Elastomeric grid including discrete cushioning elements
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- MLILY HOME TECHNOLOGY CO LTD
- Filing Date
- 2023-01-28
- Publication Date
- 2026-06-24
Smart Images
Figure CN2023073510_02082024_PF_FP
Abstract
Description
ELASTOMERIC GRID INCLUDING DISCRETE CUSHIONING ELEMENTSTechnical Field
[0001] The present disclosure relates generally to mattress assemblies. More specifically, the present disclosure relates to an elastomeric grid layer used in mattress assemblies.Background
[0002] A mattress’ construction is one of the factors that will impact its unique feel. There are various types of mattresses. One type of mattress includes a pillow top mattress that has a “floating” layer of upholstery that feels similar to having a giant pillow on top of the mattress. Pillow top mattresses may range from medium to very soft in feel. Another type of mattress includes an all-foam mattress, which can be made using some combination of polyurethane foam, memory foam, and / or latex foam. The memory foam will typically be positioned close to the sleeping surface to yield the best benefit. A further type of mattress includes a hybrid mattress that use an innerspring as a support core and added layers of specialty foam (memory foam or latex foam) on top. Hybrid mattresses provide the active support of an innerspring with the unique feel of specialty foam materials.
[0003] It is well known that one of the challenges in the mattress industry is to create a mattress that provides comfortable support to all portions of a human body. It is desirable to achieve a level of comfort that reduces localized pressure points in areas of the human body, such as shoulders, hips, back, and legs. In recent years, the mattress industry has developed mattresses pads that incorporate a combination of gel, pillow top padding, and foam layers that can conform to contours of a human body to provide support. Typically, the gel layer extends over the entire width and length of the mattress. However, the disadvantage of incorporating pillow-top padding, gel, and / or foam layers is that there exists a greater propensity for sagging mattresses and mattresses developing depressions. Also, the gel layer can increase the overall weight of the mattress.
[0004] Accordingly, there is a need in the art for an improved mattress that provides a comfortable mattress having a long useful life with increased stability. The present disclosure addresses this and other related and unrelated issues.
[0005] Summary
[0006] The present application relates to a thermoplastic elastomer grid designed to overcome drawbacks of the prior art and provide a mattress that has stability and a simple structure.
[0007] The thermoplastic elastomer grid is designed to be used in mattress assemblies, but may also be utilized in seat cushions, pet beds, etc. The thermoplastic elastomer grid includes a plurality of cushion elements that have buckling walls (e.g., cell walls, collapsible walls) that define hollow or void cells. The buckling walls may be oriented in varying shapes (e.g., a square, a rectangle, a diamond, a triangle, an oval, a hexagon, a pentagon, circles, etc. ) to create multiple patterns.
[0008] The thermoplastic elastomer grid may include a first zone with first and second cushion elements, a second zone with third and fourth cushion elements, and a third zone with fifth and sixth cushion elements. In certain examples, the cushion elements in the first, second, and third zones may each be constructed with a different hardness on the Shore A scale.
[0009] One aspect of the present disclosure relates to a mattress assembly that includes a base layer that has a base surface and a support layer that has a first support surface and a second support surface. The support layer may extend across the base surface such that the first support surface of the support layer interfaces with the base surface of the base layer.
[0010] The mattress assembly also includes a gel layer that has a first gel surface and a second gel surface. The gel layer may extend across the support layer such that the first gel surface of the gel layer interfaces with the second support surface of the support layer.
[0011] The mattress assembly also includes an adaptive foam layer that has a first foam surface and a second foam surface. The adaptive foam layer may extend across the gel layer such that the first foam surface of the adaptive foam layer interfaces with the second gel surface of the gel layer.
[0012] The mattress assembly further includes an elastomeric layer. The elastomeric layer may include a flex foam encasement; a first thermoplastic elastomer grid zone that includes a first cushion element and a second cushion element; a second thermoplastic elastomer grid zone that includes a third cushion element and a fourth cushion element, and a third thermoplastic elastomer grid zone that includes a fifth cushion element and a sixth cushion element. The flex foam encasement may provide a perimeter around the first, second and third thermoplastic elastomer grid zones. The first, second, and third thermoplastic elastomer grid zones of the elastomeric layer may have a composition that includes graphene.
[0013] The elastomeric layer may have a first elastomeric surface and a second elastomeric surface. The elastomeric layer may extend across the adaptive foam layer such that the first elastomeric surface of the elastomeric layer interfaces with the second foam surface of the adaptive foam layer.
[0014] Another aspect of the present disclosure relates to a graphite thermoplastic elastomer grid. The graphite thermoplastic elastomer grid includes a first zone with first and second cushion elements, a second zone with third and fourth cushion elements, and a third zone with fifth and sixth cushion elements.
[0015] The first, second, third, fourth, fifth, and sixth cushion elements each include two major sides extending parallel to one another. The two major sides of the respective first, second, third, fourth, fifth, and sixth cushion elements may be interconnected by two minor sides, extending parallel to one another.
[0016] The first and second cushion elements in the first zone may be attached together at a respective one of the two minor sides thereof. The third and fourth cushion elements in the second zone may be attached together at a respective one of the two minor sides thereof. The fifth and sixth cushion elements in the third zone may be attached together at a respective one of the two minor sides thereof.
[0017] These and other features and advantages will be apparent from a reading of the following detailed description and a review of the associated drawings. A variety of additional aspects will be set forth in the description that follows. These aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based.Brief Description of the Drawings
[0018] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:
[0019] FIG. 1 illustrates an exploded schematic view of an example mattress assembly including a base, a support layer, a gel layer, an adaptive foam layer, an elastomeric layer, and a cover in accordance with principles of the present disclosure.
[0020] FIG. 2 illustrates the mattress assembly of FIG. 1 with the base and the cover removed.
[0021] FIG. 3 illustrates an exploded view of a portion of the mattress assembly of FIG. 1.
[0022] FIGS. 4-5 illustrate perspective views of the elastomeric layer of FIG. 1 including two dividers in accordance with the principles of the present disclosure.
[0023] FIGS. 6-7 illustrate perspective views of the elastomeric layer without the dividers.
[0024] FIG. 8 illustrates a perspective view of the elastomeric layer including a single divider in accordance with the principles of the present disclosure.
[0025] FIG. 9 illustrates a perspective view of the elastomeric layer including a single divider of a different width in accordance with the principles of the present disclosure.
[0026] FIG. 10 illustrates a top plan view of the elastomeric layer including a plurality of cushion elements in accordance with the principles of the present disclosure.
[0027] FIG. 11 illustrates an exploded view of FIG. 3 showing a stabilization material.
[0028] FIG. 12 illustrates a plan view of the stabilization material of FIG. 11.
[0029] FIGS. 13-15 illustrate multiple views of patterns and shapes of the cushion element in accordance with the principles of the present disclosure.
[0030] FIGS. 16-17 illustrate another example mattress assembly including a memory foam layer and a spring layer in accordance with the principles of the present disclosure.Detailed Description
[0031] The present application is directed to a thermoplastic elastomer grid for use in mattresses, seats, pet beds etc. The thermoplastic elastomer grid is configured to provide lateral stability by being formed by independent cushion elements. That is, the cushion elements are separate pieces that can be arranged discretely in a mattress assembly as part of the thermoplastic elastomer grid.
[0032] The individual cushion elements may be arranged to provide different elastic properties in zones of the thermoplastic elastomer grid. That is, a first zone may include cushion elements in a shoulder region that as a desired firmness, a second zone may include cushion elements in a hip region that has a desired firmness, and a third zone may include cushion elements in a leg region that has a desired firmness. In certain examples, the elastic support of the cushion elements in the hip region may be stronger than the elastic support of the cushion elements in the shoulder region and / or the leg region.
[0033] FIG. 1 illustrates an exploded view of an example mattress assembly 100 in accordance with the principles of the present disclosure. The mattress assembly 100 includes a multilayered construction. The mattress assembly 100 may include a base 102 (e.g., a box spring, a bed frame, or a floor) , a support layer 104, a gel layer 106, an adaptive foam layer 108, an elastomeric layer 110, and a cover 112. It would be appreciated that one or more additional layers may be included as desired.
[0034] The base 102, support layer 104, gel layer 106, adaptive foam layer 108, elastomeric layer 110, and cover 112 of the mattress assembly 100 may vary in size to provide a twin bed (which generally refers to a length of about 75 inches and a width of about 38 inches) , a full or double bed (which generally refers to a length of about 75 inches and a width of about 53 inches) , a queen bed (which generally refers to a length of about 80 inches and a width of about 60 inches) or a king bed (which generally refers to a length of about 80 inches and a width of about 76 inches) , etc.
[0035] The base 102 is typically the first layer in a mattress assembly. The base 102 is disposed on a bottom of the mattress assembly 100 and provides a foundation upon which the support layer 104, the gel layer 106, the foam layer 108, the elastomeric layer 110, and the cover 112 are arranged. In certain examples, the base 102 may comprise a foam material. The foam material may include a polyurethane foam, a latex foam, a polyethylene foam, a polypropylene foam, a polystyrene, and the like. The base 102 has a first end 114 (e.g., a top end) and a second end 116 (e.g., a bottom end) . The base 102 includes a base surface 118 that extends across the base 102 between the first and second ends 114, 116. The first end 114 is associated with a header portion of a mattress and the second end 116 is associated with a footer portion of the mattress.
[0036] The base 102 may have a height or thickness T1 that may vary as desired. In certain examples, the thickness T1 of the base 102 may be about 12 inches. In certain examples, the thickness T1 of the base 102 may be no greater than 14 inches. In other examples, the thickness T1 of the base 102 may be between about 1 inch and about 18 inches, although alternatives are possible.
[0037] In the example depicted, the base 102 has a slope part 120 (e.g., incline portion, taper portion) that tapers from the thickness T1 to a height or thickness T2. The thickness T2 of the base 102 may also vary as desired. In certain examples, the thickness T2 may be between about 1 inch and about 9 inches, although alternatives are possible.
[0038] Referring to FIG. 2, the mattress assembly 100 is depicted with the base 102 and the cover 112 removed. The support layer 104 may be designed to impart additional support and structural conformation to the mattress assembly 100. The support layer 104 may comprise a foam material that provides flexibility. The foam material may include a polyurethane foam, a latex foam, a polyethylene foam, a polypropylene foam, and / or combinations thereof. The support layer 104 may also include flat foams or convoluted foams.
[0039] In certain examples, the support layer 104 may have a density of between about 1.5 lb / ft3 and about 5 lb / ft3. The support layer 104 may also comprise an indentation load deflection (ILD) between about 10 lbs. and about 25 lbs. In certain examples, the indentation load deflection may be between 20 lbs. and about 60 lbs. The support layer 104 may have a height or thickness T3. The thickness T3 of the support layer 104 may also vary. In certain examples, the thickness T3 may be between 1 inch and 10 inches, although alternatives are possible. In certain examples, the thickness T3 may be 7 inches.
[0040] The support layer 104 has a first support surface 122 (e.g., lower surface, bottom surface) and an opposite, second support surface 124 (e.g., upper surface, top surface) . During assembly, the support layer 104 may be placed on the base 102 and extend across the entirety of the base surface 118. As such, the first support surface 122 of the support layer 104 may interface (e.g., engage, bond) with the base surface 118 of the base 102. In certain examples, a water based adhesive may be used between the support layer 104 and the base 102 to form a bond.
[0041] The gel layer 106 may be formed from a liquid or solid gel, a foam gel, or a combination of a liquid, solid, and / or foam gel. In the example depicted, the gel layer 106 includes a liquid gel flexible foam layer. Example gels may include silicone gels, PVC gels, polyorganosiloxane gels, polyol gels, polyurethane gels, and polyisocyanate gels. Preferably, the gel is dimensionally stable.
[0042] In certain examples, the gel layer 106 may have a density of between 1.5 lb / ft3 and about 5 lb / ft3. The gel layer 106 may also comprise an indentation load deflection (ILD) between about 10 lbs. and about 25 lbs. In certain examples, the indentation load deflection may be between 15 lbs. and about 60 lbs. The gel layer 106 may have a height or thickness T4. The thickness T4 of the gel layer 106 may also vary. In certain examples, the thickness T4 may be between 1 inches and 3 inches, although alternatives are possible. In certain examples, the thickness T4 may be about 1 inch. In certain examples, the thickness T4 may be about 2 inches.
[0043] The gel layer 106 has a first gel surface 126 (e.g., lower surface, bottom surface) and an opposite, second gel surface 128 (e.g., upper surface, top surface) . During assembly, the gel layer 106 may be placed on the support layer 104 and extend across the entirety of the support layer 104. As such, the first gel surface 126 of the gel layer 106 may interface with the second support surface 124 of the support layer 104. A water based adhesive may be used between the support layer 104 and the gel layer 106 to form a bond.
[0044] The adaptive foam layer 108 may provide bounce-back support. That is, the adaptive foam layer 108 may be designed to contour to a human body to relieve pressure points without trapping heat. The adaptive foam layer 108 may include a polyfoam open-cell design that circulates air to help the mattress breathe. An example adaptive foam may include a polyurethane foam, a memory foam, a latex foam, and a gel memory foam, although alternatives are possible.
[0045] In certain examples, the adaptive foam layer 108 may have a density of between about 1.5 lb / ft3 and about 5 lb / ft3. The adaptive foam layer 108 may also comprise an indentation load deflection (ILD) . The indentation load deflection may be between about 5 lbs. and about 20 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 10 lbs. and about 30 lbs. The adaptive foam layer 108 may have a height or thickness T5. The thickness T5 of the adaptive foam layer 108 may also vary. In certain examples, the thickness T5 may be between 1 inches and 5 inches, although alternatives are possible. In certain examples, the thickness T5 may be about 1.5 inches.
[0046] The adaptive foam layer 108 has a first foam surface 130 (e.g., lower surface, bottom surface) and an opposite, second foam surface 132 (e.g., upper surface, top surface) . During assembly, the adaptive foam layer 108 may be placed on the gel layer 106 and extend across the entirety of the gel layer 106. As such, the first foam surface 130 of the adaptive foam layer 108 may interface with the second gel surface 128 of the gel layer 106. A water based adhesive may be used between the adaptive foam layer 108 and the gel layer 106 to form a bond.
[0047] Turning to FIG. 3, a portion of the mattress assembly 100 is depicted showing the elastomeric layer 110 and the gel layer 106. The elastomeric layer 110 may include a flex foam encasement 134 and a plurality of cushion elements. The plurality of cushion elements may include a first cushion element 136, a second cushion element 138, a third cushion element 140, a fourth cushion element 142, a fifth cushion element 144, and a sixth cushion element 146.
[0048] The flex foam encasement 134 has a rectangular shape and defines a center opening 148. The flex foam encasement 134 may comprise a foam material that provides flexibility. The foam material may include a polyurethane foam, a latex foam, a polyethylene foam, a polypropylene foam, and / or combinations thereof.
[0049] In certain examples, multiple pieces together form the flex foam encasement 134 to define the center opening 148. That is, the flex foam encasement 134 may not be made of a single unitary construction. For example, the flex foam encasement 134 may be constructed of four pieces 134a, 134b, 134c, and 134d that together define the center opening 148. The four pieces 134a, 134b, 134c, and 134d may be fixedly coupled to one another by fastener, adhesive, frictional engagement of the pieces 134a, 134b, 134c, and 134d themselves, or combinations thereof. In other examples, the flex foam encasement 134 may be formed by more or less pieces.
[0050] During assembly, the flex foam encasement 134 may surround the first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 to provide a perimeter thereabout. That is, the first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 may be received within the center opening 148 of the flex foam encasement 134 during assembly.
[0051] The flex foam encasement 134 and the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may have the same height or thickness T6 (see FIG. 2) , although alternatives are possible. The thickness T6 may also vary. In certain examples, the thickness T6 may be between 1 inch and 3 inches, although alternatives are possible. In certain examples, the thickness T6 may be between 1 inch and 2 inches. The flex foam encasement 134 may have a width W (see FIG. 4) of about 120 mm (millimeters) , although alternatives are possible. In certain examples, the flex foam encasement 134 may have a density of between about 1.5 lb / ft3 and about 5 lb / ft3. The flex foam encasement 134 may also comprise an indentation load deflection (ILD) . The indentation load deflection may be between about 10 lbs. and about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 20 lbs. and about 40 lbs.
[0052] Still referring to FIG. 3, the first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 respectively make up zones inside the center opening 148 of the flex foam encasement 134. For example, the first and second cushion elements 136, 138 together define a first thermoplastic elastomer grid zone 150, the third and fourth cushion elements 140, 142 together define a second thermoplastic elastomer grid zone 152, and the fifth and sixth cushion elements 144, 146 together define a third thermoplastic elastomer grid zone 154.
[0053] The first, second, and third thermoplastic elastomer grid zones 150, 152, 154 are separated within the center opening 148 of the flex foam encasement 134 by dividers 156 (e.g., partitions, walls, or barriers) . The dividers 156 may have a different material composition than that of the flex foam encasement 134. The dividers 156 may be mounted within the center opening 148 in perpendicular relation to major sides 158 of the flex foam encasement 134 and parallel to minor sides 160 of the flex foam encasement 134, although alternatives are possible. As such, the dividers 156 may be oriented perpendicular to a longitudinal axis X of the flex foam encasement 134 and attach to the major sides 158 of the flex foam encasement 134, although alternatives are possible.
[0054] Referring to FIGS. 4-5, two dividers 156 are shown to separate the first, second, third thermoplastic elastomer grid zones 150, 152, 154. The width W1 of the dividers 156 may vary, for example, based on the bed size. In certain examples, the width W1 of the dividers may be between about 120 mm to about 160 mm, although alternatives are possible. In other examples, a divider may not be used to separate the first, second, third thermoplastic elastomer grid zones 150, 152, 154 (see FIGS. 6-7) .
[0055] In still other examples, a single divider 156a may be provided to separate the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146, respectively along the longitudinal axis X (see FIGS. 8-9) . The divider 156a may have a width W2 (see FIG. 9) that also varies based on the bed size. In certain examples, the divider 156a may have a width W2 of about 50 mm for a queen size bed, although alternatives are possible. In certain examples, the divider 156a may have a width W2 of about 185 mm for a king size bed, although alternatives are possible. The divider 156a may be attached to the respective first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 by adhesive.
[0056] The first, second, third thermoplastic elastomer grid zones 150, 152, 154 may be positioned along the longitudinal axis X of the flex foam encasement 134 so as to provide the amount of lateral support desired. The first, second, third thermoplastic elastomer grid zones 150, 152, 154 may be disposed in a generally parallel array with respect to each other. The first, second, third thermoplastic elastomer grid zones 150, 152, 154 may extend laterally across the center opening 148 of the flex foam encasement 134.
[0057] Referring to FIG. 10, a plan, top view of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 is depicted. When assembled in the mattress assembly 100, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 are configured to be respectively separated by the two dividers 156.
[0058] The first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 each includes a first major side 162 and a second major side 164 that extend parallel to one another. The first and second major sides 162, 164 of the respective first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 are interconnected by a first minor side 166 and a second minor side 168 that extend parallel to one another.
[0059] In the example depicted in FIG. 10, the second minor side 168 of the first cushion element 136 is attached to the first minor side 166 of the second cushion element 138 along the longitudinal axis X, although alternatives are possible. Also, the second minor side 168 of the third cushion element 140 is attached to the first minor side 166 of the fourth cushion element 142 along the longitudinal axis X, although alternatives are possible. Further, the second minor side 168 of the fifth cushion element 144 is attached to the first minor side 166 of the sixth cushion element 146 along the longitudinal axis X, although alternatives are possible.
[0060] When there is no divider 156 in the elastomeric layer 110 as shown in FIGS. 6-7, the second major side 164 of the first cushion element 136 may also be attached to the first major side 162 of the third cushion element 140. Also, the second major side 164 of the third cushion element 140 may also be attached to the first major side 162 of the fifth cushion element 144. The second major side 164 of the second cushion element 138 may also be attached to the first major side 162 of the fourth cushion element 142. The second major side 164 of the fourth cushion element 142 may also be attached to the first major side 162 of the sixth cushion element 146.
[0061] When a single divider 156a is provided in the elastomeric layer 110 as depicted in FIGS. 8-9, the first, third, and fifth cushion elements 136, 140, 144 can be attached at their respective first and second major sides 162, 164. Also, the second, fourth, and sixth cushion elements 138, 142, 146 can be attached at their respective first and second major sides 162, 164.
[0062] The size of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may vary based on the bed size and what, if any, a divider is used. For example, if the mattress assembly 100 has dividers 156 for a queen size bed, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 500 mm x 642 mm. If the mattress assembly 100 has dividers 156 for a king size bed, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 500 mm x 845 mm.
[0063] Referring back to FIGS. 6-7, when there is no divider in the construction, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 are attached together at the respective major and minor sides 162, 164, 166, 168. For a queen size bed with no dividers, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 600 mm x 642 mm. For a king size bed with no dividers, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 600 mm x 845 mm.
[0064] Referring back to FIGS. 8-9, when the mattress assembly 100 includes the divider 156a, the divider 156a can be attached to the respective first and second minor sides 166, 168 of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146. For both a queen size bed and a king size bed that includes the divider 156a, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 645 mm x 690 mm.
[0065] In certain examples, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may each comprise A-B diblock copolymers and A-B-Ariblock copolymers having a ratio between 15%-85%; plasticizer (e.g., mineral oils) having a ratio between 30%-85%; polyethylene having a ratio of between 0.01%-20%; antioxidant having a ratio of between 0.1%-4%; erucylamide having a ratio between 0.01%-2%; and graphene having a ratio between . 1%-10%, although alternatives are possible. It will be appreciated that the composition of each of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may differ in the respective first, second, third thermoplastic elastomer grid zones 150, 152, 154 to achieve a desired comfort and lateral stability. For example, the first and second cushion elements 136, 138 in the first thermoplastic elastomer grid zone 150 may have a composition to achieve a desired firmness at the neck and shoulder region. The third and fourth cushion elements 140, 142 in the second thermoplastic elastomer grid zone 152 may have a composition to achieve a desired firmness at the hip region that may be different or the same relative to the first thermoplastic elastomer grid zone 150. The fifth and sixth cushion elements 144, 146 in the third thermoplastic elastomer grid zone 154 may have a composition to achieve a desired firmness at the leg region that may be different or the same relative to the first and second thermoplastic elastomer grid zones 150, 152, respectively.
[0066] Turning to FIGS. 11-12, the mattress assembly 100 may also include a stabilization material 170 (e.g., a scrim, a fabric) . During assembly, the stabilization material 170 can be attached to an underside 172 of each one of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 using an adhesive. As such, the stabilization material 170 and the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be coupled to the adaptive foam layer 108. The underside 172 of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 including the stabilization material 170 interfaces with the second foam surface 132 of the adaptive foam layer 108. In certain examples, the stabilization material 170 may be used to provide structural conformation of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 to the adaptive foam layer 108.
[0067] The stabilization material 170 defines cutouts 174 (e.g., openings, voids) that are configured to be arranged between the first, second, third thermoplastic elastomer grid zones 150, 152, 154, respectively, during assembly. The cutouts 174 may have a width W3 of about 66 mm, although alternatives are possible. When the dividers 156 are assembled into the center opening 148 of the flex foam encasement 134, the dividers 156 may extend across the cutouts 174. The dividers 156 may adhere to the stabilization material 170 and the adaptive foam layer 108 to enhance the stability of the elastomeric layer 110.
[0068] The stabilization material 170 does not extend to the flex foam encasement 134. The flex foam encasement 134 provides a strong boarder around the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146.
[0069] FIGS. 13-15 depict example cushion elements 136, 136a, 136b that have different patterns and shapes in accordance with the principles of the present disclosure. The cushion elements 136, 136a, 136b can be configured in various shapes and sizes. In certain examples, the cushion elements may have a different pattern or shape, such as a square pattern or shape, a circular pattern or shape, a diamond pattern or shape, a triangle pattern or shape, a hexagon pattern or shape, a rectangular pattern or shape, a pentagon pattern or shape, and / or any combinations thereof.
[0070] The cushion elements 136, 136a, 136b include walls 176 that form the various patterns and shapes depicted in FIGS. 13-15. The walls 176 are designed to be interconnected to one another to define voids 178 (e.g., holes, spaces, cavities) . In certain examples, the walls 176 of the cushion elements 136, 136a, 136b may have a uniform height, although alternatives are possible. The walls 176 define the grid structure of the patterns and shapes of the cushion elements 136, 136a, 136b. The voids 178 help to create air flow in the mattress assembly 100 by removing hot air under the human body. The walls 176 are made to buckle and return to its original shape after deformation. The amount of deformation may vary depending on the desired stiffness based on a hardness on the Shore A scale. The desired cushioning can be greater or lesser for each cushion element arranged in the mattress assembly 100. In certain examples, the height or thickness of the walls 176 is no greater than 3 inches, which allows the walls 176 to support the pattern or shape of the cushion elements 136, 136a, 136b.
[0071] The cover 112 of the mattress assembly 100 includes a fabric that also provides a cooling feature. The cover can comprise various materials or fabrics, including cotton, polyester, polymeric, water resistant materials, synthetics and any combination thereof. In certain examples, the cover 112 may be flexible or elastic to stretch and return to its original shape and / or size. The cover 112 can be disposed at least partially around the entirety of the construction of the multilayered construction. The cover 112 has a mating slope part 180 (see FIG. 1) to that of the slope part 120 of the base 102 such that the slope parts 120, 180 engage when attached together.
[0072] Referring to FIGS. 16-17, another example mattress assembly 200 is depicted. The mattress assembly 200 is similar to the mattress assembly 100 previously described except the mattress assembly 200 includes a spring layer 212 between a gel layer 206 and a support layer 204 and has a memory foam layer 214 between an adaptive foam layer 208 and an elastomeric layer 210. As such, only the spring layer 212 and the memory foam layer 214 will be described in detail. It will be appreciated that the features described herein with reference to the mattress assembly 100 will also apply to the mattress assembly 200. Similar reference numbers to the mattress assembly 100 will be used to reference the layers in the mattress assembly 200, but in the 200s.
[0073] The spring layer 212 may provide additional support or rigidity in the mattress assembly 100. The spring layer 212 includes a plurality of coils 216 each individually pocketed in casings 218. In certain examples, the coils 216 may be barrel-shaped. The casings 218 may include non-woven bags. The spring layer 212 may comprise an indentation load deflection (ILD) . The indentation load deflection may be between about 10 lbs. and about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 20 lbs. and about 40 lbs. The spring layer 212 may have a height or thickness T7 that ranges between about 5 inches to 10 about inches, although alternatives are possible. The coils 216 make up a coil unit that may be encased by an edge foam support 220, which may be similar in composition to the flex foam encasement 134. In certain examples, the spring layer 212 has a 15 gauge coil unit.
[0074] The memory foam layer 214 may comprise polyurethane visco-elastic foam material. The memory foam layer 214 is constructed to contour to the human body during use of the mattress assembly 100. In certain examples, the memory foam layer 214 may have a density of between about 1.5 lb / ft3 and about 5 lb / ft3. The memory foam layer 214 may have a height or thickness T8 that may be between 1 inch and 2 inches, although alternatives are possible. The memory foam layer 214 may comprise an indentation load deflection (ILD) . The indentation load deflection may be between about 10 lbs. and about 20 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 5 lbs. and about 15 lbs.
[0075] It will be appreciated that the measurements mentioned herein are entirely for purposes of illustration and not in limitation.
[0076] From the forgoing detailed description, it will be evident that modifications and variations can be made without departing from the spirit and scope of the disclosure.
Claims
1.A mattress assembly, comprising:a base layer having a base surface;a support layer having a first support surface and a second support surface, the support layer extending across the base surface such that the first support surface of the support layer interfaces with the base surface of the base layer;a gel layer having a first gel surface and a second gel surface, the gel layer extending across the support layer such that the first gel surface of the gel layer interfaces with the second support surface of the support layer;an adaptive foam layer having a first foam surface and a second foam surface, the adaptive foam layer extending across the gel layer such that the first foam surface of the adaptive foam layer interfaces with the second gel surface of the gel layer; andan elastomeric layer, including:a flex foam encasement;a first thermoplastic elastomer grid zone including first and second cushion elements configured to attach together;a second thermoplastic elastomer grid zone including third and fourth cushion elements configured to attach together; anda third thermoplastic elastomer grid zone including fifth and sixth cushion elements configured to attach together, wherein the flex foam encasement provides a perimeter around the first, second and third thermoplastic elastomer grid zones;the elastomeric layer extending across the adaptive foam layer such that a first surface of the elastomeric layer interfaces with the second foam surface of the adaptive foam layer;wherein the first, second and third thermoplastic elastomer grid zones of the elastomeric layer comprises a composition that includes graphene.2.The mattress assembly of claim 1, wherein the respective first, second, third, fourth, fifth, and sixth cushion elements are attached together by adhesive.3.The mattress assembly of claim 1, wherein the flex foam encasement is formed by a plurality of flex foam encasement parts.4.The mattress assembly of claim 1, wherein the flex foam encasement and the first, second, third, fourth, fifth, and sixth cushion elements each have the same height.5.The mattress assembly of claim 1, further comprising a fabric between the elastomeric layer and the adaptive foam layer, wherein the fabric does not extend across the flex foam encasement.6.The mattress assembly of claim 5, wherein the fabric is attached to the first surface of the elastomeric layer by an adhesive.7.The mattress assembly of claim 1, wherein the first, second, third thermoplastic elastomer grid zones extend laterally across the center opening of the flex foam encasement.8.The mattress assembly of claim 1, wherein the first, second, and third thermoplastic elastomer grid zones of the elastomeric layer each includes different material compositions.9.The mattress assembly of claim 1, further comprising a spring layer between the gel layer and the support layer.10.The mattress assembly of claim 9, wherein the spring layer includes a plurality of coils each individually pocketed in casings.11.The mattress assembly of claim 10, wherein the casings include non-woven bags.12.The mattress assembly of claim 1, wherein the first, second, and third thermoplastic elastomer grid zones have a hardness on the Shore A scale of less than 35.13.The mattress assembly of claim 1, further comprising a first divider separating the first and second thermoplastic elastomer grid zones of the elastomeric layer and a second divider separating the second and third thermoplastic elastomer grid zones of the elastomeric layer.14.The mattress assembly of claim 13, wherein the first and second dividers are separate parts from the flex foam encasement.15.The mattress assembly of claim 1, further comprising a cover that interfaces with a second surface of the elastomeric layer, wherein the cover attaches to the base.16.A graphite thermoplastic elastomer grid, comprising:a first zone including first and second cushion elements;a second zone including third and fourth cushion elements; anda third zone including fifth and sixth cushion elements;wherein the first, second, third, fourth, fifth, and sixth cushion elements each includes two major sides extending parallel to one another, wherein the two major sides of the respective first, second, third, fourth, fifth, and sixth cushion elements are interconnected by two minor sides, extending parallel to one another.17.The graphite thermoplastic elastomer grid of claim 16, further comprising a fabric that extends across the graphite thermoplastic elastomer grid.18.The graphite thermoplastic elastomer grid of claim 17, wherein the fabric is attached to the graphite thermoplastic elastomer grid by an adhesive.19.The graphite thermoplastic elastomer grid of claim 16, wherein the graphite thermoplastic elastomer grid has a hardness on the Shore A scale of less than 35.20.The graphite thermoplastic elastomer grid of claim 19, wherein the first, second, and third zones of the graphite thermoplastic elastomer grid each includes a different hardness on the Shore A scale.21.The graphite thermoplastic elastomer grid of claim 16, wherein the first and second cushion elements in the first zone are attached together at a respective one of the two minor sides thereof, the third and fourth cushion elements in the second zone are attached together at a respective one of the two minor sides thereof, and the fifth and sixth cushion elements in the third zone are attached together at a respective one of the two minor sides thereof.22.The graphite thermoplastic elastomer grid of claim 16, wherein the first and third cushion elements are attached together at a respective one of the two major sides thereof, the third and fifth cushion elements are attached together at a respective one of the two major sides thereof, the second and fourth cushion elements are attached together at a respective one of the two major sides thereof, and the fourth and sixth cushion elements are attached together at a respective one of the two major sides thereof.