Mattresses including an elastomeric cushioning element and a pocketed coil layer and related methods

Patent metadata

Field	Value
Publication number	US-11317733-B2
Application number	US-201715816983-A
Country	US
Kind code	B2
Filing date	Nov 17, 2017
Priority date	Nov 17, 2017
Publication date	May 3, 2022
Grant date	May 3, 2022

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.

First claim

What is claimed is:

1. A mattress assembly, comprising:
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;
a stabilization layer comprising a scrim fabric;
an elastomeric cushioning element disposed over the stabilization layer, an elastomeric material of the elastomeric cushioning element seeping through the stabilization layer to secure an upper surface of the stabilization layer to the elastomeric cushioning element, the elastomeric material exposed and defining a reduced slip surface or a non-slip surface on a lower surface of the stabilization layer, the reduced slip surface or the non-slip surface positioned against an upper surface of the upper layer; and
an outer covering encasing the base layer, the coil layer, the upper layer, the stabilization layer, and the elastomeric cushioning element.

2. The mattress assembly of claim 1 , wherein:
the coil layer has a thickness of about 6.00 inches to about 8.00 inches; and
the elastomeric cushioning element has a thickness of about 2.0 inches to about 4.5 inches.

3. The mattress assembly of claim 2 , wherein:
the coil layer has a thickness of about 7.50 inches; and
the elastomeric cushioning element has a thickness of about 4.0 inches.

4. The mattress assembly of claim 1 , further comprising:
one or more side panels extending around outer perimeters of the base layer and the upper layer, the outer covering also encasing the one or more side panels.

5. The mattress assembly of claim 1 , wherein the base layer and the upper layer both comprise a polyurethane foam.

6. The mattress assembly of claim 1 , wherein the stabilization layer provides a slip-resistant surface against the upper layer.

7. The mattress assembly of claim 1 , wherein the stabilization layer is secured to the upper layer.

8. The mattress assembly of claim 7 , wherein the stabilization layer is adhesively secured to the upper layer.

9. The mattress assembly of claim 1 , wherein the base layer has a thickness of about 0.75 inches to about 1.50 inches and the upper layer has a thickness of about 0.25 inches to about 0.75 inches.

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 comprising:
a plurality of nested casings; and
a single coil disposed within an innermost casting of the plurality of nested casings;

an upper layer disposed over the coil layer;
a stabilization layer comprising a scrim fabric; and
at least one elastomeric cushioning element disposed over the stabilization layer, an elastomeric material of the at least one elastomeric cushioning element seeping through the scrim fabric of the stabilization layer to secure an upper surface of the stabilization layer to the at least one elastomeric cushioning element and to provide a non-slip surface or a reduced slip surface on a lower surface of the scrim fabric, the non-slip surface or the reduced slip surface positioned against an upper surface of the upper layer; and
an outer covering encasing the base layer, the coil layer, the upper layer, the stabilization layer, and the at least one elastomeric cushioning element.

11. The mattress assembly of claim 10 , wherein the plurality of pocketed coils are oriented next to each other in a grid pattern.

12. The mattress assembly of claim 11 , wherein the at least one elastomeric cushioning element comprises a grid of interconnected walls defining hollow buckling columns.

13. The mattress assembly of claim 10 , wherein the plurality of nested casings of each pocketed coil comprises:
a first casing; and
a single second casing disposed within the first casing, with the single coil being disposed within the second casing.

14. The mattress assembly of claim 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.

15. The mattress assembly of claim 10 , wherein the at least one elastomeric cushioning element covers a portion of an upper surface of the upper layer.

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 including positioning a stabilization layer and a non-slip surface or a reduced slip surface formed by elastomeric material on a lower surface of the stabilization layer against the upper layer, the stabilization layer being located on a bottom surface of the elastomeric cushioning element, the elastomeric material of the elastomeric cushioning element securing the elastomeric cushioning element to an upper surface of the stabilization layer; and
encasing the base layer, the coil layer, the upper layer, the stabilization layer, and the elastomeric cushioning element in an outer casing.

17. The method of claim 16 , further comprising:
individually disposing each coil of the coil layer within a first casing; and
individually disposing the first casing within a second casing.

18. The method of claim 17 , wherein individually disposing each coil of the coil layer within the first casing comprises individually disposing the coil within a polypropylene bag.

19. The method of claim 18 , wherein individually disposing the first casing within the second casing comprises individually disposing the first casing within the polypropylene bag.

20. The method of claim 16 , further comprising:
securing the stabilization layer to the upper layer.

Assignees

• Purple Innovation Llc

Inventors

• Pearce Tony M
• Hamilton Lars Christen
• Wheadon Tanner Rick

Classifications

• A47C27/148

  of different resilience · CPC title

• A47C27/146

  on the outside surface of the mattress or cushion · CPC title

• A47C27/15

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

• A47C27/20 Primary

  with springs moulded in, or situated in openings in foamed material · CPC title

• A47C27/056 Primary

  with different layers of foamed material · CPC title