FIELD OF THE INVENTION;
The present invention relates to an orthopedic mattress which is designed such that it provides both luxurious comfort and orthopedic support to the body of the person sleeping on it
BACKGROUND OF THE INVENTION:
In modern times, due to stressful living, a good mattress is essential for sleeping which provides both support and comfort to the body of a person, making him feel relaxed and providing him with deep, comfortable and uninterrupted sleep. A mattress is a large pad for supporting the reclining body which may be used as a bed for sleeping or which may be spread on a bed for sleeping. Mattresses consist of a quilted or similarly fastened case, usually of heavy cloth, that contains hair, straw, cotton, foam, rubber etc. and may be inflatable or may have a framework of metal or plastic springs. A conventional mattress consists of two primary sections, a core or support layer and the upholstery or somfort layer which are wrapped in a thick fabric. Upholstery layers cover the mattress and provide cushioning and comfort.
US Patent 4122568 describes mattress of the hard surface type in which an orthopedic mattress is made of a plurality of rigid supporting members each including a vertical post with a rigid flat platform at its upper and tower ends. The platforms are preferably square in shape and may include connecting means on each of the side edges thereof. The supporting members are arranged in longitudinal and transverse rows and the entire assembly is covered with a soft material such as foam rubber.
US Patent 4128907 discusses a mattress foundation apparatus which includes a flat continuous upper component from which downwardly depend a pair of end walls and a pair of side walls. A continuous raised rim about the upper perimeter of the flat upper component retains the mattress in its desired position. A series of solid lateral struts are integrally formed with the upper component and depend downwardly therefrom. The entire mattress foundation apparatus constitutes an inelastic, downwardly opening, hollow structure useful for persons with back or orthopedic problems.
US Palest 4985951 discloses a flexible mattress including vegetable fibers which has a layer of a material formed of or including vegetable fibers which may be covered on one or both faces with a layer of foam material which is capable of undergoing a localized deformation along a fold line while retaining the continuity of its surface. The layer of material including vegetable fibers is constituted by at least two blocks having a junction zone which is located roughly in a transverse plane aad along a fold line. A layer of foam material is provided in the vicinity of the junction zone on each side of a transverse plane, this layer of foam material being fixed to each of the upper and lower faces of the layer of material including vegetable fibers.
US Patent 5819349 gives a mattress in which the multi-layer mattress provides a separation sheet, for example, made of plastic or cloth, between foam layers to allow them to better flex and compress separately.
US Patent 6295674 provides a foldable sleeper sofa mattress and method of manufacturing in which the foldable sprmgless mattress for a sleeper sofa has a hard but bendable bottom insulator pad, a first flexible foam layer adhered on top of the insulator pad, an all-natural latex rubber layer adhered on top of the first flexible foam layer, and a composite panel adhered on top of the rubber layer. The composite panel includes an intermediate layer of antimicrobial-treated fibers quitted together with a second flexible foam layer and a moisture-resistant damask fabric. This damask fabric covers all surfaces of the mattress. A process of making the foldable springless mattress includes the steps of providing the insulator pad, adhering the first flexible foam layer on top of the pad, adhering the rubber layer oh top of the first flexible foam layer, and adhering the composite panel on top of the rubber layer. The composite panel is formed preliminarily by quilting the layer of antimicrobial-treated fibers together with the second flexible foam layer and the damask fabric.
US Patent 6687935 relates to a mattress structure in which the mattress (900) provides a user with three-dimensional firmness zoning, the mattress (900)
cooperating with a mattress shell (720). The mattress (900) includes a plurality of longitudinally spaced, transversely extending resilient blocks (910) being mdepeadently movable relative to one another, an inflatable bladder (914) positioned to lie upon the top side of at least one of the blocks (910), and a topper (912) positioned to lie upon the inflatable Madder (914), the topper nictating opposite ends configured for attachment to the shell (720). IIS Patent 7496981 describes a foam spring mattress in which the mattress (1) is made of a Mock of flexible polyurethane foam (4) with a density of 40 Kg/m3 or of any other density, said block being firstly cut with a cut programmable automatic machine, by the main side and then tamed at a 90° degree angle by its small side. A certain amount of springs (5) is thereby formed depending on each type of mattress (1). The amount of spirals (5.1) of every spring (5) depends on the position of each spring in the mattress (1) with the purpose of varying the flexibility thereof so that the mattress (1) can perfectly adapt to the contour to of every user or so that the flexibility can remain constant throughout the entire mattress. Multiple variations can be realized while the height of the mattress remains the same (less spirals having the same spiral thickness and more base and uncut etc.; the width of a spiral can be changed, as well as the number of spirals, the inclination of the axis of the spirals, the total height of an area-budge or cavity,
etc. The upper surface of the product is covered with a viscous elastic layer (3) of polyurethane with a 50 Kg/m3 density, 4 cm thickness and threaded padding (2). US .Patent Application 20010013147 discusses a multiple module mattress system wherein the mattress system offers combinations of comfort and support comprissig at least two modules, positioned side-by-side along their longest dimension to define at least two recumbent user areas, and a comfort cushion receivable atop each of the at least two modules. The mattress system provides an immense array of combinations of firmness and support, allowing each user to adjust, to a very wide degree, the comfort, firmness and support beneath their upper body, lumbar area, and lower body. The adaptable structure of the mattress system also allows the individual user to customize his/her side of the bed and easily change his/her side of the bed as his/her preferences change. Additionally, the construction increases the longevity of the bed, because components may be replaced one at a time as deemed necessary. Further, the various components of the modular-mattress system enable the manufacturer to ship the bed at reduced cost to the customer, because the mattress system may be shipped in smaller freight components.
US patent Application 2001401834H3 relates to increasing the heat flow of flexible cellular foam through the incorporation of highly thermally conductive
solids in which methods and combinations of mattress support surfaces comprising one or more flexible polyurethane foam layers containing highly mermally-conducttive solids, such as diamond or silicon carbide, and said layer combination is capable of transferring heat from a warm surface, such as a person sleeping on a bed, to .a cooler region at a faster tale throughout the mattress than the thermal dissipation rate obtained from flexible polyurethane foam without highly thermally-conductive solids.
W1PO- Patent Application WO 2001056428 provides an anatomic orthopedic mattress which comprises the mattress retainer (a), the mattress that consists of a fixed part (b), holders (g) and movable parts, spring pins (d), a steel netting (1), a fabric cover and optionally resistance and a thermostat for heating. The pins (d) are moving retrogressively on the fixed part (b) of the mattress inside the holders (g), so as whenever a person lies on the mattress the latter automatically takes the shape of his/her body and distributes the weight of the body offering thus a comfortable and pleasant sleep.
Although a number of mattresses are available in the prior art, an orthopedic mattress which gives a perfect balance of comfort and support to the person sleeping on it basedon various factors like his age, weight, height, lifestyle etc, is the need of the day.
OBJECT OF THE INVENTION:
The main object of the invention is to provide for mattresses providing luxurious comfort and orthopedic support to the body based on the age, weight, height and lifestyle of the person by providing thousands of combinations and degrees of balancing the comfort and support in the mattresses.
Another object of the invention is to provide for mattresses providing luxurious comfort and orthopedic support to the body which can be made from latex foam, polyurethane foam, visco-elastic foam, rubberized coir or springsmade of steel wire or plastic.
Still another object of the invention is to provide for mattresses providing luxurious comfort and Orthopedic support to the body which can have additional cohstruction by closing the top of the mattresses with cushioning materials like dcmm sad feather, polyester fibers, wool, cotton etc.
Yet another object of the present invention is to provide for mattresses providing luxurious comfort and orthopedic support to the body which has tremendous flexibility to adjust to the requirement of an individual to provide his body with comfort and support while sleeping.
SUMMARY OF THE INVENTION:
The present invention relates to mattresses providing luxurious comfort and orthopedic support to the body, the formation of which involves two steps. In the first step a mattress shell is produced from latex foam, polyurethane foam, visco-elastic foam or rubberized coir. In the second step, the mattress is orthopedically filled in by various cushioning materials like latex foam, polyurethane foam, visco-elastic foam, rubberized coir or springs made of steel wire or plastic. Following this, the top of the mattresses are closed by using the sheets of the same cushioning material which has been used in orthopedically filling the mattress. Special constructions can be added to the mattress by closing the top of the mattress with cushioning materials like down and feather, polyester fibers, wool, cotton etc.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 gives the diagrammatic representation of the different layers of the orthopedic mattress.
DETAILED DESCRIPTION:
The nature of the invention and the manner in which it is performed is
clearly described in the specification. The invention has various components and they are clearly described in the detailed description.
The growth and development of today's world has led to faster life. People work for long hours and remain stressed. Long hours of working in front of computers have created pains in their back and spine. Moreover, lesser physical activity, tesser time for exercising, sitting for longer hours, bad postures etc. have taken their toll on human bodies. To provide relief to these stressed bodies, many composes have made different kinds of mattresses which provide comfort to people. The regular standard mattresses are made horizontally by adding layers of different kinds of soft cushioning materials which provide comfort to the body but do pot support the body while sleeping. Sleeping on such soft mattresses provide so much comfort to the body that the person tends to sink into the mattress causing damage to his back and spine. Orthopedic mattresses are orthopedically desired mattresses which provide relief from various kinds of pains, induced in the body due to improper mattresses. Most of the orthopedic mattresses are hard as it is believed that hard best for body and back support. Normally orthopedic matbesses are made of hard cushioning materials which provide support to the body while
sleeping but do not provide any comfort to the body. Sleeping on such hard mattresses feels like sleeping on sand. None of these orthopedic mattresses have -plush or luxurious feeling. Sleeping on such regular orthopedic mattresses makes anyone feel like the sleeper is a patient or is in great pain.
Both these kinds of mattresses aren't good as one provides only comfort to the body along with causing damage to the body while the other gives support to the body and prevents damage but does not provide any kind of comfort to the body so that the person sleeping on such mattresses doesn't get comfortable and uninterrupted sleep which is essential for relieving from stress.
A good mattress is one which provides a perfect balance of comfort and support to a person sleeping on it. This perfect balance of comfort and support varies from person to person, based on the age of the person, weight of the person in relation to his height and finally the lifestyle of the person. These factors vary from person to person and thousands of combinations and degrees of balancing the comfort and support to a person sleeping on it can be prepared.
The present invention relates to mattresses providing luxurious comfort and orthopedic support to the body which are designed to provide such mousahds of combinations and the degrees of balancing the comfort and support to a person
sleeping on it. Such mattresses have an absolute plush feel in them. The orthopedic mattresses of the present invention are produced in two major steps: Step 1: In this step, the mattress shell is produced with any one from latex foam, polytirethane foam, visco-elastic foam or rubberized coir. This mattress shell has the following specifications:
The base of the mattress shell is 2" thick flat, has all four side borders, which are 3" thick and 4" high. The centre of the mattress shell has square divisions which are approximately 8" X 8" long, 3" thick and 4" high. In this invention, the side walls and the centre division walls of the mattress shell can be upto 10" high. A standard mattress shell has 7 TOWS of squares through its length and 6 tows of squares through its width. Thus the mattress shell is divided into a total of 42 square blocks.
The mattress shell of the present invention can be made in different sizes which have different dimensions. For eg., a King Size Mattress shell is of the size of 2meters in length and 1.8 meters in width, while a Queen Size Mattress is of the size of 2 meters in Length and 1.6 meters in width. A single bed size mattress shell is of the size of 2 meters length and 0.9 meters wide. However, in all these dimensions, the length wise rows of squares are always 7. The horizontal number of the rows of squares varies with the width of the mattress. A King Size Mattress
has 7 rows of squares in its length and 6 rows in its width, a queen size mattress has 7 rows of squares in its length and 5 rows of squares in its width while a single size mattress shell has 7 rows of squares in its length and 3 rows of squares is its width. The length of the mattress shell can also vary between 2 meters to 1.8 meters So the size of the square blocks also varies marginally depending on the size of the mattress shell required. However, lengthwise, a mattress shell always has 7 rows of square blocks.
Step 2: In the second step of fabricating the mattress, all the square blocks of the mattress are "orthopedically filled in" with various cushioning materials. Orthopedically filled in means, in the length of the mattress, from the seven rows of square blocks, the top two rows of square blocks and the bottom two rows of square blocks are filled in with relatively softer materials as compared with the central three rows. This is because, when a person sleeps on a mattress, the weight of his body varies. The weight of his back and hips is relatively more compared to the weight of his neck and legs. So, relatively firmer cushioning material is filled in the central three rows of the mattress due to which the heavier weight of the back and the hip is taken care of by not allowing it to sink more in the mattress, than the seek and the legs. This is the reason, the filling of the square Mocks is divided into zones of varying firmness to give a perfect alignment of the neck,
back, hips and legs. Now as the neck, back, hips and legs are at the same level, no unevenness is faced by the body eliminating the chances of pain. These square blocks can be orthopedically filled in by using cushioning specials like latex foam, polyurethane foam, visco-elastic foam, rubberized coir or springs made of steel wire or plastic.
After orthopedically filling in the square blocks, the tops of all the mattresses of the present invention are closed by using sheets of the same cushioning materials which are used for orthopedically filling the square blocks. For example, -if the blocks are filled in by latex foam, the top of the mattress is closed by using 2" thick latex foam sheet, if the blocks are filled with polyurethane foam, the top of the mattress is closed by using 2" thick polyurethane foam sheet, if the blocks are filled With visco-elastic filling, the top of the mattress is closed by using 2" visco-elastic foam sheet and if the block are filled with rubberized coir, the top of the mattress is closed by 2" thick rubberized coir sheet. However, when the square blocks are filled by springs, the top of the mattress can be closed by any of the cushioning 2" sheets mentioned above.
After these mattress shells are orthopedically filled in and closed with the top sheet, it is covered with and inner protective knitted fabric cover and then finally
the outer cover of the mattress ticking fabric. This completes the production of the mattresses.
The orthopedic mattresses of the present invention are available in different variations depending on the material used for its production. These include but are not limited to latex foam mattresses, polyurethane foam mattresses, visco-elastic foam mattresses, rubberized coir mattresses or spring mattresses.
Apart from producing the mattresses as mentioned previously, special constructions can be made in the present invention by closing the top of any of the above mentioned type of mattresses using cushioning materials like down and feather, polyester fibers, wool or cotton making them exclusive and more comfortable.
The orthopedic mattresses of the above invention are highly advantageous as they provide both luxurious comfort and orthopedic support to the person sleeping on it. These mattresses are made of square blocks filled with different materials which give support to the body. The fitting of the mattresses is done orthopedically such hat the centre part of the mattresses remain firm so that the back and hips of the person sleeping on the mattress do not sink into the mattress thereby preventing pain, induced by improper sleeping, in the body. Various filling materials can be
used in these mattresses such as latex foam, polyurethane foam, visco-elastic foam, rubberized coir, spring etc. due to which different variants of these mattresses are available providing the user with options to choose according to their requirements. Moreover exclusive variations of these mattresses are also produced using cushioning materials like down and feather, polyester fibers, wool or cotton, making these mattresses more comfortable. These mattresses are uniquely designed which have tremendous flexibility to use any kind of cushioning materials available in the world which allows to produce mattresses with an absolute customized feeling for the individuals for whom the mattresses are designed. Thus the mattresses of the present invention are orthopedically destpied with an absolute plush feel making them highly advantageous.
Although the preferred embodiment as well as the method and use have been specifically described, it should be understood that variations in the preferred embodiment could be achieved by a person skilled in the art without departing from the spirit of the invention. The invention has been described with reference to specific embodiment which is merely illustrative and not intended to limit the scope of fee invention as defined in the claims.
CLAIMS:
I/ We claim,
1. Mattresses providing luxurious comfort and orthopedic support to the body which are produced in two steps wherein the first step involves die production of mattress shells while the second step involves fabricating the mattress in which all the square blocks moulded in the first Step are orthopedically filled in with cushioning materials followed by closifig the top of the mattress with sheets of cushioning materials.
2. Tte mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 1 wherein, the first step of producing the mattress shells involves the use of any one among, but not limited to, latex foam, polyurethane foam, visco-elastic foam and rubberized coir
3. "The mattresses providing luxurious comfort and Orthopedic support to the
body as claimed in claim 2 wherein, using the chosen material, a mattress
shell is produced which is 2" thick flat, has all four side borders which are
3" thick and 4" high while the centre of the mattress shell is divided into
square divisions of the approximate size of 8" x 8", 3" thick and 4" high whose side walls and centre division walls can be upto 10" high.
4. The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 3 wherein, a standard mattress shell has 7 rows of squates in the length and 6 rows of squares in the width, thereby dividing the mattress shell in totally 42 square blocks.
5. The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 4 wherein, the mattress shells are made in different sizes as per the requirement like, but not limited to, a king size mattress is 2 meters long and i .8 meters wide, a queen size mattress is 2 meters long and 1:6 meters wide while a single bed size mattress is 2 meters long and 0.9 meters wide.
6. The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 5 wherein, the rows of square blocks lengthwise, in different sizes of mattresses remains 7 while the rows of square blocks changes along the width like, but not limited to 6 in a king size mattresses, 5 in a queen size mattress and 3 in a single bed size mattress.
7. The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 5 wherein, the length of the mattresses can be in
the range of 2 meters to 1.8 meters as per the requirements, but the number of rows of square blocks will always be 7 lengthwise.
8. The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 1 wherein, the second step involves orthopedically filling up the square blocks of the mattresses prepared in the first step in which the top two and the bottom two rows of square blocks are filled with relatively softer materials as compared with the central three rows of square blocks which are filled with relatively firmer cushioning materials.
9. The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 8 wherein, for filling the square blocks, the cushioning material used may be one among, but not limited to, latex foam, polyurethane foam, visco-elastic foam, rubberized coir and springs made of steel wire or plastic.
lO.The mattresses providing luxurious comfort and Orthopedic support to the bedy as claimed in claim 9 wherein after orthopedically filling in the square blocks with the selected cushioning material, the tops of the mattresses are closed with 2" thick sheets of the same or any other selected cusMohing material which is used for filling the square blocks.
11. The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 10 wherein after closing the tops of the mattresses, they are covered with an inner protective knitted fabric cover and then finally with the outer cover of the mattress ticking fabric.
12.The mattresses providing luxurious comfort and Orthopedic support to the body as claimed in claim 11 wherein special construction can be done in the produced mattresses by closing the top of the orthopedic mattresses with any other cushioning materials, like but not limited to down and feather, polyester fiber, wool and cotton.
13. The mattresses providing luxurious comfort and orthopedic support to the body substantially herein described with reference to the foregoing description and diagrams.