Composite mattresses with air chambers

Patent metadata

Field	Value
Publication number	US-11213139-B2
Application number	US-202117176498-A
Country	US
Kind code	B2
Filing date	Feb 16, 2021
Priority date	Feb 13, 2020
Publication date	Jan 4, 2022
Grant date	Jan 4, 2022

Abstract

A composite mattress includes a base panel of a cover, a base layer, a pressurizable layer, an intermediate layer, a top layer, and a top panel of the cover. A foundation, or rail, laterally surrounds the pressurizable layer, the intermediate layer, and the top layer. A periphery of the cover laterally surrounds the foundation and, with the top panel and the base panel, encases the other components of the composite mattress. A coiled spring layer may also be included in the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples customize a mattress by selecting one or more tops from a plurality of available for use with one or more bases from a plurality of available bases.

First claim

What is claimed:

1. A mattress, comprising:
a bottom cover including a cover base with a peripheral edge;
a cover periphery extending from the peripheral edge of the bottom cover, and a cover receptacle defined by the cover periphery and the cover base;
a foundation within the cover receptacle, the foundation including at least one peripheral foundation member located adjacent to the cover periphery and defining a foundation receptacle;
a base layer within the foundation receptacle;
a coiled spring layer over the base layer and within the foundation receptacle;
a pressurizable layer over the base layer and within the foundation receptacle;
an intermediate layer on the pressurizable layer;
a top layer on the intermediate layer and comprising a plurality of compressible walls defining an array of buckling columns; and
a top cover on the top layer and the foundation.

2. The mattress of claim 1 , wherein at least a portion of the cover periphery is continuous with the cover base and further comprising:
a coupler at or adjacent to a top edge of the cover periphery, the coupler coupling the top cover to the cover periphery.

3. The mattress of claim 1 , wherein the pressurizable layer comprises a plurality of air chambers.

4. The mattress of claim 1 , wherein the plurality of compressible walls of the top layer is defined from an elastomeric material.

5. The mattress of claim 4 , wherein the elastomeric material comprises an extended triblock copolymer.

6. The mattress of claim 1 , wherein the coiled spring layer is located over the pressurizable layer.

7. The mattress of claim 1 , wherein the coiled spring layer is located between the base layer and the pressurizable layer.

8. The mattress of claim 1 , wherein:
the bottom cover, a portion of the cover periphery, the foundation, the base layer, the pressurizable layer, and at least a portion of the intermediate layer comprise a mattress base of the mattress;
the top layer and the top cover comprise a modular top of the mattress.

9. The mattress of claim 8 , wherein the modular top of the mattress further comprises:
an upper foundation laterally surrounding at least a portion of the top layer.

10. The mattress of claim 8 , wherein the modular top further comprises:
a web of elastomeric material defining a structural grid defining a plurality of polygonal openings superimposed with the top layer.

11. The mattress of claim 8 , wherein the modular top further comprises:
a pressure sensor associated with the top layer.

12. A mattress, comprising:
a pressurizable layer;
a coiled spring layer;
a top layer over the pressurizable layer and the coiled spring layer and comprising a plurality of compressible walls defining an array of buckling columns; and
a cover over the top layer.

13. The mattress of claim 12 , wherein the pressurizable layer comprises an array of independently pressurizable air chambers.

14. The mattress of claim 12 , wherein the pressurizable layer is located over the coiled spring layer.

15. A cushioning method, comprising:
positioning at least part of an individual's body on a cushioning layer comprising a plurality of compressible walls defining an array of buckling columns to support at least the part of the individual's body; and
individually pressurizing at least one air chamber of an array of air chambers to define a contour of the cushioning layer.

16. The cushioning method of claim 15 , further comprising:
adjusting pressure within at least one air chamber of the array of air chambers after positioning at least part of the individual's body on the cushioning layer.

17. The cushioning method of claim 16 , wherein adjusting pressure comprises adjusting pressure in accordance with a program.

18. A method for personalizing a mattress, comprising:
providing a mattress base, including:
pressurizable layer;
a base cover with a bottom that extends over a base of the pressurizable layer and a periphery that laterally surrounds the pressurizable layer; and
a base coupler on the periphery of the base cover; and

selecting a modular top from a plurality of modular tops compatible with the mattress base, the modular top including:
a top layer comprising a plurality of compressible walls defining an array of buckling columns;
a top cover with a top that extends over the top layer and a periphery that laterally surrounds the top layer; and
a top coupler on the periphery of the top cover; and

positioning the modular top on the mattress base; and
coupling the base coupler and the top coupler to secure the modular top to the mattress base.

19. The method of claim 18 , wherein selecting the modular top comprises selecting the modular top from a plurality of modular tops having different thicknesses.

20. The method of claim 18 , wherein selecting the modular top comprises selecting the modular top from a plurality of modular tops having different cushioning characteristics.

21. The method of claim 18 , wherein:
selecting the modular top comprises selecting a pair of modular tops for use with the mattress base;
positioning the modular top comprises:
positioning a first modular top over a first half of the mattress base; and
positioning a second modular top over a second half of the mattress base; and

coupling the base coupler and the top coupler comprises securing the first modular top and the second modular top to the mattress base.

Assignees

• Purple Innovation Llc
• Purple Innovations Llc

Inventors

• Harris Brock Keith
• Grutta James T
• Pearson Brett
• Pierce Michael Allen

Classifications

• A47C27/18

  in combination with inflatable bodies · CPC title

• A47C27/15

  consisting of two or more layers (A47C27/16 takes precedence) · CPC title

• A47C27/10 Primary

  with two or more independently-fillable chambers · CPC title

• A47C27/083 Primary

  with pressure control, e.g. with pressure sensors · CPC title

• A47C27/056

  with different layers of foamed material · CPC title