US20220167753A1

Movatterモバイル変換

Info

Publication number: US20220167753A1
Application number: US17/110,137
Authority: US
Inventors: Robert Rasmussen
Original assignee: Advanced Comfort Technologies Inc
Current assignee: Purple Innovation LLC
Priority date: 2020-12-02
Filing date: 2020-12-02
Publication date: 2022-06-02

Abstract

Mattress assemblies are disclosed herein. The mattress assemblies can include a multilayered construction having a base layer, a coil layer, and a zoned cushioning layer. The zoned cushioning layer can include two or more cushioning members made of an elastomeric cushioning material. The cushioning members can be disposed in a hip region, a shoulder region, and/or a leg region of the mattress assembly. One or more support and/or comfort layers can also be included.

Description

TECHNICAL FIELD

The present disclosure relates generally to mattress assemblies and related methods. More particular, the present disclosure relates to mattress assemblies including a zoned cushioning layer and related methods.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments disclosed herein will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. These drawings depict only typical embodiments, which will be described with additional specificity and detail through use of the accompanying drawings in which:

FIG. 1 is a perspective view of a mattress assembly according to one embodiment of the present disclosure.

FIG. 2 is a cut away perspective view of the mattress assembly ofFIG. 1.

FIG. 3 is an exploded cross-sectional view of the mattress assembly ofFIG. 1.

FIG. 4 is a cross-sectional view of the mattress assembly ofFIG. 1, depicted with a person laying on the mattress.

FIG. 5 is an exploded cross-sectional view of a mattress assembly according to another embodiment of the present disclosure.

FIG. 6 is an exploded cross-sectional view of a mattress assembly according to another embodiment of the present disclosure.

DETAILED DESCRIPTION

Mattress assemblies are disclosed herein. In some embodiments, the mattress assemblies are multilayered assemblies that include a base layer, a coil layer, and a zoned cushioning layer. One or more additional layers can also be included depending on the mattress design and/or configuration. For example, in certain embodiments, the mattress assemblies include a base layer, a coil layer, a zoned cushioning layer, and one or more support and/or comfort layers. In a particular embodiment, the one or more support and/or comfort layers comprise one or more foam layers. These and other embodiments are further detailed below.

As set forth herein, embodiments may be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood by one of ordinary skill in the art having the benefit of this disclosure that the components of the embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the disclosure but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

It will be appreciated that various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. Many of these features may be used alone and/or in combination with one another.

The phrases “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be coupled to or in communication with each other even though they are not in direct contact with each other. For example, two components may be coupled to or in communication with each other through an intermediate component.

The phrase “elastomeric polymer” refers to a polymer capable of recovering or substantially 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.” Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).

The phrase “elastomeric block copolymer” refers to 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).

The phrase “elastomeric material” refers to 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.”

Any relational and/or directional term, such as “first,” “second,” “top,” “bottom” 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.

FIGS. 1-3 depict various views of amattress assembly100 according to an embodiment of the present disclosure. More particularly,FIG. 1 is a perspective view of themattress assembly100;FIG. 2 is a cut-away perspective view of themattress assembly100; andFIG. 3 is an exploded cross-sectional view of themattress assembly100.

As shown in the illustrated embodiment, themattress assembly100 includes a multilayered construction. For instance, themattress assembly100 includes abase layer110, acoil layer120, and a zonedcushioning layer130. One or more additional layers can also be included depending on the mattress design and/or configuration. For example, in certain embodiments the mattress assemblies100 include abase layer110, acoil layer120, a zonedcushioning layer130, and one or more support and/or

comfort layers

140,150,160. In particular embodiments, the one or more support and/or

comfort layers

140,150,160 comprise one or more foam layers.

With continued reference toFIGS. 1-3, thebase layer110 is generally disposed on the bottom of themattress assembly100 and provides a base or foundation upon which the remaining layers are disposed. Thebase layer110 can comprise various materials, including, but not limited to, a foam material such as a polyurethane foam or latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used. In some embodiments, thebase layer110 comprises a foam material (e.g., polyurethane foam) having a density of between about 1 lbs/ft³and about 5 lbs/ft³, between about 1 lbs/ft³and about 4 lbs/ft³, between about 1 lbs/ft³and about 3 lbs/ft³, or between about 1 lbs/ft³and about 2 lbs/ft³. Thebase layer110 can also comprise an indentation load deflection (ILD) of between about 20 lbs and about 100 lbs, between about 30 lbs and about 70 lbs, or between about 40 lbs and about 60 lbs. As used herein, the indentation load deflection (ILD) is the amount of force (in pounds) required to indent the foam or layer a total of 25 percent of its original thickness. The thickness T₁of thebase layer110 can also vary. In some embodiments, thebase layer110 comprises a thickness of between about 1 inch and about 18 inches, between about 1 inch and about 12 inches, between about 1 inch and about 5 inches, or between about 1 inch and about 3 inches. For instance, greater thicknesses can be used in instances in which thebase layer110 serves as a core layer and themattress assembly100 is devoid of acoil layer120. In such embodiments, the zonedcushioning layer130 can be disposed on thebase layer110.

Thecoil layer120 is disposed on thebase layer110. As shown inFIGS. 2 and 3, thecoil layer120 can include a plurality ofcoils122, each of which may be encased in at least one respective casing orcover124. For example, eachcasing124 may form a pocket for arespective coil122. In such embodiments, the plurality ofcoils122 may be referred to as a plurality ofpocketed cods122. In some embodiments, eachcoil122 may include a relatively thin-gauge, barrel-shaped (e.g., helical-shaped), knotless coil. Thecoils122 may comprise a metal material, such as steel. In other embodiments, thecoils122 are formed from a polymeric material such as a foam or gel. Further, in certain embodiments eachcoil122 may be encased inmultiple casings124. For instance, eachcoil122 may be double bagged or triple bagged. In some embodiments, thecasings124 may include a polypropylene material. Other materials can also be used. For instance, in some embodiments, the plurality ofcons122 are encased in a foam material, which may or may not include anadditional casing124.

As further illustrated, in some embodiments eachcasing124 and eachcoil122 of the plurality ofcons122 may be individual and discrete. In certain embodiments, thecasings124 of the plurality ofcoils122 may be coupled or otherwise joined to one another. Further, eachcoil122 of the plurality ofcons122 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of thebase layer110. The plurality ofcods122 may be oriented next to each other in an array (e.g., rows and columns or a grid pattern) to form thecoil layer120. In other embodiments, thecoil layer120 does not comprisecoils122 that are individual and discrete units. Rather, thecoil layer120 can comprise a continuous wire unit, or coil or spring-like structures that are not barrel shaped. Any such innerspring units can be used in thecoil layer120. Further in particular embodiments, thecoils122 of thecoil layer120 are substituted with gel structures or air pockets that can function as thecoil layer120.

The number ofcoils122 in thecoil layer120 can vary depending on the size and/or shape of themattress assembly100. The height or thickness T₂of thecoil layer120 can also vary. In some embodiments, thecoil layer120 comprises a thickness of between about 4 inches and about 10 inches, or between about 5 inches and about 8 inches. Other thicknesses are also contemplated. For instance, coil layers122 comprising other types of innerspring units, foam or gel coils, or air pockets can have a thickness T₂that is less than about 5 inches, about 4 inches, about 3 inches, or about 2 inches.

Thecoil layer120 can further comprise a rail orsidewall126 extending around the plurality ofcoils122 or innerspring units. For example, as shown in the illustrated embodiment, thesidewall126 extends around a perimeter or periphery of thecoil layer120. Thesidewall126 can be configured to retain thecoils122 or innerspring units within a central region of thecoil layer120. In some embodiments, thesidewall126 comprises a foam material, such as a polyurethane foam or a latex foam. Thesidewall126 can also comprise wood, metal, or other reinforcing members if desired. Other types of materials can also be used, including, but not limited to, foams and other forms of polyethylene, polypropylene, fiber, and/or latex. The thickness of thesidewall126 can be substantially the same thickness as thecoils122 within thecoil layer120. The width W₂of thesidewall126 can be between about 1 inch and about 10 inches.

As previously discussed, themattress assembly100 further includes a zonedcushioning layer130. This zonedcushioning layer130 includes a plurality of individual or discrete regions or zones ofcushioning members132 so as to provide a zoned arrangement. As shown in the illustrated embodiment, the regions ofcushioning members132 extend laterally across themattress assembly100. The regions ofcushioning members132 are also spaced along a longitudinal length of themattress assembly100. Regions of asupport material134, such as a polyurethane foam or latex foam, are disposed between and around the regions of thecushioning members132. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used as thesupport material134. Flat foams or convoluted foams can be used. In some embodiments, the zonedcushioning layer130 includes two or more regions of cushioningmember132. In further embodiments, the zonedcushioning layer130 includes three or more regions of cushioningmember132. In yet further embodiments, the zonedcushioning layer130 includes four or five or more regions of cushioningmember132.

In some embodiments, the regions of cushioningmember132 can be disposed at areas of which increased pressure or weight is expected to be applied from a subject during use of themattress assembly100. For instance, a first region of cushioningmember132acan be disposed in a hip region and a second region of cushioningmember132bcan be disposed at a shoulder region. In some embodiments, a third region of cushioningmember132ccan be disposed at a leg region. This is exemplified inFIG. 4, which depicts a subject10 laying on themattress assembly100. As shown inFIG. 4, the subject'ships12 are generally aligned within the first region of the cushioningmember132a, the subject'sshoulders14 are generally aligned within the second region of the cushioningmember132b, and a portion of the subject'slower legs16 are generally aligned within the third region of the cushioningmember132c. Providing the

cushioning members

132a,132b,132cin such areas can increase the comfort of themattress assembly100 as the hips, shoulders, and lower legs are known to exhibit increased pressure on themattress assembly100. In some embodiments, the regions of cushioningmember132 are symmetrically disposed along a longitudinal length of themattress assembly100. In such embodiments, themattress assembly100 can be rotated 180 degrees such that the subject'sshoulders14 generally align with the third region of the cushioningmember132c, and the subject'slower legs16 generally align with the second region of the cushioningmember132b.

The width W₃of thecushioning members132 can vary. For instance, the width W₃of thecushioning members132 can be between about 6 inches and about 20 inches, between about 8 inches and about 20 inches, or between about 12 inches and about 20 inches. In some embodiments, each of thecushioning members132 comprises the same width W₃. In other embodiments, thecushioning members132 can comprise different widths W₃. For instance, in some embodiments, the width W₃of the cushioningmember132ain the hip region is greater than the width W₃of the

cushioning members

132b,132cin the shoulder region and/or leg region. In some of such embodiments, the width W₃of the cushioningmember132ain the hip region is between about 12 inches and about 20 inches, and the width W₃of the

cushioning members

132b,132cin the shoulder region and/or leg region is between 8 inches and about 15 inches. Other widths W₃and/or sizes are also contemplated.

Various materials can be used in thecushioning members132. In some embodiments, each region of cushioningmember132 comprises an elastomeric cushioning material. Each region ofelastomeric cushioning member132 may also include buckling walls. The buckling walls of theelastomeric cushioning member132 may be interconnected to one another and may define hollow columns or voids in an expanded form. The term “expanded form” can refer to a state in which theelastomeric cushioning member132 has its original size and shape and wherein the buckling walls are separated and define hollow columns.

The buckling walls may extend in two directions, intersecting at right angles, and defining square or rectangular voids. The buckling walls may define a grid structure. However, in some embodiments, the buckling walls may intersect at other angles and define voids of other shapes, such as triangles, parallelograms, hexagons, etc. Theelastomeric cushioning member132 may comprise additional structures and configurations such as those structures and configurations described in, for example, U.S. Pat. No. 5,749,111, titled “Gelatinous Cushions with Buckling Columns,” issued May 12, 1998; U.S. Pat. No. 6,026,527, titled “Gelatinous Cushions with Buckling Columns,” issued Feb. 22, 2000; and U.S. Pat. No. 7,076,822, titled “Stacked Cushions,” issued Jul. 18, 2006, the entire disclosure of each of which is incorporated herein by reference.

The buckling walls may be formed of an elastomeric material. Exemplary 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, and U.S. Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW in Mid-Block” issued Jun. 21, 2011, the disclosures of each of which are incorporated herein by reference in theft entirety. In some embodiments, the elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (which can also be referred to as a gel, an elastomer gel, or an elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc.

In some embodiments, the elastomeric polymer may be a block copolymer. For instance, the elastomeric polymer may be an A-B diblock copolymer. In some embodiments, the elastomeric polymer may be an A-BA triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEPS), and styrene ethylene propylene styrene (SEEPS). The elastomeric material may also 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 optionally include one or more plasticizers, such as hydrocarbon fluids.

The elastomeric material may include any type of gelatinous elastomer. 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.

With continued reference toFIGS. 2 and 3, the areas or regions of the zonedcushioning layer130 between and around thecushioning members132 can comprise asupport material134, such as a polyurethane foam or latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used as thesupport material134. Flat foams or convoluted foams can be used. In further embodiments, the areas orregions134 of the zonedcushioning layer130 between and around thecushioning members132 comprise an elastomeric cushioning material or gel having one or more different properties than the material in thecushioning members132. In such embodiments, the materials identified above for the regions of zoned cushioningmember132 can also be used as thesupport material134, but with one or more different properties such as a different firmness, hardness, structure, chemical composition, etc. In certain embodiments, the width W₄ofsupport material134 between adjacent regions of zonedcushioning members132 is at least about 4 inches, at least about 6 inches, or more. As illustrated, thesupport material134 can extend around a perimeter or periphery of the zonedcushioning layer130. Thesupport material134 can also extend between the various regions of cushioningmember132. The properties of thesupport material134 can also differ from the properties of the cushioningmember132. For instance, in some embodiments thesupport material134 can have a stiffness or rigidity that is different from or greater than the cushioningmember132. In certain embodiments, thesupport material134 can be configured to aid in maintaining the structural conformation of the zonedcushioning layer130. For instance, thesupport material134 along the perimeter or periphery of the zonedcushioning layer130 can provide increased support for a subject to sit on a side or edge of themattress assembly100. In other embodiments, the stiffness or rigidity of thesupport material134 is substantially the same as that of thecushioning members132.

The thickness T₃of the zonedcushioning layer130 can vary as desired. In some embodiments, the zonedcushioning layer130 may have a thickness T₃of within a range of about 0.75 inches to about 5 inches, about 1 inch to about 4 inches, or between about 1.5 inches to about 3 inches. Other thicknesses are also contemplated. It will further be appreciated that in some embodiments themattress assembly100 can include two or more zoned cushioning layers130. These two more zoned cushioning layers130 can be stacked vertically, either directly adjacent one another or with one or more additional layers in between.

As previously discussed, themattress assembly100 can further comprise one or more optional and/or additional layers depending on the mattress design and/or configuration. For example, one or more support and/or comfort layers140,150,160 can be included on either or both sides of the zonedcushioning layer130. In some embodiments, such as the illustrated embodiment, one or more support and/or comfort layers140,150,160 are optionally disposed between thecoil layer120 and the zonedcushioning layer130. With reference toFIGS. 2 and 3, for example, at least one or afirst support layer140 is disposed between thecoil layer120 and the zonedcushioning layer130. Thisfirst support layer140 can provide additional support and structural conformation to themattress assembly100. For instance, thefirst support layer140 can comprise a stiffness or rigidity that is greater than that of the zonedcushioning layer130. Thefirst support layer140 can also provide a different feel to themattress assembly100. In certain embodiments, thefirst support layer140 comprises a foam material, such as a polyurethane foam or a latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used. Flat foams or convoluted foams can be used. In particular embodiments, thefirst support layer140 comprises a foam material (e.g., polyurethane foam) having a density of between about 1 lbs/ft³and about 5 lbs/ft³, between about 1 lbs/ft³and about 4 lbs/ft³, between about 1 lbs/ft³and about 3 lbs/ft³, or between about 1 lbs/ft³and about 2 lbs/ft³. Thefirst support layer140 can also comprise an indentation load deflection (ILD) of between about 20 lbs and about 100 lbs, between about 10 lbs and about 40 lbs, or between about 10 lbs and about 30 lbs. The thickness T₄of thefirst support layer140 can also vary. In some embodiments, the thickness T₄of thefirst support layer140 is between about 0.5 inches and about 2 inches, or between about 0.5 inches and about 1.5 inches. Other thicknesses T₄can also be used, such as between about 1 inch and about 18 inches, between about 1 inch and about 12 inches, between about 1 inch and about 5 inches, or between about 1 inch and about 3 inches.

One or more additional support and/or comfort layers can also be disposed between thecoil layer120 and the zonedcushioning layer130 if desired. The one or more additional support and/or comfort layers can comprise a different material than thefirst support layer140, such as a different foam material or foam having a different density and/or indentation load deflection (ILD) to impart additional properties to themattress assembly100.

One or more

additional layers

150,160 can also be disposed above the zonedcushioning layer130 if desired. For instance, in the illustrated embodiment, themattress assembly100 comprises two

additional layers

150,160 disposed above the zoned cushioning layer. In some embodiments, themattress assembly100 comprises at least onecomfort layer150 disposed above the zonedcushioning layer130. In particular embodiments, the at least onecomfort layer150 comprises a memory material, such as a polyurethane memory foam material. The memory foam material can include polyurethane material that is viscoelastic and can be configured to contour to the body of a subject during use. Flat foams or convoluted foams can be used. The thickness T₅of thecomfort layer150 can also vary. In some embodiments, thecomfort layer150 comprises a thickness T₅of between about 0.5 inches and about 3 inches, or between about 0.75 inches and about 2 inches.

One or more additional support and/or comfort layers can also be disposed above the zonedcushioning layer130. For instance, in some embodiments, one or more support layers160 are also disposed between the zonedcushioning layer130 and thecomfort layer150. In such embodiments, thesupport layer160 can comprise a different material than thecomfort layer150, such as a different foam material or foam having a different density to impart additional properties to themattress assembly100. In certain embodiments, thesupport layer160 comprises a material having a higher stiffness or rigidity than thecomfort layer150 and can provide additional support and structural conformation to themattress assembly100, similar to thefirst support layer140. In some embodiments, thesecond support layer160 comprises a foam material, such as a polyurethane foam or a latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used. Flat foams or convoluted foams can be used. In particular embodiments, thesupport layer160 comprises a foam material (e.g., polyurethane foam) having a density of between about 1 lbs/ft³and about 5 lbs/ft³, between about 1 lbs/ft³and about 4 lbs/ft³, between about 1 lbs/ft³and about 3 lbs/ft³, or between about 1 lbs/ft³and about 2 lbs/ft³. Thesupport layer160 can also comprise an indentation load deflection (ILD) of between about 20 lbs and about 100 lbs, between about 10 lbs and about 70 lbs, such as between about 10 lbs and about 25 lbs, or between about 40 lbs and about 60 lbs depending on the desired firmness. The thickness T₆of thesupport layer160 can also vary. In some embodiments, thesupport layer160 comprises a thickness of between about 0.5 inches and about 3 inches, or between about 0.75 inch and about 2 inches. Other thicknesses T₆can also be used, such as between about 1 inch and about 18 inches, between about 1 inch and about 12 inches, between about 1 inch and about 5 inches, or between about 1 inch and about 3 inches.

In certain embodiments, one or more of the additional support and/or comfort layers140,150,160 comprises a layer of elastomeric cushioning material or gel. In such embodiments, the materials and structures (e.g., buckling walls defining hollow columns) identified above for the regions of zoned cushioningmember132 can also be used in the one or more additional support and/or comfort layers140,150,160. The one or more additional support layers140,150,160 comprising a layer of elastomeric cushioning material or gel can be stacked vertically on one or both sides of the zonedcushioning layer130, either directly adjacent the zonedcushioning layer130 or with one or more additional layers in between.

With reference toFIG. 1, themattress assembly100 can also comprise acover105 disposed at least partially around or encapsulating the entirety of multilayered construction. Various types ofcovers105 can be used, including quilted or paddedcovers105 and the like. Thecover105 can also comprise various materials or fabrics, including, but not limited to, cotton materials, polyester materials, polymeric materials, water resistant materials, synthetic materials, and combinations thereof. Thecover105 can be flexible and stretchable (or elastic) such that it can stretch and return to its original size and/or shape.

Themattress assembly100 can further include adhesives, stitching, or other fasteners for coupling the one or

more layers

FIG. 5 depicts amattress assembly200 according to another embodiment. As shown inFIG. 5, themattress assembly200 includes abase layer210, acoil layer220, and a zonedcushioning layer230. Themattress assembly200 further includes one or more additional support and/or comfort layers240,250,260.

In particular, themattress assembly200 ofFIG. 5 includes two support and/or comfort layers240,260 disposed between thecoil layer220 and zonedcushioning layer230. An additional support and/orcomfort layer250 is also disposed above the zonedcushioning layer230. Thus, as illustrated inFIG. 5, the arrangement and number of support and/or comfort layers240,250,260 can vary depending on the mattress configuration.

FIG. 6 depicts amattress assembly300 according to yet another embodiment. As shown inFIG. 6, themattress assembly300 includes abase layer310, acoil layer320, and a zonedcushioning layer330. Themattress assembly300 further includes one or more additional support and/or comfort layers340,350.

In particular, themattress assembly300 ofFIG. 6 includes one support and/orcomfort layer340 disposed between thecoil layer320 and zonedcushioning layer330. An additional support and/orcomfort layer350 is also disposed above the zonedcushioning layer330. Thus, as illustrated inFIG. 6, the arrangement and number of support and/or comfort layers340,350 can vary depending on the mattress configuration.

Without limitation, it will be appreciated that the zoned cushioning layer of the present disclosure can be incorporated into various types of mattress assemblies and configurations. For instance, the zoned cushioning layer can be incorporated into traditional mattress assemblies and configurations. The zoned cushioning layer can also be incorporated into mattress assemblies that can be folded or rolled into packaging materials. Incorporation of the zoned cushioning layer into other types of mattress assemblies is also within the scope of this disclosure.

It will further be appreciated that any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified. Methods contemplated by the present disclosure include methods of manufacturing a mattress assembly having a base layer, a coil layer, and a zoned cushioning layer. Other methods can also be employed.

References to approximations are made throughout this specification, such as by use of the term “about.” For each such reference, it is to be understood that, in some embodiments, the value, feature, or characteristic may be specified without approximation. For example, where qualifiers such as “about” and “substantially” are used, these terms include within their scope the qualified words in the absence of their qualifiers. All ranges also include both endpoints.

Similarly, in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment.

The claims following this written disclosure are hereby expressly incorporated into the present written disclosure, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims. Moreover, additional embodiments capable of derivation from the independent and dependent claims that follow are also expressly incorporated into the present written description.

Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art, with the aid of the present disclosure, that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. Moreover, the order of the steps or actions of the methods disclosed herein may be changed by those skilled in the art without departing from the scope of the present disclosure. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order or use of specific steps or actions may be modified. The scope of the invention is therefore defined by the following claims and their equivalents.

Claims

1. A mattress assembly, comprising:

a base layer;

a coil layer; and

a zoned cushioning layer, wherein the zoned cushioning layer comprises at least two cushioning members spaced apart along a longitudinal length of the zoned cushioning layer, each of the cushioning members extending laterally across the zoned cushioning layer.

2. The mattress assembly ofclaim 1, wherein the base layer comprises a polyurethane foam or a latex foam.

3. The mattress assembly ofclaim 1, wherein the coil layer comprises a plurality of encased metal coils.

4. The mattress assembly ofclaim 1, wherein the zoned cushioning layer comprises three cushioning members spaced apart along the longitudinal length of the zoned cushioning layer.

5. The mattress assembly ofclaim 1, wherein each of the cushioning members comprises an elastomeric cushioning material.

6. The mattress assembly ofclaim 5, wherein the elastomeric cushioning material comprises a styrene-based copolymer.

7. The mattress assembly ofclaim 1, wherein each cushioning member comprises a plurality of buckling walls that define hollow columns.

8. The mattress assembly ofclaim 1, further comprising a support layer disposed between the coil layer and the zoned cushioning layer.

9. The mattress assembly ofclaim 1, further comprising a comfort layer disposed above the zoned cushioning layer, the comfort layer comprising a memory material.

10. The mattress assembly ofclaim 9, further comprising a support layer disposed between the zoned cushioning layer and the comfort layer.

11. A mattress assembly, comprising:

a base layer;

a coil layer; and

a zoned cushioning layer, wherein the zoned cushioning layer comprises at least three cushioning members spaced apart along a longitudinal length of the zoned cushioning layer, each of the cushioning members extending laterally across the zoned cushioning layer;

wherein a first cushioning member is disposed in a hip region, a second cushioning member is disposed in a shoulder region, and a third cushioning member is disposed in a leg region; and

wherein each cushioning member comprises an elastomeric material that comprises a plurality of buckling walls that define hollow columns.

12. The mattress assembly ofclaim 11, wherein the base layer comprises a polyurethane foam or a latex foam.

13. The mattress assembly ofclaim 11, wherein the coil layer comprises a plurality of encased metal coils.

14. The mattress assembly ofclaim 11, wherein the elastomeric cushioning material comprises a styrene-based copolymer.

15. The mattress assembly ofclaim 11, further comprising a support layer disposed between the coil layer and the zoned cushioning layer.

16. The mattress assembly ofclaim 11, further comprising a comfort layer disposed above the zoned cushioning layer, the comfort layer comprising a memory material.

17. The mattress assembly ofclaim 16, further comprising a support layer disposed between the zoned cushioning layer and the comfort layer.

18. A mattress assembly, comprising:

a base layer;

a coil layer;

a first support layer;

a zoned cushioning layer, wherein the zoned cushioning layer comprises at least three cushioning members spaced apart along a longitudinal length of the zoned cushioning layer, each of the cushioning members extending laterally across the zoned cushioning layer, wherein a first cushioning member is disposed in a hip region, a second cushioning member is disposed in a shoulder region, and a third cushioning member is disposed in a leg region, and wherein each cushioning member comprises an elastomeric material that comprises a plurality of buckling walls that define hollow columns; and

a comfort layer.

19. The mattress assembly ofclaim 18, wherein the comfort layer comprises a memory material.

20. The mattress assembly ofclaim 18, wherein the elastomeric cushioning material comprises a styrene-based copolymer.