US20210076835A1 - Mattresses including an elastomeric cushioning element and a pocketed coil layer and related methods - Google Patents

Abstract

A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

Description

CROSS REFERENCE TO RELATED APPLICATION
• This application is a continuation of U.S. patent application Ser. No. 15/816,983, filed on Nov. 17, 2017 and titled MATTRESSES INCLUDING AN ELASTOMERIC CUSHIONING ELEMENT AND A POCKETED COIL LAYER AND RELATED METHODS (“the '983 application”). The entire disclosure of the '983 application is hereby incorporated herein.
FIELD
• Embodiments of the disclosure relate generally to cushioning elements such as mattresses including a pocketed coil layer, and to methods of making such mattresses.
BACKGROUND
• Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and/or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well suited to different applications. Cushioning materials may be used in combination with one another to achieve selected properties. For example, mattresses may include pocketed coils in combination with layers of foam, elastomer gels, etc., in order to achieve desired results in the cushioning materials.
• In mattresses, springs (e.g., coil springs) may be preferable to foam for their durability and ability to withstand compression. Springs may also impart a feel that may be more desirable to users than that of foam. Despite these advantages, springs may not provide a positive aesthetic and/or tactile experience if they are seen or felt through side panels of the mattress, prompting manufacturers to conceal the feel of springs on the sides of mattresses. One solution includes a wire frame around the edge of the mattress to provide structure to a cover of the mattress. However, the metal of the wire frame may be felt through the cover of the mattress. In addition, such a wire frame may not be particularly suited to handle compression during use and to packing mattresses for shipping and/or storage, such as direct-to-consumer mattresses that are shipped in logs, boxes, etc.
SUMMARY
• In some embodiments, a mattress assembly may include a base layer, a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer, wherein the elastomeric cushioning element has a thickness within a range of about 2.0 inches to about 4.5 inches.
• In other embodiments, a mattress assembly may include a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and at least one elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils, and each pocketed coil of the plurality of pocketed coils may include a plurality of casings and a coil disposed within the plurality of casings. The at least one elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches.
• In further embodiments, a method of forming a mattress assembly may include disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, wherein a thickness of the elastomeric cushioning element comprises between about 15.0% and about 32.0% of an overall thickness of the mattress assembly, and disposing an outer covering over at least the upper layer.
BRIEF DESCRIPTION OF THE DRAWINGS
• While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:
• FIG. 1 is a perspective view of a mattress assembly according to the present disclosure;
• FIG. 2 is a simplified perspective view of the mattress assembly ofFIG. 1;
• FIG. 3 is a perspective view of an elastomeric cushioning element according to one or more embodiments of the present disclosure;
• FIG. 4 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;
• FIG. 5 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;
• FIG. 6 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;
• FIG. 7 is a side cross-sectional view of a mattress assembly according to one or more embodiments of the present disclosure;
• FIG. 8 is a top schematic view of a mattress assembly according to one or more embodiments of the present disclosure;
• FIG. 9 is a top schematic view of a mattress assembly according to one or more embodiments of the present disclosure; and
• FIG. 10 is a flowchart of a method of forming a mattress assembly according to one or more embodiments of the present disclosure.
DETAILED DESCRIPTION
• The following description provides specific details, such as material types, manufacturing processes, uses, and structures in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional manufacturing techniques and materials employed in the industry.
• In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice the disclosure. However, other embodiments may be utilized, and structural, procedural, and other changes may be made without departing from the scope of the disclosure. The illustrations presented herein are not meant to be actual views of any particular system, device, structure, or process, but are idealized representations that are employed to describe the embodiments of the disclosure. The drawings presented herein are not necessarily drawn to scale. Similar structures or components in the various drawings may retain the same or similar numbering for the convenience of the reader; however, the similarity in numbering does not mean that the structures or components are necessarily identical in size, composition, configuration, or other property.
• As used herein, any relational term, such as “first,” “second,” “top,” “bottom,” “upper,” “base,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise. For example, these terms may refer to an orientation of elements of a mattress when oriented for sleeping in a conventional manner. Furthermore, these terms may refer to an orientation of elements of a mattress assembly as illustrated in the drawings.
• As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially met may be at least about 90% met, at least about 95% met, or even at least about 99% met.
• As used herein, the term “elastomeric polymer” means and includes a polymer capable of recovering its original size and shape after deformation. In other words, an elastomeric polymer is a polymer having elastic or viscoelastic properties. Elastomeric polymers may also be referred to as “elastomers” in the art. Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).
• As used herein, the term “elastomeric block copolymer” means and includes an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B).
• As used herein, the term “plasticizer” means and includes a substance added to another material (e.g., an elastomeric polymer) to increase a workability of the material. For example, a plasticizer may increase the flexibility, softness, or extensibility of the material. Plasticizers include, without limitation, hydrocarbon fluids, such as mineral oils. Hydrocarbon plasticizers may be aromatic or aliphatic.
• As used herein, the term “elastomeric material” means and includes elastomeric polymers and mixtures of elastomeric polymers with plasticizers and/or other materials. Elastomeric materials are elastic (i.e., capable of recovering size and shape after deformation). Elastomeric materials include, without limitation, materials referred to in the art as “elastomer gels,” “gelatinous elastomers,” or simply “gels.”
• Embodiments of the present disclosure include a mattress assembly having an elastomeric cushioning element that comprises between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. For example, the elastomeric cushioning element may comprise about 30.8% of the overall thickness of the mattress assembly.
• Additional embodiments of the present disclosure include a mattress assembly having a coil layer that includes a plurality of coils with each coil of the plurality of coils being disposed in multiple casings (e.g., bags). For example, each coil may be disposed within two or more polypropylene bags.
• Further embodiments of the present disclosure include a mattress assembly having a latex water based adhesive disposed between one or more layers of the mattress assembly.
• FIG. 1 shows amattress assembly100 according to one or more embodiments of the present disclosure.FIG. 2 shows a simplified top perspective view of themattress assembly100 ofFIG. 1. InFIG. 2, various portions of themattress assembly100 are removed to provide a cutaway view and to better show internal components of themattress assembly100. Referring toFIGS. 1 and 2 together, in one or more embodiments, themattress assembly100 may include abase layer102, acoil layer104, anupper layer106, anelastomeric cushioning element108, anedge portion119, one ormore side panels114, and theouter covering112.
• Thebase layer102 may have generally planar top and bottom surfaces. Thecoil layer104 may be disposed on the top surface of thebase layer102 and between thebase layer102 and theupper layer106. In particular, theupper layer106 may be disposed over and may at least substantially extend over thecoil layer104. Theelastomeric cushioning element108 may be disposed over an upper surface of theupper layer106 and may extend over at least a portion of theupper layer106. Theedge portion119 may extend around an outer peripheral edge of theelastomeric cushioning element108. The one ormore side panels114 may extend along outer perimeters of thebase layer102 and theupper layer106 and may be disposed between theupper layer106 and thebase layer102. Furthermore, the one ormore side panels114 may extend within a plane perpendicular to a plane defined by the top surface of thebase layer102. Theouter covering112 may extend from thebase layer102 and may at least substantially encase thecoil layer104,upper layer106, andelastomeric cushioning element108.
• In some embodiments, themattress assembly100 may include astabilization material116 between theelastomeric cushioning element108 and theupper layer106. In some instances, thestabilization material116 may include a relatively thin material (e.g., cotton spandex blend “scrim”) and may be used to provide a surface for adhering (e.g., gluing) theelastomeric cushioning element108 to surrounding materials, such as anotherelastomeric cushioning element108 and/or an upper surface of theupper layer106. In some embodiments, thestabilization material116 may comprise a scrim fabric (e.g., a woven or non-woven fabric material) and portions of theelastomeric cushioning element108 may seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric of thestabilization material116. For example, when theelastomeric cushioning element108 includes a gel material (as described below), portions of the gel material may be heat fused through thestabilization material116. The portions of theelastomeric cushioning element108 that extend through the scrim fabric of thestabilization material116 may create a non-slip surface or reduced slip surface on a lower surface of the stabilization material116 (e.g., surface that would contact an upper surface of the upper layer106). The non-slip surface or reduced slip surface created by theelastomeric cushioning element108 may help the cushioning materials stay in place relative to one another.
• Furthermore, in some embodiments, an adhesive may be disposed between thestabilization material116 and the upper surface of theupper layer106. However, an adhesive may not be disposed between theedge portion119 and theupper layer106. Furthermore, an adhesive may be disposed between thebase layer102 and thecoil layer104. Moreover, an adhesive may be disposed between thecoil layer104 and theupper layer106. Additionally, an adhesive may be disposed between the one ormore side panels114 and thecoil layer104. In some embodiments the adhesive(s) may include a latex water based adhesive. For instance, in one or more embodiments, the adhesive(s) may include one or more of SIMALFA® 338 and SIMALFA® 310.
• In one or more embodiments, themattress assembly100 may not include astabilization material116 between thecoil layer104 and theupper layer106 of themattress assembly100. However, in some instances, an adhesive may be disposed between thestabilization material116 and the upper surface of theupper layer106. For example, the adhesive may include any of the adhesives described above.
• In some embodiments, theouter covering112 may comprise a stretchable material that may be secured to or be integral with theelastomeric cushioning element108. Such a stretchable material is described in U.S. patent application Ser. No. 15/062,621, to Pearce, filed Mar. 7, 2016, the entire disclosure of which is incorporated herein by this reference.
• In one or more embodiments, thebase layer102 and theupper layer106 may include a polyurethane foam. In additional embodiments, thebase layer102 and theupper layer106 may include one or more of a memory polyurethane foam, a latex foam rubber, or any other suitable foam. In some embodiments, thebase layer102 may include a polyurethane foam having a nominal density of about 2.0 lb/ft³and an indention load deflection (ILD) of 55 (i.e., 55 ILD). Additionally, theupper layer106 may include a polyurethane foam having a nominal density of about 2.0 lb/ft³and 18 ILD. The one ormore side panels114 may also include a polyurethane foam or any other spacer fabric known in the art. For example, the one ormore side panels114 may include any of the side panels described in U.S. patent application Ser. No. 15/662,934, to Moon et al., filed Jul. 28, 2017, the disclosure of which is incorporated in its entirety by this reference herein.
• Thecoil layer104 may include a plurality of coils118 (e.g., steel coils), and eachcoil118 of the plurality ofcoils118 may be encased in at least one respective casing120 (e.g., polypropylene socks or bags). For example, eachcasing120 may form a pocket for arespective coil118. In other words, the plurality ofcoils118 may include a plurality of pocketed coils118. In some embodiments, eachcoil118 may include a relatively thin-gauge, barrel-shaped (e.g., helical-shaped), knotless coil. Furthermore, in one or more embodiments, eachcoil118 may be encased inmultiple casings120. For instance, eachcoil118 may be double bagged or triple bagged. In one or more embodiments, thecasings120 may include a polypropylene material.
• Thecasings120 may include a two-ply polypropylene non-woven material. In one or more embodiments, the polypropylene non-woven material may include one or more of BERRY® products 1430408, 1430379, and 1430538. In some embodiments, each ply of thecasings120 may have a thickness within a range of about 0.10 mm and about 0.40 mm. As a non-limiting example, each ply of thecasings120 may have a thickness within a range of about 0.15 mm and about 0.30 mm. However, any suitable material may be used. Thecasings120 may provide sound dampening effects.
• For example, themattress assembly100 was tested according to a test method of utilizing the application SOUND METER by Abc Apps from the Google Play Store on a Galaxy S6 Active phone to measure sound levels from themattress assembly100. During the test method, a 3×3 coil structure having eachcoil118 covered by the above-describedcasings120 was compressed multiple times for the duration of 15 seconds, and the 3×3 coil structure exhibited an average sound level within a range of about 35 decibels and about 45 decibels. For example, the 3×3 coil structure exhibited an average sound level of about 40 decibels. In comparison, conventional mattresses, when tested according to the above test method, exhibited an average sound level of about 50 decibels. Accordingly, by encasing eachcoil118 with multiple casings120 (e.g., afirst casing120 and a second casing120), the mattress assembly200 of the present disclosure may be advantageous over conventional mattress assemblies. For example, themattress assembly100 may be quieter than conventional mattresses (e.g., may exhibit about 20% less sound than conventional mattresses).
• In some embodiments, eachcasing120 of eachcoil118 of the plurality ofcoils118 may be individual and discrete. In additional embodiments, thecasings120 of the plurality ofcoils118 may be connected (i.e., joined) and may form a single body. Furthermore, eachcoil118 of the plurality ofcoils118 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of thebase layer102. Furthermore, the plurality ofcoils118 may be oriented next to each other in an array (e.g., rows and columns or a grid pattern) to form thecoil layer104.
• FIG. 3 a simplified perspective view of theelastomeric cushioning element108. Theelastomeric cushioning element108 may include a singly-moldedelastomeric cushioning element108. For example, the entirety of theelastomeric cushioning element108 may be formed via a single molding process. In some embodiments, theelastomeric cushioning element108 may include bucklingwalls122. The bucklingwalls122 of theelastomeric cushioning element108 may be interconnected to one another and may definehollow columns124 or voids in an expanded form. As used herein, the term “expanded form” means and includes a state in which aelastomeric cushioning element108 has its original size and shape and wherein the bucklingwalls122 are separated and definehollow columns124.
• The bucklingwalls122 may extend in two directions, intersecting at right angles, and defining square voids126. However, in some embodiments, the bucklingwalls122 may intersect at other angles and definevoids126 of other shapes, such as triangles, parallelograms, hexagons, etc. Theelastomeric cushioning element108 may comprise additional structures and configurations such as those structures and configurations described in, for example, U.S. Pat. No. 8,434,748, titled “Cushions Comprising Gel Springs,” issued May 7, 2013; U.S. Pat. No. 8,628,067, titled “Cushions Comprising Core Structures and Related Methods,” issued Jan. 14, 2014; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014; and U.S. Pat. No. 8,932,692, titled “Cushions Comprising Deformable Members and Related Methods,” issued Jan. 13, 2015, the entire disclosure of each of which is incorporated herein by this reference.
• The bucklingwalls122 may be formed of an elastomeric material. Elastomeric materials are described in, for example, U.S. Pat. No. 5,994,450, titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom,” issued Nov. 30, 1999 (hereinafter “the '450 patent”); U.S. Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW in Mid-Block” issued Jun. 21, 2011; U.S. Pat. No. 4,369,284, titled “Thermoplastic Elastomer Gelatinous Compositions” issued Jan. 18, 1983; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014 (hereinafter “the '750 patent”); the disclosures of each of which are incorporated herein in their entirety by this reference. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc.
• The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). For example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc., of Houston, Tex., under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, Tex., under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651. In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene/propylene or ethylene/butylene or ethylene/ethylene/propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers.
• The elastomeric material may include one or more plasticizers, such as hydrocarbon fluids. For example, elastomeric materials may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, N.J., under the trade names BLANDOL® and CARNATION®.
• In some embodiments, the elastomeric material may have a plasticizer-to-polymer ratio from about 0.1:1 to about 50:1 by weight. For example, elastomeric materials may have plasticizer-to-polymer ratios from about 1:1 to about 30:1 by weight, or even from about 1.5:1 to about 10:1 by weight. In further embodiments, elastomeric materials may have plasticizer-to-polymer ratios of about 4:1 by weight.
• The elastomeric material may have one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. For example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer. As another example, metal particles (e.g., aluminum, copper, etc.) may increase the thermal conductivity of the resulting elastomeric material because such particles may have greater thermal conductivity than the plasticizer or polymer. Microspheres filled with wax or another phase-change material (i.e., a material formulated to undergo a phase change near a temperature at which a cushioning element may be used) may provide temperature stability at or near the phase-change temperature of the wax or other phase-change material within the microspheres (i.e., due to the heat of fusion of the phase change). The phase-change material may have a melting point from about 20° C. to about 45° C.
• The elastomeric material may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate), commercially available asIRGANOX® 1010, from BASF Corp., of Iselin, N.J. or as EVERNOX®-10, from Everspring Corp. USA, of Los Angeles, Calif.; octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, commercially available as IRGANOX® 1076, from BASF Corp. or as EVERNOX® 76, from Everspring Chemical; and tris(2,4-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® 168, from BASF Corp. or as EVERFOS® 168, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of elastomeric material. The use of antioxidants in mixtures of plasticizers and polymers is described in columns 25 and 26 of the '450 patent. The elastomeric material may include up to about 5 wt % antioxidants. For instance, the elastomeric material may include from about 0.10 wt % to about 1.0 wt % antioxidants.
• In some embodiments, the elastomeric material may include a resin. The resin may be selected to modify the elastomeric material to slow a rebound of theelastomeric cushioning element108 after deformation. The resin, if present, may include a hydrogenated pure monomer hydrocarbon resin, such as those commercially available from Eastman Chemical Company, of Kingsport, Tenn., under the trade name REGALREZ®. The resin, if present, may function as a tackifier, increasing the stickiness of a surface of the elastomeric material.
• In some embodiments, the elastomeric material may include a pigment or a combination of pigments. Pigments may be aesthetic and/or functional. That is, pigments may provide theelastomeric cushioning element108 with an appearance appealing to consumers. In addition, anelastomeric cushioning element108 having a dark color may absorb radiation differently than anelastomeric cushioning element108 having a light color.
• The elastomeric material may include any type of gelatinous elastomer. For example, the elastomeric material may include a melt-blend of one part by weight of a styrene-ethylene-ethylene-propylene-styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® 4055) with four parts by weight of a 70-weight straight-cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and/or other additives.
• The elastomeric material may include a material that may return to its original shape after deformation, and that may be elastically stretched. The elastomeric material may be rubbery in feel, but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials, and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5.
• Referring again toFIG. 2 again, a configuration of having thecoil layer104 with theupper layer106 on top of thecoil layer104 and theelastomeric cushioning element108 on top of theupper layer106 may provide advantages over conventional mattress assemblies. For example, in comparison to conventional mattress assemblies, the plurality ofcoils118 of thecoil layer104 may better conform to an upper surface of themattress assembly100. For instance, when subjected to a weight (e.g., a person on the mattress assembly100) and a resulting deformation, the plurality ofcoils118 of thecoil layer104 may better conform to the deformation. Furthermore, the configuration may provide an increase in lateral stability in comparison to conventional mattress assemblies. Additionally, the foregoing configuration may make methods of manufacturing themattress assembly100 easier in comparison to conventional methods of manufacturing mattresses because it removes a need to laminate/glue thecoil layer104 to theelastomeric cushioning element108. Having theupper layer106 between thecoil layer104 and theelastomeric cushioning element108 provides a porous surface to adhere to both of thecoil layer104 and theelastomeric cushioning element108. Furthermore, theupper layer106 dampens sound from thecoil layer104.
• FIGS. 4-7 show schematic side cross-sectional views of mattress assemblies according to embodiments of the present disclosure. As shown inFIG. 4, in some embodiments, theelastomeric cushioning element108 may not cover an entirety of an upper surface of theupper layer106 of themattress assembly100. In such embodiments, themattress assembly100 may further include one ormore segments128 of foam (e.g., a polyurethane foam) in place of theelastomeric cushioning element108 to provide an at least substantially planar upper surface of themattress assembly100. For instance, the one ormore segments128 of foam may be disposed adjacent to theelastomeric cushioning element108 on theupper layer106 of themattress assembly100.
• In some embodiments, theelastomeric cushioning element108 may be disposed only over a center portion of theupper layer106 of themattress assembly100. For example, theelastomeric cushioning element108 may not cover a portion of theupper layer106 extending around a perimeter of theupper layer106 of themattress assembly100. In such embodiments, the segments offoam128 may be disposed over the portion of theupper layer106 extending around a perimeter of theupper layer106. The foregoing configuration may be utilized with mattress sizes where only one sleeper is expected (i.e., twin and full sized mattress).
• In additional embodiments, theelastomeric cushioning element108 may be disposed only in areas anticipated as predominant sleeping areas of sleepers. For example, theelastomeric cushioning element108 may include two separate sections centered on opposing longitudinal halves of themattress assembly100. The foregoing configuration may be utilized with mattress sizes where two sleepers are expected (i.e., king, queen, and full sized mattresses). Furthermore, the foregoing embodiment is described in further detail with reference toFIG. 8.
• As show inFIGS. 5-7, a thickness of theelastomeric cushioning element108 may vary. In some embodiments, theelastomeric cushioning element108 may have a thickness T of within a range of about 1.5 inches to about 2.5 inches. Furthermore, in some instances, the thickness T of theelastomeric cushioning element108 may comprise between about 15.0% and about 20.0% of an overall thickness of themattress assembly100. For instance, theelastomeric cushioning element108 may have a thickness T of about 2.0 inches and a thickness T that comprises about 18.2% of the overall thickness of themattress assembly100. In additional embodiments, theelastomeric cushioning element108 may have a thickness T of within a range of about 2.5 inches to about 3.5 inches. Moreover, in some embodiments, the thickness T of theelastomeric cushioning element108 may comprise between about 20.0% and about 30.0% of an overall thickness of themattress assembly100. For example, theelastomeric cushioning element108 may have a thickness T of about 3.0 inches and a thickness T that comprises about 25.0% of the overall thickness of themattress assembly100. In further embodiments, theelastomeric cushioning element108 may have a thickness T of within a range of about 3.5 inches to about 4.5 inches. Additionally, in one or more embodiments, the thickness T of theelastomeric cushioning element108 may comprise between about 30.0% and about 35.0% of an overall thickness of themattress assembly100. As a non-limiting example, theelastomeric cushioning element108 may have a thickness T of about 4.0 inches and a thickness T that comprises about 30.8% of the overall thickness of themattress assembly100.
• Referring still toFIGS. 5-7, in some embodiments, theupper layer106 of themattress assembly100 may have a thickness within a range of about 0.25 inch and about 0.75 inch. For instance, theupper layer106 of themattress assembly100 may have a thickness of about 0.50 inch. Additionally, thecoil layer104 of themattress assembly100 may have a thickness (e.g., height) within range of about 6.0 inches and about 9.0 inches. For example, thecoil layer104 of themattress assembly100 may have a thickness of about 7.5 inches. Moreover, thebase layer102 of themattress assembly100 may a thickness within a range of about 0.50 inch and about 1.50 inches. As a non-limiting example, thebase layer102 may have a thickness of about 1.00 inch.
• FIGS. 8 and 9 show top views of mattress assemblies according to embodiments of the present disclosure. As shown inFIG. 8, in some embodiments, themattress assembly800 may include one or more elastomericcushioning element sections802,804 (e.g., a plurality of distinct elastomeric cushioning elements). Furthermore, the one or more elastomericcushioning element sections802,804 may be disposed (e.g., located) in anticipated sleeping areas of one or more sleepers. For example, for a mattress size where two sleepers are anticipated (e.g., a queen and/or king size bed), themattress assembly800 may include a first elastomericcushioning element section802 and a second elastomericcushioning element section804. The first elastomericcushioning element section802 may be centered longitudinally within afirst half806 of the overall mattress assembly800 (divided longitudinally), and the second elastomericcushioning element section804 may be centered longitudinally within asecond half808 of theoverall mattress assembly800. In some embodiments, each of the first elastomericcushioning element section802 and the second elastomericcushioning element section804 may have a width within a range of about 22.0 inches to about 28.0 inches. For instance, each of the first and second elastomericcushioning element sections802,804 may have a width of about 25.0 inches. Furthermore, each of the first and second elastomericcushioning element sections802,804 may have a length (e.g., longitudinal length) within a range of about 50.0 inches to about 65 inches. For example, the first and second elastomericcushioning element sections802,804 may have a length of about 56.0 inches. Furthermore, apolyurethane foam810 may be disposed where coverage is not provided by the first and second elastomericcushioning element sections802,804. In some instances, thepolyurethane foam810 may include a polyurethane foam having a nominal density of about 2.0 lb/ft³and 18 ILD.
• As shown inFIG. 9, in some embodiments, theelastomeric cushioning element902 may provide complete coverage over amattress assembly900. For example, theelastomeric cushioning element902 may cover at least substantially an entire upper surface of the upper layer106 (FIG. 2) of themattress assembly900.
• FIG. 10 shows a schematic flowchart of amethod1000 of forming amattress assembly100. In some embodiments, themethod1010 may include anact1000 of disposing acoil layer104 over abase layer102. For example,act1010 may include disposing a plurality ofcoils118 within a plurality ofcasings120, wherein eachcoil118 of the plurality ofcoils118 is disposed within at least tworespective casings120, and disposing the plurality ofcoils118 over thecoil layer104. Additionally,act1010 can include disposing the plurality ofcoils118 within polypropylene bags. Furthermore,act1010 may include orienting the plurality ofcoils118 within an array (e.g., rows and columns) over thebase layer102. Moreover,act1010 may include disposing thecoil layer104 over thebase layer102 according to any of the configurations described above in regard toFIGS. 1, 2, and 4-7.
• Additionally, themethod1000 may include anact1020 of disposing anupper layer106 over thecoil layer104. In some embodiments,act1020 may not include disposing a stabilization material between thecoil layer104 and theupper layer106. However, in some embodiments,act1020 may include disposing an adhesive between thecoil layer104 and theupper layer106. For example,act1020 may include disposing any of the adhesives described above between thecoil layer104 and theupper layer106. Furthermore,act1020 may include disposing anupper layer106 over thecoil layer104 according to any of the configurations described above in regard toFIGS. 1, 2, and 4-7.
• Moreover, themethod1000 may include anact1030 of disposing anelastomeric cushioning element108 over theupper layer106. For example,act1030 can include disposing anelastomeric cushioning element108 over theupper layer106 that comprises between about 15.0% and about 32.0% of an overall thickness of themattress assembly100. For instance, a thickness of theelastomeric cushioning element108 comprises between about 20.0% and about 32.0% of an overall thickness of themattress assembly100. In additional embodiments,act1030 can include disposing anelastomeric cushioning element108 over theupper layer106 that comprises between about 25.0% and about 32.0% of an overall thickness of themattress assembly100. In further embodiments,act1030 can include disposing anelastomeric cushioning element108 over theupper layer106 that comprises between about 30.0% and about 32.0% of an overall thickness of themattress assembly100. For instance,act1030 can include disposing anelastomeric cushioning element108 over theupper layer106 that comprises about 30.8% of an overall thickness of themattress assembly100.
• In some embodiments,act1030 can include disposing a plurality ofelastomeric cushioning element108 segments over theupper layer106. Moreover,act1030 can include disposing anelastomeric cushioning element108 over theupper layer106 according to any of the configurations described above and including any of the materials described in regard toFIGS. 1-9.
• Additionally, themethod1000 may includeact1040 of disposing anouter covering112 over at least theupper layer106. For example,act1040 can include disposing anouter covering112 over themattress assembly100 such that theouter covering112 covers at least substantially an entirety of theupper layer106 andside panels114 of themattress assembly100. In one or more embodiments, the method600 can include disposing an adhesive between any of the layers of themattress assembly100.
• Additional non-limiting example embodiments of the disclosure are described below.
• Embodiment 1: A mattress assembly, comprising: a base layer; a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coil; an upper layer disposed over the coil layer; and an elastomeric cushioning element disposed over the upper layer, wherein the elastomeric cushioning element has a thickness within a range of about 2.0 inches to about 4.5 inches.
• Embodiment 2: The mattress assembly of Embodiment 1, wherein the coil layer has a thickness within a range of about 6.00 inches and about 8.00 inches.
• Embodiment 3: The mattress assembly of Embodiment 2, wherein the coil layer has a thickness of about 7.50 inches.
• Embodiment 4: The mattress assembly of Embodiment 1, further comprising: one or more side panels extending around outer perimeters of the base layer and the upper layer; and an outer covering disposed over the upper layer at least partially around the one or more side panels.
• Embodiment 5: The mattress assembly of Embodiment 1, wherein the base layer and the upper layer both comprise a polyurethane foam.
• Embodiment 6: The mattress assembly of Embodiment 1, wherein the elastomeric cushioning element has a thickness of about 4.0 inches.
• Embodiment 7: The mattress assembly of Embodiment 1, further comprising an adhesive disposed between the elastomeric cushioning element and the upper layer.
• Embodiment 8: The mattress assembly of Embodiment 7, wherein the adhesive comprises a latex water based adhesive.
• Embodiment 9: The mattress assembly of Embodiment 1, wherein the base layer has a thickness within a range of about 0.75 inch and about 1.50 inches, and wherein the upper layer has a thickness within a range of about 0.25 inch and about 0.75 inch.
• Embodiment 10: A mattress assembly, comprising: a base layer; a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils, each pocketed coil of the plurality of pocketed coils comprises: a plurality of casings; and a coil disposed within the plurality of casings; an upper layer disposed over the coil layer; and at least one elastomeric cushioning element disposed over the upper layer, wherein the at least one elastomeric cushioning element has a thickness within a range of about 2.0 inches to about 4.5 inches.
• Embodiment 11: The mattress assembly of Embodiment 10, wherein the plurality of pocketed coils is oriented next to each other in a grid pattern.
• Embodiment 12: The mattress assembly of Embodiment 10, wherein the plurality of casings of each pocketed coil comprises: a first casing; and a second casing disposed within the first casing, wherein the coil is disposed within the second casing.
• Embodiment 13: The mattress assembly of Embodiment 10, wherein the at least one elastomeric cushioning element comprises a plurality of distinct elastomeric cushioning elements disposed at different locations over the upper layer.
• Embodiment 14: The mattress assembly of Embodiment 10, wherein the at least one elastomeric cushioning element does not cover an entirety of an upper surface of the upper layer.
• Embodiment 15: The mattress assembly of Embodiment 11, wherein the at least one elastomeric cushioning element comprises interconnected buckling walls.
• Embodiment 16: A method of forming a mattress assembly, comprising: disposing a coil layer over a base layer; disposing an upper layer over the coil layer; disposing an elastomeric cushioning element over the upper layer, wherein a thickness of the elastomeric cushioning element comprises between about 15.0% and about 32.0% of an overall thickness of the mattress assembly; and disposing an outer covering over at least the upper layer.
• Embodiment 17: The method of Embodiment 16, wherein disposing a coil layer over a base core layer comprises: disposing a plurality of coils within a plurality of casings, wherein each coil of the plurality of coils is disposed within at least two respective casings; and disposing the plurality of coils over the coil layer.
• Embodiment 18: The method of Embodiment 17, wherein disposing a plurality of coils within a plurality of casings comprises disposing the plurality of coils within polypropylene bags.
• Embodiment 19: The method of Embodiment 16, wherein the elastomeric cushioning element comprises about 30.8% of the overall thickness of the mattress assembly.
• Embodiment 20: The method of Embodiment 16, further comprising disposing an adhesive between the elastomeric cushioning element and the upper layer.
• While the present disclosure has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the disclosure as hereinafter claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the disclosure as contemplated. Further, embodiments of the disclosure have utility with different and various mattress types and configurations.

Claims (23)

What is claimed:

1. A mattress, comprising:

a first layer comprising a plurality of coils;

a second layer over at least a portion of the first layer, the second layer comprising a foam;

an elastomeric cushioning element over at least a portion of the second layer and adhered to the second layer.

2. The mattress ofclaim 1, wherein:

the plurality of coils comprises a plurality of individually wrapped coils.

3. The mattress ofclaim 1, further comprising:

an outer covering encasing the first layer, the second layer, and the elastomeric cushioning element.

4. The mattress ofclaim 1, further comprising:

one or more side panels extending around outer perimeters of the first layer and the second layer.

5. The mattress ofclaim 4, further comprising:

an outer covering encasing the first layer, the one or more side panels, the second layer, and the elastomeric cushioning element.

6. The mattress ofclaim 1, wherein the second layer comprises a polyurethane foam.

7. The mattress ofclaim 1, wherein the elastomeric cushioning element comprises a grid of interconnected walls defining hollow buckling columns.

8. A mattress, comprising:

a coil layer comprising an array of coils;

a foam layer over the coil layer, the foam layer including a lower surface oriented toward the coil layer and an upper surface oriented away from the coil layer;

an elastomer layer over the upper layer, the elastomer layer including a lower surface oriented toward the foam layer and an upper surface oriented away from the foam layer, the lower surface of the elastomer layer adhered to the foam layer.

9. The mattress ofclaim 8, wherein the array of coils comprises individually wrapped coils.

10. The mattress ofclaim 9, wherein each coil of the array of coils is disposed within a first polypropylene bag and the first polypropylene bag is disposed within a second polypropylene bag.

11. The mattress ofclaim 10, further comprising:

a base layer beneath the coil layer.

12. The mattress ofclaim 11, further comprising:

at least one side panel surrounding an outer periphery of the coil layer.

13. The mattress ofclaim 12, wherein the base layer, the at least one side panel, and the foam layer encase the coil layer, dampening sound from the coil layer.

14. The mattress ofclaim 13, further comprising:

a cover over the base layer, the coil layer, the foam layer, the at least one side panel, and the elastomer layer.

15. The mattress ofclaim 14, having a maximum sound level of about 45 decibels.

16. The mattress ofclaim 14, having a maximum sound level of about 40 decibels.

17. The mattress ofclaim 8, wherein the foam layer has a thickness of about 0.5 inch to about 1 inch.

18. The mattress ofclaim 8, wherein the upper surface of the foam layer is porous to enable the elastomer layer to adhere to the upper surface of the foam layer.

19. The mattress ofclaim 18, wherein the elastomer layer includes a scrim fabric at lower surface.

20. The mattress ofclaim 19, wherein an elastomeric material of the elastomer layer secures the scrim fabric in place at the lower surface.

21. The mattress ofclaim 20, wherein the scrim fabric enables the elastomer layer to adhere to the upper surface of the foam layer.

22. The mattress ofclaim 18, wherein the lower surface of the foam layer is porous to enable the foam layer to adhere to the coil layer.

23. The mattress ofclaim 8, wherein the elastomer layer is superimposed with a central location of the foam layer but not with peripheral portions of the foam layer.

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