress support apparatus may comprise two support sections, each having a size of 27″ by 37.5″, and two such apparatuses would fit in a full bed. Further, the thickness of the corrugated board 130 is also customizable to accommodate various mattress types and user preferences.

In addition, it should be noted that the at least one corrugated board 130 should be securely retained in its respective interior space 115. This can be achieved either by ensuring a snug fit within the interior space 115 or by attaching the corrugated board 130 to the top layer 110 and/or the bottom layer 120. In a preferred embodiment, the present invention further comprises a padding layer 119 between the inner surface of the top layer and the top sheet of the corrugated board to enhance comfort and noise reduction. It should be noted that the components of the present invention, including the top layer, the bottom layer, the corrugated board, an/or the padding layer, may be made of recycled or sustainably sourced materials.

Although the disclosure has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the disclosure.