US20220287469A1 - Adjustable mattress side rails - Google Patents

Abstract

A side rail of a mattress that may be used with an adjustable bed may include a main body that facilitate adjustment of the mattress while maximizing contact between a bottom of the mattress and an upper supporting surface of an adjustable bedframe. More specifically, the main body of the side rail may include a top edge with one or more upper recesses therein and a bottom edge with one or more lower recesses therein. An upper insert may be secured within each upper recess, while a lower insert may be secured within each lower recess. The material from which each upper insert and lower insert is formed may be more compressible than a material from which the main body of the side rail is formed to enable the side rail and the mattress to bend with the supporting surface of the adjustable bedframe.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• A claim for priority to the Mar. 9, 2021 filing date of U.S. Provisional Patent Application No. 63/158,753, titled ADJUSTABLE MATTRESS SIDE RAILS (“the '753 Provisional Application”), is hereby made pursuant to 35 U.S.C. § 119(e). The entire disclosure of the '753 Provisional Application is hereby incorporated herein.
TECHNICAL FIELD
• This disclosure relates generally to internal side edges, or side rails, for mattresses and, more specifically, to side rails for mattresses that may be used with adjustable beds. Even more specifically, this disclosure relates to side rails with main bodies that impart lateral structure to a mattress of which they are a part and compressible inserts that facilitate adjustment of the mattress while maximizing contact between a bottom of the mattress and an upper supporting surface of an adjustable bedframe. This disclosure also relates to mattresses, to adjustable beds, and to associated methods.
RELATED ART
• Adjustable beds provide for adjustment of the mattresses thereon and of each individual laying on the mattress. An adjustable bed typically bends at two or more locations across its width to provide three sections that may be oriented for a variety of purposes. By way of example, an upper, or head, section of a mattress on an adjustable bed may be oriented to position an individual's head and back in a somewhat upright orientation, in more reclined orientations, or in a substantially horizontal orientation. As another example, a lower, or foot, section of a mattress on an adjustable bed may be oriented to position an individual's feet between inclined, horizontal, and reclined orientations. An intermediate section of the mattress on an adjustable bed may provide a transition between the head section and the foot section.
• Conventionally, adjustable beds have found wide use in hospitals, care centers, and at other locations where individuals may need assistance in sitting up as they convalesce, where it may be desirable to occasionally change an individual's orientation as he or she lays in bed, or for other purposes. Individuals also use adjustable beds at home, as they many people enjoy laying in non-flat orientations as they rest or sleep. In addition, many people have found adjustable mattresses to provide certain additional benefits in helping them obtain a good night's rest, as well as health benefits, including, without limitation, the ability to improve breathing during sleep (e.g., by elevating the individual's head, neck, and back, etc.).
• As a mattress is adjusted, or bent, by an adjustable bedframe, the side rails of the mattress are compressed at locations where the top of the mattress is bent concavely and stretched at locations where the top of the mattress is bent convexly. Conventional mattresses, however, resist such bending, compression, and stretching somewhat. As a result, the bottom of a conventional mattress usually does not conform well to the upper supporting surface of an adjustable bedframe, particularly at corners where the upper supporting surface of the adjustable bedframe is bent concavely, where the bottom of the mattress remains suspended above the concavely bent upper supporting surface of the adjustable bedframe.
• One attempted solution has been to provide mattress-retaining brackets at the head and foot ends of adjustable bedframes. Due to their locations, such brackets are unable to influence bending at intermediate locations along the length of the mattress. Other attempted solutions have been to provide weakened regions (e.g., cutouts, accordion-like features, etc.) along the internal side edges, or side rails, of the mattress. Although weakened regions reduce the mattress's resistance to bending, they also reduce the structural integrity of the side rails.
SUMMARY
• In various embodiments, a side rail of an adjustable mattress according to this disclosure has a configuration that enables its bottom edge and, thus, a bottom of a mattress of which it is a part, to conform to bends in an upper supporting surface of an adjustable bedframe.
• A side rail according to this disclosure may include a main body with at least one upper recess and at least one lower recess, an upper insert within the at least one upper recess, and a lower insert within the at least one lower recess. In some embodiments, the side rail may include a plurality of upper recesses and corresponding upper inserts and/or a plurality of lower recesses and corresponding lower inserts.
• Each upper recess may extend downwardly into a top edge of the main body, partially into the height of the main body, and across an entirety of a width of the main body. Each lower recess may extend upwardly into a bottom edge of the main body, partially into the height of the main body, and across an entirety of a width of the main body. Without limitation, an upper recess may have the shape of a triangular prism, a substantially triangular prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), a trapezoidal prism, a substantially trapezoidal prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), or the like. A lower recess may have the shape of a triangular prism, a substantially triangular prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), a trapezoidal prism, a substantially trapezoidal prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), a rectangular prism, a substantially rectangular prism (accounting for more radiused or truncated corners, curvatures in surfaces, etc.), or the like.
• The shape, dimensions, and location of each upper recess and each lower recess in the main body of a side rail may enable the upper recess and/or lower recess to accommodate bending of a mattress of which the side rail is a part, as well as enable a bottom of the mattress to maintain optimal contact with an upper supporting surface of an adjustable bedframe that carries the mattress. More specifically, each upper recess may be located at a position where an upper supporting surface of the adjustable bedframe and, thus, a top of a mattress thereon are expected to be bent at a concave angle. Each lower recess may be located at a position where the upper supporting surface of the adjustable bedframe and the top of the mattress thereon are expected to be bent at a convex angle.
• The main body may comprise a material having a rigidity that imparts the side rail with sufficient structural integrity to laterally support a remainder of the mattress of which the side rail is a part. The material of the main body may also be compressible to prevent it from detracting from the overall compressibility and comfort provided by the mattress of which the side rail is a part.
• An upper insert may be provided in each upper recess of the side rail, while a lower insert may be provided in each lower recess of the side rail. Each upper insert may substantially fill its corresponding upper recess. Thus, each upper insert may have a shape or configuration that complements, is the same as, or is substantially the same as a shape or configuration of the upper recess in which the upper insert is positioned. Each upper insert may be secured within its corresponding upper recess in a suitable manner (e.g., with a suitable cement or other adhesive material, etc.). Each lower insert may substantially fill its corresponding lower recess. Thus, each lower insert may have a shape or configuration that complements, is the same as, or is substantially the same as a shape or configuration of the lower recess in which the lower insert is positioned. Each lower insert may be secured within its corresponding lower recess in a suitable manner (e.g., with a suitable cement or other adhesive material, etc.).
• A shape of each upper insert and each lower insert and a material from which each upper insert and each lower insert is formed may enables the side rail to readily flex when the mattress of which it is a part is bent in a corresponding direction. For example, the shape and material of each upper insert may enable the side rail to readily flex when a top of the mattress is bent concavely at a location where the upper insert is located. As another example, the shape and material of each lower insert may enable the side rail to readily flex when a top of the mattress is bent convexly at a location where the lower insert is located. Without limitation, the shape of each upper insert may be a triangular prism, a substantially triangular prism, or the like, while the shape of each lower insert may be a triangular prism, a substantially triangular prism, a trapezoidal prism, a substantially trapezoidal prism, a rectangular prism, a substantially rectangular prism, or the like.
• The material from which each upper insert and each lower insert is formed may be readily compressible, but have sufficient rigidity to impart the side rail with acceptable structural integrity. By way of example only, each upper insert and each lower insert may comprise a compressible, resilient material. The compressible, resilient material may comprise a foam.
• In another aspect, this disclosure includes mattresses that include side rails according to this disclosure. The side rails of such a mattress may, along with a base, a head rail, and a foot rail, define a foundation for a cushioning element of the mattress. More specifically, the elements of the foundation may define a receptacle for the cushioning element. The cushioning element may comprise coil springs, pressurizable bladders, memory foam, or any other suitable cushioning element for a mattress, or a combination of cushioning elements.
• Additionally, such a mattress may include a gel cushion, such as those disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750, the entire disclosures of which are hereby incorporated herein. Such a gel cushion may include a plurality of resiliently compressible interconnected or intersecting walls defining an array of interconnected, resiliently buckling columns, with a void in each column. Stated another way, the interconnected or intersecting walls may define an array of hollow columns, or voids. Such a gel cushion may be formed from any of a variety of compressible, resilient materials, including cushioning foams and elastomeric materials, such as the extended A B A triblock copolymers disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein.
• In addition, the mattress may include a cover over the foundation, cushioning element, and any gel cushion over the foundation and cushioning element.
• As another aspect, adjustable beds are disclosed. An adjustable bed of this disclosure includes an adjustable bedframe and a mattress that includes side rails according to this disclosure.
• Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosure, should be apparent to those of ordinary skill in the art through consideration of the preceding disclosure, the description that follows, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
• In the drawings:
• FIG. 1 is a side view of an embodiment of a side rail that may be included in an adjustable mattress;
• FIG. 2 is an enlarged view of the upper recesses and upper inserts of the embodiment of the side rail shown inFIG. 1;
• FIG. 3 is a side view of the embodiment of the side rail shown inFIG. 1, with the top edge of the side rail bent concavely between the two upper recesses and upper inserts shown inFIG. 2;
• FIG. 4A is a perspective view another embodiment of a side rail that may be included in an adjustable mattress;
• FIG. 4B is a top view of the embodiment of the side rail shown inFIG. 4A;
• FIG. 4C is a side view of the embodiment of the side rail shown inFIG. 4A;
• FIG. 4D is an end view of the embodiment of the side rail shown inFIG. 4A;
• FIG. 5A is a perspective view of yet another embodiment of a side rail that may be included in an adjustable mattress;
• FIG. 5B is a top view of the embodiment of the side rail shown inFIG. 5A;
• FIG. 5C is a side view of the embodiment of the side rail shown inFIG. 5A;
• FIG. 5D is a bottom view of the embodiment of the side rail shown inFIG. 5A; and
• FIG. 6 is a perspective view of the interior of an embodiment of a mattress that includes the embodiment of the side rail shown inFIGS. 4A-4D.
DETAILED DESCRIPTION
• With reference toFIGS. 1 and 2, an embodiment of aside rail10 for an adjustable mattress (not shown inFIG. 1 orFIG. 2) is depicted. Theside rail10 includes amain body20 with atop edge22, abottom edge24, ahead end26, and afoot end28. One or moreupper recesses30 may open to thetop edge22 of themain body20 and extend toward thebottom edge24 of themain body20. One or morelower recesses40 may open to thebottom edge24 of themain body20 and extend toward thetop edge22 of themain body20. Anupper insert60 may be provided in eachupper recess30. Alower insert70 may be provided in eachlower recess40.
• A height of themain body20 and, thus, of theside rail10 extends between thetop edge22 andbottom edge24 of themain body20. Themain body20 also includes an interior surface21, which faces an interior of a mattress (not shown inFIG. 1 orFIG. 2) of which theside rail10 is a part, as well as anexterior surface29, which is opposite from the interior surface21 and faces outwardly when theside rail10 is assembled with other components of the mattress. Both the interior surface21 and theexterior surface29 extend between thetop edge22 and thebottom edge24 of theside rail20. A width of themain body20 and, thus, of theside rail10 extends between the interior surface21 andexterior surface29 of themain body20.
• Themain body20 may be formed from a material having a rigidity that imparts theside rail10 with sufficient structural integrity to laterally support a remainder of the mattress (not shown inFIG. 1 orFIG. 2) of which theside rail10 is a part. The material of themain body20 may also be compressible to prevent it from detracting from the overall compressibility and comfort provided by the mattress of which theside rail10 is a part. In a specific embodiment, themain body20 may comprise a so-called “structured foam,” which may comprise a compressible foam material with an indentation load deflection (ILD) rating of about 35 to about 65 (e.g., 40, 45, 50, 55, 60, 65, etc.). An ILD rating is the amount of pressure, converted to weight in pounds, it takes to indent a circular area of 50 square inches (i.e., lbs/50 in²) over a four inch thick piece of the structured foam by 25% (i.e., one inch). In a specific embodiment, themain body20 may comprise a high density polyethylene (HDPE) foam.
• Eachupper recess30 may extend downwardly into thetop edge22 of themain body20, partially into the height of themain body20, and across an entirety of the width of themain body20. Eachupper recess30 may include: a base32 adjacent to but spaced apart from thebottom edge24 of themain body20; ahead surface34 extending at a non-perpendicular angle to thetop edge22, from thetop edge22 to thebase32 and toward thefoot end28 of themain body20; and afoot surface36 extending at a non-perpendicular angle to thetop edge22, from thetop edge22 to thebase32 and toward thehead end26 of themain body20. Thebase32 of theupper recess30 may be defined by a junction between thehead surface34 and thefoot surface36 of theupper recess30. In some embodiments, that junction may be radiused (e.g., it may comprise an arc of a circle, etc.) or otherwise rounded. Alternatively, thebase32 of theupper recess30 may be elongated. Anelongated base32 may be substantially parallel to thebottom edge24 of themain body20.
• Eachupper recess30 may be positioned at a location along the length of themain body20 of theside rail10 where the top of the mattress (not shown inFIG. 1 orFIG. 2) is expected to be bent concavely. For example, eachupper recess30 may be positioned at a location that will be superimposed over a joint between a head section and an intermediate section of an adjustable bedframe (not shown inFIG. 1 orFIG. 2). Alternatively, a plurality ofupper recesses30 may be positioned locations that will be superimposed with an area on both sides of a joint between the head section and the intermediate section of the adjustable bedframe. As illustrated byFIGS. 1 and 2, theupper recesses30 are positioned between or at a transition between ahead portion12 of theside rail10 and anintermediate portion14 of theside rail10.
• Theside rail10 may include amain body20 with a plurality ofupper recesses30. In the embodiment shown inFIGS. 1 and 2, theside rail10 may include twoupper recesses30. In the embodiment ofside rail10′ shown inFIGS. 4A-4D, themain body20′ may include fourupper recesses30′. Regardless of how manyupper recesses30 are included, they may be grouped together.
• With continued reference toFIGS. 1 and 2, eachlower recess40 in thebottom edge24 of themain body20 of theside rail10 extends upwardly from thebottom edge24 into themain body20, partially into the height of themain body20, and across an entirety of the width of themain body20. Eachlower recess40 may include: a top42 adjacent to but spaced apart from thetop edge22 of themain body20; ahead surface44 extending at an angle (e.g., a non-perpendicular angle, a perpendicular angle, etc.) to thebottom edge24, from thebottom edge24 to the top42 of themain body20 and, in embodiments where the angle is a non-perpendicular angle, toward thefoot end28 of themain body20; and afoot surface46 extending at an angle (e.g., a non-perpendicular angle, a perpendicular angle, etc.) to thebottom edge24, from thebottom edge24 to the top42 and, in embodiments where the angle is a non-perpendicular angle, toward thehead end26 of themain body20. The top42 of thelower recess40 may be defined by a junction between thehead surface44 and thefoot surface46 of theupper recess40. In some embodiments, that junction may be radiused or otherwise rounded. Alternatively, the top42 of thelower recess40 may be elongated. An elongated top42 may be substantially parallel to thetop edge22 of themain body20.
• Eachlower recess40 may be positioned at a location along the length of themain body20 of theside rail10 where the top of the mattress (not shown inFIG. 1 orFIG. 2) is expected to be bent convexly. For example, eachlower recess40 may be positioned at a location that will be superimposed over a joint between an intermediate section and a foot section of an adjustable bedframe (not shown inFIG. 1 orFIG. 2). Alternatively, a plurality oflower recesses40 may be positioned at locations that will be superimposed with an area on both sides of a joint between the intermediate section and the foot section of the adjustable bedframe. As illustrated byFIG. 1, thelower recess40 is positioned between or at a transition between theintermediate portion14 of theside rail10 and afoot portion16 of theside rail10.
• Theside rail10 may include one or more lower recesses40. In the embodiment depicted byFIGS. 1 and 2, theside rail10 may include a singlelower recess40. In the embodiment ofside rail10′ shown inFIGS. 4A-4D, themain body20′ may include twolower recesses40′. Regardless of how manylower recesses40 are included, they may be grouped together.
• Anupper insert60 may be provided in eachupper recess30 of themain body20 of theside rail10. Eachupper insert60 may substantially fill its correspondingupper recess30 and include atop edge62 that is coplanar or substantially coplanar with thetop edge22 of themain body20, abase64 adjacent to thebase32 of the correspondingupper recess30, ahead surface66 adjacent to thehead surface34 of the correspondingupper recess30, and afoot surface68 adjacent to thefoot surface36 of the correspondingupper recess30. An entirety of each of thebase64,head surface66, andfoot surface68 of theupper insert60 may contact and be secured to (e.g., with a suitable cement or other adhesive material, etc.) its correspondingbase32,head surface34, andfoot surface36 of the correspondingupper recess30. Thus, a shape or configuration of eachupper insert60 may complement, be the same as, or be substantially the same as a shape or configuration of theupper recess30 in which theupper insert60 is positioned.
• Alower insert70 may be provided in eachlower recess40 of themain body20 of theside rail10. Eachlower insert70 may substantially fill its correspondinglower recess40 and include abottom edge72 that is coplanar or substantially coplanar with thebottom edge24 of themain body20 of theside rail10, a top74 adjacent to the top42 of the correspondinglower recess40, ahead surface76 adjacent to thehead surface44 of the correspondinglower recess40, and afoot surface78 adjacent to thefoot surface46 of the correspondinglower recess40. An entirety of each of the top74,head surface76, andfoot surface78 of thelower insert70 may contact and be secured to (e.g., with a suitable cement or other adhesive material, etc.) its corresponding top42,head surface44, andfoot surface46 of the correspondinglower recess40. Thus, a shape or configuration of eachlower insert70 may complement, be the same as, or be substantially the same as a shape or configuration of thelower recess40 in which thelower insert70 is positioned.
• A shape of eachupper insert60 and eachlower insert70 and a material from which eachupper insert60 and eachlower insert70 is formed may enable theside rail10 to readily flex when the mattress (not shown inFIG. 1 orFIG. 2) of which it is a part is bent in a corresponding direction. For example, the shape and material of eachupper insert60 may enable theside rail10 to readily flex when a top of the mattress is bent concavely at a location where theupper insert60 is located. As another example, the shape and material of eachlower insert70 may enable theside rail10 to readily flex when a top of the mattress is bent convexly at a location where thelower insert70 is located.
• The material from which eachupper insert60 and eachlower insert70 is formed may be readily compressible, but have sufficient rigidity to impart theside rail10 with acceptable structural integrity. By way of example only, eachupper insert60 and eachlower insert70 may comprise a compressible, resilient material. The compressible, resilient material may comprise a foam. The compressible, resilient material of eachupper insert60 and eachlower insert70 may be more readily compressible than the compressible, resilient material of themain body20 to which theupper insert60 andlower insert70 are secured. For example, an ILD rating of the compressible, resilient material of eachupper insert60 and eachlower insert70 of aside rail10 may be less than an ILD rating of the compressible, resilient material from which themain body20 of theside rail10 is formed. An ILD rating of the compressible resilient material may be 18 to about 24 (e.g., 18, 20, 22, 24, etc.). In a specific embodiment, eachupper insert60 and/or eachlower insert70 may be formed from a medium density polyethylene (MDPE) foam.
• WhileFIGS. 1 and 2 show eachupper recess30 with anupper insert60 therein and eachlower recess40 with alower insert70 therein, one, more than one, or all of theupper recesses30 and/orlower recesses40 may lack a correspondingupper insert60 orlower insert70 and, thus, remain open, comprising a relief cut in themain body20 of theside rail10.
• FIG. 3 shows how theupper inserts60 of an embodiment of aside rail10 may compress and, thus, give way more readily than themain body20 of theside rail10. As illustrated, thetop edge22 of themain body20 of theside rail10 is bent concavely at a location where twoupper recesses30 and their correspondingupper inserts60 are located. While theupper inserts60 compress from between theirhead surfaces66 and their foot surfaces68, shortening theirtop edges62, thetop edge22 of themain body20 remains substantially unbent and otherwise unaffected. Moreover, theupper recesses30 and theupper inserts60 therein control the location at which thebottom edge24 of themain body20 bends and limits the distance along a length of thebottom edge24 along which bending occurs.
• The embodiment ofside rail10′ depicted byFIGS. 4A-4D includes amain body20′ with fourupper recesses30a′,30b′,30c′,30d′ (each also referred to as anupper recess30′) and twolower recesses40a′ and40b′ (each also referred to as alower recess40′). Anupper insert60a′,60b′,60c′,60d′ (each also referred to as anupper insert60′) is secured in place within a correspondingupper recess30a′,30b′,30c′,30d′. Alower insert70a′,70b′ (each also referred to as alower insert70′) is secured in place within a correspondinglower recess40a′,40b′.
• The fourupper recesses30′ and correspondingupper inserts60′ are grouped together at a location where a top of a mattress (not shown inFIGS. 4A-4D) of which theside rail10′ is a part will be bent concavely (e.g., between or at a transition between a head region and an intermediate region along the length, or height, of the mattress, etc.). For example, theupper recesses30′ may be positioned between or at a transition between ahead portion12′ of theside rail10′ and anintermediate portion14′ of theside rail10′. The twolower recesses40′ and correspondinglower inserts70′ are grouped together at a location where a top of the mattress of which theside rail10′ is a part will be bent convexly (e.g., between or at a transition between an intermediate region and a foot region along the length, or height, of the mattress, etc.). For example, thelower recesses40′ may be positioned between or at a transition between theintermediate portion14′ of theside rail10′ and afoot portion16′ of theside rail10′.
• WhileFIGS. 4A-4D show aside rail10′ with eachupper recess30′ including anupper insert60′ therein and eachlower recess40′ including alower insert70′ therein, one, more than one, or all of theupper recesses30′ and/orlower recesses40′ may lack a correspondingupper insert60′ orlower insert70′ and, thus, remain open, comprising a relief cut in themain body20′ of theside rail10′.
• FIGS. 5A-D depict yet another embodiment of aside rail10″. Theside rail10″ includes amain body20″ with at least oneupper recess30″ (fiveupper recesses30a″,30b″,30c″,30d″,30e″ are depicted) in thetop edge22″ of themain body20″. In addition, theside rail10″ includes at least onelower recess40″ (a singlelower recess40″is depicted) in abottom edge24″ of themain body20″. As depicted, eachupper recess30″ andlower recess40″ may have the same or substantially the same dimensions. Alternatively, the dimensions of the upper recess(es)30″ and lower recess(es)40″ may differ from each other.
• The upper recesses30″ and/orlower recesses40″ of theside rail10″ may be grouped. As shown inFIGS. 5A-5D, a first group31A″ ofupper recesses30a″,30b″,30c″ may be located between or at a transition between ahead region12″ and anintermediate region14″ of theside rail10″. A second group31B″ ofupper recesses30d″,30e″ may be positioned between or at a transition between theintermediate region14″ of theside rail10″ and afoot region16″ of theside rail10″. Thelower recess40″ may also be positioned between or at a transition between theintermediate region14″ and thefoot region16″, closer to thefoot end28″ of themain body12″ of theside rail10″ than the second group31B″ ofupper recesses30d″,30e″. Alternatively, thelower recess40″ may be positioned at an intermediate location along the length of thefoot portion16″ of theside rail10″.
• WhileFIGS. 5A-5D show aside rail10″ with eachupper recess30″ andlower recess40″lacking an insert and, thus, remaining open, comprising a relief cut in themain body20″ of theside rail10″, one, more than one, or all of theupper recesses30″ and/orlower recesses40″ may include an insert.
• FIGS. 4A-4D andFIGS. 5A-5D illustrate specific shapes and dimensions for the embodiments of side rails10′ and10″ depicted thereby and the elements of the depicted embodiments of the side rails10′ and10″, including themain body20′,20″, eachupper recess30′,30″,upper insert60′,60″, lower,recess40′,40″, andlower insert70′,70″. AlthoughFIGS. 4A-4D andFIGS. 5A-5D provide specific shapes and dimensions for each of the features of the illustrated side rails10′ and10″, the details provided byFIGS. 4A-4D andFIGS. 5A-5D are merely representative.
• Turning now toFIG. 6, an embodiment of amattress100 is depicted with a side rails10′ (see alsoFIGS. 4A-4D) positioned along eachside102 of themattress100. The side rails10′, along with a base (not shown), a head rail (not shown), and a foot rail (not shown), may define at least part of afoundation110 of themattress100. Thefoundation110 may define a receptacle (not shown) for at least one cushioning element (not shown) of the mattress.
• The cushioning element (not shown) of themattress100 may comprise coil springs (not shown) (see, e.g., U.S. Patent Application Publication US 2019/0150632 A1, the entire disclosure of which is hereby incorporated herein), one or more pressurizable bladders (see, e.g., U.S. Pat. No. 11,213,139, the entire disclosure of which is hereby incorporated herein), memory foam, and/or any other suitable cushioning element for a mattress, or a combination of cushioning elements.
• Anintermediate layer120 may be positioned over thefoundation110. Atop cushioning element130 may be positioned over theintermediate layer120. Thetop cushioning element130 may comprise a gel cushion (not shown). The gel cushion of thetop cushioning element130 may include a plurality of resiliently compressible intersecting or interconnected walls defining an array of interconnected, resiliently buckling columns, with a void in each column, as described by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750. Stated another way, the interconnected or intersecting walls may define an array of hollow columns, or voids. Such a gel cushion may be formed from any of a variety of compressible, resilient materials, including cushioning foams and elastomeric materials, such as the extended A-B-A triblock copolymers described by U.S. Pat. Nos. 6,413,458, 6,797,765, and 7,964,664. While such a gel cushion may extend to the periphery of the inner assembly of themattress100, such a gel cushion may be surrounded by foam edge pieces135. Although not shown inFIG. 6, the depicted inner assembly of themattress100 may be enclosed within a mattress cover.
• InFIG. 6, aside rail10′ of themattress100 is shown in a bent arrangement, in which a top104 of themattress100 and thetop edge22′ (FIGS. 4A-4C) of themain body20′ of theside rail10′ are bent concavely at a location between ahead region106 of themattress100 and anintermediate region107 of themattress100. The upper inserts60′ of theside rail10′, especiallyupper inserts60a′ and60b′, are shown in compressed states. In addition, the top104 of themattress100 and thetop edge22′ of themain body20′ of theside rail10′ are bent convexly at a location between theintermediate region107 and afoot region108 of themattress100. The lower inserts70′ of theside rail10′, particularly thelower insert70a′, is in a compressed state.
• In addition to illustrating an embodiment of aside rail10′ and an embodiment of amattress100,FIG. 6 depicts an embodiment of anadjustable bed200, with themattress100 resting upon an adjustable bedframe210. The adjustable bedframe210 may include asupport surface212 that includes a plurality ofsupport elements214,216, and218. More specifically, thesupport surface212 may include ahead support element212, anintermediate support element214, and afoot support element216. As illustrated, at least one concavely bending joint215 may be located between thehead support element212 and theintermediate support element216. At least one convexly bending joint217 may be located between theintermediate support element216 and thefoot support element218. Specifically, the adjustable bedframe210 may comprise the PURPLE POWERBASE adjustable bedframe available from Purple Innovation, LLC, of Lehi, Utah. See, e.g., U.S. Patent Application Publication US 2018/0168359 A1, the entire disclosure of which is hereby incorporated herein. Of course, a bed according to this disclosure may include any other embodiment of adjustable bedframe with support elements and joints that differ from those (in number, location, etc.) shown inFIG. 6, as well as a mattress with side rails that include upper and lower recesses and upper and lower inserts that are positioned for use with the arrangement of support elements and joints of the adjustable bedframe.
• Although the preceding disclosure provides many specifics, these should not be construed as limiting the scope of any of the claims that follow, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, and of their elements and features, may be devised which do not depart from the spirit or scope of any of the claims. Features from different embodiments may be employed in combination. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.

Claims (20)

What is claimed:

1. A side rail for a mattress for an adjustable bed, comprising:

a main body comprising a first material having a first rigidity and a first compressibility;

at least one upper recess extending into a top edge of the main body, partially into a height of the main body, and across an entirety of a width of the main body, the at least one upper recess including:

a base adjacent to but spaced apart from a bottom edge of the main body;

a head surface extending at a non-perpendicular angle to the top edge, to the base and toward a foot end of the main body; and

a foot surface extending at a non-perpendicular angle to the top edge, to the base and toward a head end of the main body;

at least one upper insert substantially filling the at least one upper recess, the at least one upper insert comprising a second material and including a top edge coplanar with the top edge of the main body, a base adjacent to the base of the at least one upper recess, a head surface adjacent to the head surface of the at least one upper recess, and a foot surface adjacent to the foot surface of the at least one upper recess;

at least one lower recess extending into the bottom edge of the main body, partially into the height of the main body, and across the entirety of the width of the main body, the at least one lower recess including:

a top adjacent to but spaced apart from the top edge of the main body;

a head surface extending at an angle to the bottom surface, to the top; and

a foot surface extending at an angle to the bottom surface, to the top; and

at least one lower insert substantially filling the at least one lower recess, the at least one lower insert comprising a third material and including a bottom edge coplanar with the bottom edge of the main body, a top adjacent to the top of the at least one lower recess, a head surface adjacent to the head surface of the at least one lower recess, and a foot surface adjacent to the foot surface of the at least one lower recess.

2. The side rail ofclaim 1, wherein the at least one upper recess is positioned at a location where an upper surface of the mattress is expected to bend concavely.

3. The side rail ofclaim 1, wherein the at least one lower recess is positioned at a location where the upper surface of the mattress is expected to bend convexly.

4. The side rail ofclaim 1, comprising a plurality of upper recesses, a plurality of upper inserts, a plurality of lower recesses, and a plurality of lower inserts.

5. The side rail ofclaim 4, wherein the plurality of upper recesses and the plurality of upper inserts are grouped together.

6. The side rail ofclaim 4, wherein the plurality of lower recesses and the plurality of lower inserts are grouped together.

7. The side rail ofclaim 1, wherein the base of the at least one upper recess is defined by a junction between the head surface and the foot surface of the at least one upper recess.

8. The side rail ofclaim 1, wherein the base of the at least one upper recess is elongated.

9. The side rail ofclaim 8, wherein the base of the at least one upper recess is substantially parallel to the bottom edge of the main body.

10. The side rail ofclaim 1, wherein the top of the at least one lower recess is defined by a junction between the head surface and the foot surface of the at least one lower recess.

11. The side rail ofclaim 1, wherein the top of the at least one lower recess is elongated.

12. The side rail ofclaim 11, wherein the top of the at least one lower recess is substantially parallel to the top edge of the main body.

13. The side rail ofclaim 1, wherein the second material and the third material are less rigid and more compressible than the first material.

14. A mattress for an adjustable bed, comprising:

a foundation including a base, a head rail, a foot rail, and a pair of side rails defining a receptacle, each side rail including:

a main body formed from a first compressible material and including a top edge with at least one upper recess therein and a bottom edge with at least one lower recess therein;

at least one upper insert formed from a second compressible material secured within the at least one upper recess;

at least one lower insert formed from a third compressible material secured within the at least one lower recess;

a cushioning element within the receptacle defined by the foundation; and

a cover over the cushioning element, the head rail, the foot rail, and the pair of side rails of the foundation.

15. The mattress ofclaim 14, wherein the at least one upper recess and the at least one upper insert has a shape of a triangular prism.

16. The mattress ofclaim 15, wherein the at least one lower recess and the at least one lower insert has a shape of a triangular prism, a trapezoidal prism, or a rectangular prism.

17. The mattress ofclaim 14, wherein the second compressible material and the third compressible material are more compressible than the first material.

18. The mattress ofclaim 14, further comprising:

a gel cushion over the cushioning element and comprising interconnected walls formed from an elastomeric material and defining an array of columnar voids.

19. The mattress ofclaim 14, wherein the cushioning element comprises an array of coils and/or at least one pressurizable bladder.

20. An adjustable bed, comprising:

an adjustable frame including:

a support surface including a plurality of support elements;

at least one concavely bending joint between a head support element and an intermediate support element of the plurality of support elements; and

at least one convexly bending joint between the intermediate support element and a foot support element of the plurality of support elements; and

a mattress on a support surface of the adjustable frame and including:

a foundation including a base, a head rail, a foot rail, and a pair of side rails defining a receptacle, each side rail including:

a main body formed from a first compressible material and including a top edge with at least one upper recess therein, the upper recess positioned over the at least one concavely bending joint of the adjustable frame, and a bottom edge with at least one lower recess therein, the at least one lower recess positioned over the at least one convexly bending joint of the adjustable frame;

at least one upper insert formed from a second compressible material secured within the at least one upper recess;

at least one lower insert formed from a third compressible material secured within the at least one lower recess;

a cushioning element within the receptacle defined by the foundation; and

a cover over the cushioning element, the head rail, the foot rail, and the pair of side rails of the foundation.

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