Mattress with stable upper surface

Abstract

A mattress assembly has a surface that is stabilized to prevent separation of a surrounding edge (e.g., a side surrounding edge, an end surrounding edge) of the mattress assembly from an edge of a main cushion layer. The web fabric strip may overlap each rim and an adjacent portion of the primary cushion layer to stabilize an interface or seam between an edge of the primary cushion layer and the rim positioned against the edge. A method for stabilizing an upper surface of a mattress assembly, and an adjustable bed including a mattress having a stabilized upper surface, are also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 440,591, filed January 23, 2023, entitled “MATTRESSES WITH STABILIZED UPPER SURFACES” (the “’591 Provisional Application”). The entire disclosure of the ’591 Provisional Application is hereby incorporated herein. Technical Field

[0002] The present disclosure relates generally to mattresses, and more particularly to mattresses having a surface that is stabilized to prevent the side rails of the mattress from separating from the side edges of the primary cushion of the mattress. Even more particularly, the present disclosure relates to a mattress having an upper surface stabilized by a scrim positioned above the boundary between the side rails of the mattress and the sides of the primary cushion. Also disclosed are methods for stabilizing the upper surface of a mattress, and an adjustable bed including a mattress having a stabilized upper surface. Related technologies

[0003] Purple Innovation produces mattresses that include a main cushioning layer surrounded by skirts (including side and end skirts). The main cushioning layer of such mattresses includes interconnected walls that define an array of cells or hollow columns. The interconnected walls are formed from a dense gel material that can sink, sag, or "fall" when the main cushioning layer is not restrained by its perimeter. The skirts of such mattresses are typically formed from polyurethane foam that has sufficient rigidity to define the perimeter of the mattress and, when held in place by an adhesive material and the mattress cover, constrain the main cushioning layer peripherally when the mattress is placed on a flat surface, preventing it from sinking, sagging, or falling.

[0004] When a mattress is placed on an adjustable platform and the adjustable platform is moved to impart a specific contour or shape to the mattress, portions of the mattress may not fully settle into the concavely angled joints between adjacent sections of the adjustable platform. While the side edges of the mattress may remain elevated above the concavely angled joints in the adjustable platform, the denser gel of the mattress's main padding may fall into the concavely angled joints, potentially causing the main padding of the mattress to separate from the side edges, which may lead to premature wear of the mattress. Overview

[0005] In one aspect, a mattress having a stable surface is disclosed. The mattress includes a main cushioning layer adjacent to its top surface and a surrounding edge at least partially surrounding the main cushioning layer. The main cushioning layer may be formed from a material having a density exceeding that of the surrounding edge. In some embodiments, the main cushioning layer may include interconnected walls defining a plurality of cells. Each cell and the walls defining the cells may together define a hollow column, which may include a buckling column. The interconnected walls may be formed into a grid defining an array of cells.

[0006] An embodiment of a mattress assembly having a stable surface includes a main padding layer, side skirts, and a backing fabric strip. The mattress assembly may also include end skirts.

[0007] The main cushioning layer includes an upper surface and a lower surface opposite the upper surface. The main cushioning layer also includes a periphery including a first end edge (e.g., a head edge, etc.), a second end edge (e.g., a foot edge, etc.), and side edges. In some embodiments, the main cushioning layer may include an elastic gel. The elastic gel may define interconnected walls that define a plurality of cells. Each cell and the walls defining the cell may together define a hollow column, which may include a buckling column. The interconnected walls may form a grid that defines an array of cells.

[0008] Each side edge may include an upper surface and a lower surface. In addition, each side edge may include an outer edge and an inner edge and an end. The inner edge of each side edge may be positioned adjacent to the side edge of the primary cushioning layer. The upper surface of the side edge may be substantially flush or substantially coplanar with the upper surface of the primary cushioning layer. The side edge may include a compressible elastic foam material. The stiffness or hardness of the material forming the side edge may exceed the stiffness or hardness of the material forming the primary cushioning layer.

[0009] In embodiments where the mattress assembly includes end skirts, each end skirt may include upper and lower surfaces, an outer edge, an inner edge, and an end portion. The inner edge of each end skirt may be positioned adjacent to an end edge of the primary padding layer. The upper surface of the end skirt may be substantially flush or substantially coplanar with the upper surface of the primary padding layer. The end skirt may include a compressible, resilient foam material. The stiffness or hardness of the material forming the end skirt may exceed the stiffness or hardness of the material forming the primary padding layer.

[0010] Each backing fabric strip can include a material that can receive (e.g., bonded to, impregnated with, etc.) a bonding material (e.g., glue), a material forming the primary padding layer, etc. In some embodiments, the backing fabric can include cotton, such as a blend of cotton and a synthetic material (e.g., a cotton-spandex blend, etc.). The backing fabric can be woven or nonwoven.

[0011] Each lining fabric strip can include an outer edge, an inner edge, and an end. The lining fabric strip can be positioned above the interface or seam between each side edge and the side portion of the upper surface of the main padding layer adjacent to the side edge, and above at least a portion of the side portion of the upper surface of the side edge and the upper surface of the main padding layer. The outer edge of the lining fabric strip can be positioned above or near the outer edge of the side edge. The inner edge of the lining fabric strip can be positioned above the side portion of the upper surface of the main padding layer. In some embodiments, the inner edge of the lining fabric strip is located about 2 inches to about 6 inches inside the side edge of the main padding layer. The center portion of the upper surface of the main padding layer can remain exposed outside the lining fabric strip.

[0012] In embodiments where the mattress assembly further includes one or more end skirts, at least a portion of the end portion of each backing fabric strip extending above the side skirt can be positioned above a portion of the upper surface of the end skirt. Additionally, another backing fabric strip can be positioned at the interface or seam between the end skirt and the end edge of the primary padding layer, and above a portion of the end skirt and the upper surface of the primary padding layer adjacent to the interface. Alternatively, the ends of such backing fabric strips can be positioned above portions of the end portions of the side skirts of the mattress assembly.

[0013] Each backing fabric strip can be secured directly or indirectly (e.g., by overlapping another backing fabric strip, etc.) to the portion of the upper surface of the side and / or end skirts that it covers and to the portion of the upper surface of the primary padding layer that it covers. Without limitation, each backing fabric strip can be glued or otherwise adhesively secured to the portion of the upper surface of the side and / or end skirts that it covers. Each backing fabric strip can be secured directly or indirectly (e.g., by overlapping another backing fabric strip, etc.) to the portion of the upper surface of the primary padding layer that it covers with an adhesive material (e.g., glue), or by bonding the material of the primary padding layer's upper surface itself (e.g., by fusion bonding, where the primary padding layer's elastomeric material can wick into the backing fabric strip, or by impregnating the backing fabric strip, etc.), i.e., the material of the primary padding layer's upper surface is joined to (e.g., impregnated with, etc.) the backing fabric strip.

[0014] In another aspect, a method for assembling a mattress includes positioning a strip of backing fabric over an interface between a side edge of a primary padding layer and a side skirt adjacent to the side edge of the primary padding layer, and over a portion of the side skirt and an upper surface of the primary padding layer adjacent to the interface. The method also includes securing the strip of backing fabric to the upper surface of the side skirt and securing the strip of backing fabric to the upper surface of the primary padding layer.

[0015] Where the mattress assembly includes one or more end skirts, the backing mesh strip may also be positioned over the interface between an end edge of the primary padding layer (e.g., a head edge, a foot edge, etc.) and an end skirt adjacent to the end edge of the primary padding layer, and over a portion of the end skirt and the upper surface of the primary padding layer adjacent to the interface. The backing mesh strip may be secured to the upper surface of the end skirt and the upper surface of the primary padding layer.

[0016] In some embodiments, the primary cushion layer may comprise an elastomeric gel. The elastomeric gel may define interconnected walls that define a plurality of cells. Each cell and the walls defining the cell may together define a hollow column that may comprise a buckling column. The interconnected walls may be formed into a grid that defines an array of cells.

[0017] Each side edge and / or end edge may include an upper surface and a lower surface. In addition, each side edge may include an outer edge and an inner edge and an end. The inner edge of each side edge and / or end edge may be positioned adjacent to a corresponding edge (e.g., a side edge, an end edge, etc.) of the primary cushioning layer. The upper surface of each side edge and / or end edge may be substantially flush or substantially coplanar with the upper surface of the primary cushioning layer. Each side edge and / or end edge may include a compressible elastic foam material. The stiffness or hardness of the material forming the side edge and / or end edge may exceed the stiffness or hardness of the material forming the primary cushioning layer.

[0018] Positioning the backing fabric strip may include positioning the outer lateral side of the backing fabric strip above or near the outer edge of the side skirt and positioning the inner lateral side of the backing fabric strip above the side portion of the primary padding layer. Positioning the backing fabric strip may include exposing a central portion of the elastomeric cushioning element outside the backing fabric strip. Positioning the backing fabric strip may include positioning the inner lateral side of the backing fabric strip about 2 inches to about 6 inches inside the side edge of the elastomeric cushioning element.

[0019] In embodiments where the mattress assembly includes side edges and at least one end edge adjacent to at least one end of the main padding layer, positioning the lining fabric strip along the side edges may include positioning at least one end portion of the lining fabric strip above a portion of at least one end edge, and / or positioning the lining fabric strip along the end edge may include positioning an end portion of the lining fabric strip above a portion of the side edges.

[0020] The portions of the backing fabric strip secured to the upper surfaces of the side and / or end edges covered by the backing fabric strip may include being secured to the upper surfaces of the side and / or end edges covered by the backing fabric strip directly or indirectly (e.g., via an overlapping portion of another backing fabric strip, etc.). The backing fabric strip may be secured to the portions of the upper surfaces of the side and / or end edges covered by the backing fabric strip using an adhesive material (e.g., glue).

[0021] The portion of the backing fabric strip secured to the upper surface of the primary cushioning layer it overlies may include being secured to the portion of the upper surface of the primary cushioning layer it overlies directly or indirectly (e.g., via an overlapping portion of another backing fabric strip). The backing fabric strip may be secured to the portion of the upper surface of the primary cushioning element using an adhesive material such as glue. Alternatively, the backing fabric strip may be bonded to the upper surface of the primary cushioning layer. In embodiments where the material on the upper surface of the primary cushioning layer reflows upon heating (i.e., the material is thermoplastic) (e.g., in embodiments where the primary cushioning layer comprises an elastomeric gel), the backing fabric strip may be melt-bonded to the upper surface of the primary cushioning layer. The backing fabric strip may be melt-bonded to the upper surface of the primary cushioning layer by heating the upper surface of the elastomeric cushioning element (e.g., via the backing fabric strip) to a temperature that melts the elastomeric material on the upper surface of the elastomeric cushioning element, and the molten elastomeric material wicks into or impregnates the backing fabric strip.

[0022] In some embodiments, the backing fabric strips can be simultaneously secured to the side / end surrounding edges and the upper surface of the primary padding layer. In embodiments where the mattress assembly includes multiple backing fabric strips, two or more backing fabric strips (e.g., backing fabric strips on the side surrounding edges and the side portions of the primary padding layer, etc.) can be simultaneously secured to the side / end surrounding edges and / or the primary padding layer.

[0023] Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, should become apparent to one of ordinary skill in the art from consideration of the foregoing disclosure, the drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In the attached figure: Figure 1 is a schematic diagram of a top surface of an embodiment of a mattress assembly including a main mattress layer, a skirt (e.g., side skirts, end skirts, etc.) surrounding an outer perimeter of the main mattress layer, and a backing fabric strip positioned over an interface or seam between the main mattress layer and one or more side skirts of the mattress assembly; Figure 2 is a perspective view of the mattress assembly, again illustrating the upper surface of the main padding layer and the surrounding edges of the mattress assembly, and strips of backing fabric covering the side surrounding edges of the mattress assembly and adjacent side portions of the main padding layer; Figure 3 is a fragmentary close-up view of a strip of backing fabric covering the interface or seam between the skirt of the mattress assembly and the peripheral portion of the main padding of the mattress assembly; and Figure 4is a schematic diagram of the top surface of another embodiment of a mattress assembly, the mattress assembly including a main cushioning layer, a skirt (e.g., side skirts, end skirts, etc.) surrounding an outer perimeter of the main cushioning layer, and strips of backing fabric positioned above interfaces or seams between sides of the main cushioning layer and one or more side skirts of the mattress assembly and above interfaces or seams between ends of the main cushioning layer and one or more end skirts of the main cushioning layer. Detailed description

[0025] refer to Figure 1 and Figure 2 , depicts an embodiment of a mattress assembly 10 that includes a main mattress layer 20, side borders 30, optional end borders 35, and a backing fabric strip 50. The side borders 30 are positioned adjacent to the side edges 22 and 23 of the main mattress layer 20. The end borders 35, if present, are positioned adjacent to the end edges 24 and 25 of the main mattress layer 20. For simplicity, each side border 30 and each end border 35 may also be referred to as a "border" (i.e., as "border 30," "border 35," or "borders 30, 35"). Each backing fabric strip 50 is positioned above the interface or seam 42, 43 between the side edges 22, 23 of the main mattress layer 20 and the border 30 positioned against the side edges 22, 23. Thus, each backing fabric strip 50 overlaps a portion of the main mattress layer 20 and at least a portion of the corresponding side border 30. In embodiments where the mattress assembly 10 includes end skirts 35 , each backing fabric strip 50 may also overlap a portion of one or both end skirts 35 .

[0026] In addition to including side edges 22 and 23 and end edges 24 and 25 (e.g., end edge 24 may include a first end edge or head edge; end edge 25 may include a second end edge or foot edge; etc.), the main padding layer 20 also includes an upper surface 26 and a lower surface (not shown) opposite the upper surface 26. Each side skirt 30 and end skirt 35 may also include an upper surface 31, 36, respectively, and a lower surface 33, 38, respectively, opposite the upper surfaces 31, 36. Although Figure 1 and Figure 2 The backing strips 50 are shown as being positioned on and secured to the upper surfaces 26 and 31 of the main padding layer 20 and the side skirts 30, respectively, but embodiments of the mattress assembly having the backing strips 50 overlapping and secured to the lower surfaces 28 and 33 of the main padding layer 20 and the side skirts 30, respectively, are also within the scope of the present disclosure.

[0027] The primary pad 20 may include a plurality of resiliently compressible walls 102 defining an array of resilient buckling posts 104 and voids 106 within each resilient buckling post 104. Examples of such primary pads 20 are disclosed in U.S. Patents 7,060,213, 7,076,822, and 8,919,750, the entire disclosures of which are hereby incorporated herein. The resiliently compressible walls 102, buckling posts 104, and voids 106 may extend completely through the thickness of the primary pad 20, substantially through the thickness of the primary pad 20 (e.g., a film of material forming the primary pad 20 may extend over a major surface of the primary pad 20 (e.g., top surface 26, bottom surface 28), etc.), or partially through the thickness of the primary pad 20 (e.g., extending partially from one major surface of the primary pad 20 into the thickness of the primary pad 20, etc.).

[0028] The resiliently compressible wall 102 of the primary cushion layer 20 can be formed from any suitable material, including, but not limited to, an elastomeric material. The elastomeric material may include a gel-like material, or an elastomeric gel or gel elastomer. Examples of elastomeric materials comprising a gel-like material include, but are not limited to, plasticizer-extended block copolymers, diblock copolymers, and triblock copolymers. U.S. Patents 6,413,458, 6,797,765, and 7,964,664 (the disclosures of which are incorporated herein in their entireties) disclose various examples of plasticizer-extended ABA triblock copolymers that can be used to form the primary cushion layer.

[0029] A backing fabric (not shown) can be secured to the bottom surface (not shown) of the primary cushioning layer 20. The backing fabric can include the same type of fabric as, or a type of fabric similar to, the fabric forming the backing fabric strips 50, a fabric similar to, or any other suitable fabric. The backing fabric can be secured to the bottom surface of the primary cushioning layer 20 by impregnating the elastomeric material of the primary cushioning layer 20 with an adhesive material, or by any other suitable means. In embodiments where the mattress assembly 10 includes a cushioning element (e.g., a foam layer, etc.) positioned beneath the primary cushioning layer 20 (not shown), the backing fabric or elastomeric material impregnated therein can be positioned against the intermediate cushioning element. In some embodiments, the backing fabric can be secured to the intermediate cushioning element (e.g., using an adhesive material, etc.). In some embodiments, the main pad 20 can be disposed over a spring coil (not shown; see, for example, U.S. Patent 11,317,733, issued May 3, 2022, the disclosure of which is hereby incorporated herein in its entirety), over one or more pressurizable chambers (not shown; see, for example, U.S. Patent Application Publication US 2021 / 0251393 A1, published August 19, 2021 (“the '393 Publication”), the disclosure of which is hereby incorporated herein in its entirety; U.S. Patent Application Publication US 2022 / 0273113 A1, published September 1, 2022, the disclosure of which is hereby incorporated herein in its entirety), or over a combination of a spring coil and one or more pressurizable chambers (see, for example, the '393 Publication).

[0030] Each of the side edges 30, 35 can include an outer edge 30o, 35o and an inner edge 30i, 35i and an end 30e, 35e. The inner edge 30i, 35i of each side edge 30, 35 can be positioned near the side edge 22, 23 or the end edge 24, 25 of the main cushion layer 20. The upper surface 31, 36 of each side side edge 30, 35 can be substantially flush or substantially coplanar with the upper surface 26 of the main cushion layer 20. Each of the side edges 30, 35 can include a compressible elastic foam material. The rigidity or hardness of the material forming the side edges 30, 35 can exceed the rigidity or hardness of the material forming the main cushion layer 20. In some embodiments, the side edges 30, 35 can prevent the side edges 22, 23 and the end edges 24, 25 of the main cushion layer 20 from protruding outwards.

[0031] Each backing fabric strip 50 may comprise a fabric that can receive (e.g., bond, impregnate, etc.) a bonding material (e.g., glue), the material forming the primary padding layer 20, or the like. In some embodiments, the fabric of the backing fabric strips 50 may comprise cotton, such as a blend of cotton and a synthetic material (e.g., a cotton-spandex blend). The fabric of the backing fabric strips 50 may be woven or non-woven. In a specific embodiment, each backing fabric strip 50 may comprise a 90% cotton / 10% spandex blend having a weight of 100 gsm (grams per square meter).

[0032] Each backing fabric strip 50 can include an outer edge 50o, an inner edge 50i, and an end 50e. The backing fabric strip 50 can be positioned over the interface or seam 42, 43 between each side panel 30 and a side portion 26s of the upper surface 26 of the primary padding layer 20 adjacent to the side panel 30, as well as over at least a portion of the upper surface 31 of the side panel 30 and the side portion 26s of the upper surface 26 of the primary padding layer 20. The outer edge 50o of the backing fabric strip 50 can be positioned over or near the outer edge 30o of the side panel 30. The inner edge 50i of the backing fabric strip 50 can be positioned over the side portion 26s of the upper surface 26 of the primary padding layer 20.

[0033] In some embodiments, the inner edge 50 i of the backing fabric strip 50 is located from about 0.75 inches (about 2 cm) to about 6 inches (about 15 cm) inward from the side edges 22 , 23 of the primary padding layer 20 . Figure 3 An embodiment is shown in which the inside edge 50i of the backing fabric strip 50 overlaps the side portion 26s of the upper surface 26 of the primary padding layer 20 by approximately four flexure columns 104, or from about 4 inches (about 10 cm) to about 6 inches (about 15 cm). It will be understood that each backing fabric strip 50 may extend a lesser or greater distance over the side portion 26s of the upper surface 26 of the primary padding layer 20, or a lesser distance over each side surround edge 30. The distance that each backing fabric strip 50 extends over the side portion 26s of the upper surface 26 of the primary padding layer 20 may depend on the width of the upper surface 26 of the primary padding layer 20. The central portion 26c of the upper surface 26 of the primary padding layer 20 may remain exposed outside of the backing fabric strip 50.

[0034] Continue to refer Figure 1 and Figure 2 In embodiments where the mattress assembly 10 further includes one or more end edges 35, at least a portion of the end portion 50e of each backing fabric strip 50 extending above the side edges 30 may be positioned above a portion of the upper surface 36 of the end edges 35. Figure 1As shown, each backing fabric strip 50 extending over upper surface 31 of side skirt 30 and adjacent side portions 26s of upper surface 26 of primary padding layer 20 may also extend over end skirts 35 located adjacent both end edges 24 and 25 of primary padding layer 20 .

[0035] Now go to Figure 4 , an embodiment of a mattress assembly 10 ', the mattress assembly includes a main padding layer 20, side skirts 30, end skirts 35 and a backing fabric strip 50. In addition, Figure 4 The mattress assembly 10 ′ includes a backing fabric strip 55 .

[0036] Each backing fabric strip 55 may comprise a fabric that can receive (e.g., bonded to, impregnated with, etc.) a bonding material (e.g., glue), a material forming the primary padding layer 20, or the like. In some embodiments, the fabric of the backing fabric strips 55 may comprise cotton, such as a blend of cotton and a synthetic material (e.g., a cotton-spandex blend). The fabric of the backing fabric strips 55 may be woven or non-woven. In a specific embodiment, each backing fabric strip 55 may comprise a 90% cotton / 10% spandex blend having a weight of 100 gsm (grams per square meter).

[0037] Each backing fabric strip 55 can include an outer edge 55o, an inner edge 55i, and an end portion 55e. The backing fabric strip 55 can be positioned over the interface or seam 44, 45 between each end skirt 35 and the end portion 26e of the upper surface 26 of the primary padding layer 20 adjacent the end skirt 35, as well as over at least a portion of the upper surface 36 of the end skirt 35 and the end portion 26e of the upper surface 26 of the primary padding layer 20. The outer edge 55o of the backing fabric strip 55 can be positioned over or near the outer edge 35o of the end skirt 35. The inner edge 55i of the backing fabric strip 55 can be positioned over the end portion 26e of the upper surface 26 of the primary padding layer 20.

[0038] In some embodiments, the inner edge 55i of the backing fabric strip 55 is located about 0.75 inches (about 2 cm) to about 6 inches (about 15 cm) inward from the end edges 24, 25 of the primary padding layer 20. More specifically, the inner edge 55i of the backing fabric strip 55 can overlap the end portion 26e of the upper surface 26 of the primary padding layer 20 by about four flexure columns 104, or about 4 inches (about 10 cm) to about 6 inches (about 15 cm) (see Figure 3). It will be understood that each backing fabric strip 55 can extend a lesser distance or a greater distance over the end portions 26 e of the upper surface 26 of the primary padding layer 20, or a lesser distance over each end skirt 35. The distance that each backing fabric strip 55 extends over the end portions 26 e of the upper surface 26 of the primary padding layer 20 can depend on the length of the upper surface 26 of the primary padding layer 20. The central portion 26 c of the upper surface 26 of the primary padding layer 20 can remain exposed outside the backing fabric strip 55.

[0039] In other embodiments, a single piece of backing fabric that extends across and beyond the entire width and / or length of upper surface 26 of primary cushioning layer 20 may be used in place of two or more backing fabric strips 50 , 55 .

[0040] Continue to refer Figure 4 At least a portion of the end portion 55e of each lining fabric strip 55 extending on the end skirt 35 may be positioned on a portion of the upper surface 31 of the side skirt 30. Figure 4 As shown, each lining fabric strip 55 extending on the upper surface 36 of the end skirt 35 and the adjacent end portion 26e of the upper surface 26 of the main padding layer 20 may also extend on the side skirt 30 positioned adjacent to the two side edges 22 and 23 of the main padding layer 20 and / or on the end portion 50e of the lining fabric strip 50 on the side skirt 30 and the adjacent side portion 26s of the upper surface 26 of the main padding layer 20.

[0041] Overall reference Figures 1-4 Each backing fabric strip 50, 55 can be secured directly or indirectly (e.g., via an overlapping portion of another backing fabric strip 50, 55, etc.) to the upper surface 31, 36 of the surrounding edge 30, 35, respectively. The backing fabric strip 50, 55 covers and is secured to the covered portion 26s, 26e of the upper surface 26 of the primary cushioning layer 20. Without limitation, each backing fabric strip 50, 55 can be glued or otherwise adhesively secured to the upper surface 31, 36 of the surrounding edge 30, 35 that it covers. Each lining fabric strip 50, 55 can be fixed to the portion 26s, 26e of the upper surface 26 of the main padding layer 20 it covers directly or indirectly (for example, by an overlapping portion of another lining fabric strip 50, 55, etc.) using an adhesive material (such as glue), or by bonding the material of the upper surface 26 of the main padding layer 20 itself (for example, melt bonding, where the elastomeric material of the main padding layer 20 can impregnate the lining fabric strips 50, 55, etc.), that is, the material of the upper surface 26 of the main padding layer 20 is joined to (for example, has been impregnated, etc.) the lining fabric strip 50.

[0042] The mattress assemblies 10, 10' of the present disclosure can be incorporated into a mattress that can be used in an adjustable bed. Each backing fabric strip 50, 55 of such a mattress assembly 10, 10' can maintain the top surface 31, 36 of the surrounding edges 30, 35, respectively, substantially flush with the top surface 26 of the main padding 20 of the mattress assembly 10, 10' while the mattress of which the mattress assembly 10, 10' is a part is adjusted (e.g., its contour is changed, etc.).

[0043] Although this disclosure provides many details, these should not be construed as limiting the scope of any of the appended claims, but rather as providing illustrations of some embodiments of the elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter and its elements and features can be envisioned without departing from the spirit or scope of any claim. Features from different embodiments can be used in combination. Therefore, the scope of each claim is limited only by its plain language and its legal equivalents.

Claims

1. A mattress assembly, comprising: a main cushion layer comprising an upper surface, a lower surface opposite the upper surface, and a perimeter comprising a first end edge, a second end edge, and side edges; a side circumference edge adjacent to each of the side edges of the primary padding layer, each side circumference edge including an upper surface substantially flush with the upper surface of the primary padding layer; and A strip of backing fabric is positioned on the upper surface of each side skirt and on a side portion of the upper surface of the primary padding adjacent to the side skirt, each strip of backing fabric being secured to the side portion of the upper surface of the primary padding and to the upper surface of the side skirt.

2. The mattress assembly according to claim 1, wherein: The outboard edge of the backing fabric strip is positioned over or adjacent to the outboard edge of the side skirt, and the inboard edge of the backing fabric strip is positioned over the side portion of the primary padding layer.

3. The mattress assembly according to claim 2, wherein: The inner edge of the backing fabric strip is located about 2 inches to about 6 inches inward from the side edge of the primary padding layer.

4. The mattress assembly according to any one of claims 1 to 3, wherein: The backing fabric strip does not extend over the central portion of the primary padding layer.

5. The mattress assembly according to any one of claims 1 to 4, wherein: The backing fabric strips are adhered to the side skirt edges.

6. The mattress assembly according to any one of claims 1 to 5, wherein: The primary padding layer includes an elastomeric gel.

7. The mattress assembly according to claim 6, wherein: The backing fabric strips are fusion bonded to the primary backing layer.

8. The mattress assembly of claim 7, wherein: The material of the primary padding layer impregnates the backing fabric strips.

9. The mattress assembly according to any one of claims 1 to 8, further comprising: A first end skirt is provided, the first end skirt being adjacent to the first end edge of the primary padding layer, the first end portion of the backing fabric strip extending over and secured to the first end skirt.

10. The mattress assembly of claim 9, further comprising: A second end skirt is provided, the second end skirt being adjacent to the second end edge of the primary padding layer, the second end portion of the backing fabric strip extending over and secured to the second end skirt.

11. A method for assembling a mattress, comprising: Positioning a strip of backing fabric at an interface between a side edge of a primary padding layer and a side skirt adjacent to the side edge of the primary padding layer, wherein an upper surface of the side skirt is substantially flush with an upper surface of the primary padding layer; securing the lining fabric strip to the upper surface of the side skirt; and The backing fabric strip is secured to the upper surface of the primary padding layer.

12. The method according to claim 11, wherein Positioning the backing fabric strip includes positioning an outer edge of the backing fabric strip over or near an outer edge of the side skirt and positioning an inner edge of the backing fabric strip over a side portion of the primary padding.

13. The method according to claim 12, wherein: Positioning the backing fabric strip includes positioning an inner edge of the backing fabric strip about 2 inches to about 6 inches inward from the side edge of the primary padding layer.

14. The method according to any one of claims 11 to 13, wherein Positioning the backing fabric strip includes exposing a central portion of the primary cushioning layer outside the backing fabric strip.

15. The method according to any one of claims 11 to 14, wherein Fixing the lining fabric strip includes gluing the lining fabric strip to the upper surface of the side skirt.

16. The method according to any one of claims 11 to 15, wherein The primary padding layer includes an elastomeric gel.

17. The method according to claim 16, wherein Securing the backing fabric strip to the upper surface of the primary backing layer includes melt bonding the backing fabric strip to the upper surface of the primary backing layer.

18. The method according to claim 17, wherein: Fusion bonding includes heating the upper surface of the primary backing layer through a backing fabric to a temperature at which material at the upper surface of the primary backing layer melts and the melted material wicks into the backing fabric strips.

19. The method according to any one of claims 11 to 18, wherein The fixing of the backing mesh fabric strip to the upper surface of the side panel and the fixing of the backing mesh fabric strip to the upper surface of the main padding layer are performed simultaneously.

20. The method according to any one of claims 11 to 19, wherein Positioning the backing fabric strip includes positioning at least one end portion of the backing fabric strip over a portion of at least one end skirt adjacent to an end of the primary padding and an end of the side skirt, and the method further includes: The strip of backing fabric is secured to the portion of the at least one end skirt.

21. The method according to claim 20, wherein: Positioning the backing fabric strip includes positioning end portions of the backing fabric strip over portions of the end skirt adjacent each end of the primary padding layer; and Securing the strip of backing fabric to the at least one end skirt includes securing a portion of the end skirt.

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