Mattress assemblies

Abstract

To provide a mattress including a bottom mattress assembly and a top mattress assembly that may be assembled with each other.SOLUTION: An internal overlap 40 may be associated with a bottom mattress assembly 20 and protrude beyond a top of a bottom core 22 of the bottom mattress assembly 20 to define a receptacle for a base portion of a top mattress assembly 60. A cover top 86 and a cover bottom may be placed over the assembly and secured to each other at a location vertically below an upper extent of the internal overlap 40. The mattress may be modular and, thus, include a bottom mattress assembly 20 selectable from a plurality of different configurations of bottom mattress assemblies 20 and / or a top mattress assembly 60 selectable from a plurality of different configurations of top mattress assemblies 60.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 164,358, filed on March 22, 2021, entitled "MATTRESS ASSEMBLIES" (the "Provisional Application '358"). The entire disclosure of the Provisional Application '358 is hereby incorporated herein by reference.

[0002] The present disclosure generally relates to mattresses, and more particularly to mattresses comprising a lower mattress assembly and an upper mattress assembly that can be assembled together. In some embodiments, the mattress may be modular and thus may comprise a lower mattress assembly selectable from a plurality of differently configured lower mattress assemblies and / or an upper mattress assembly selectable from a plurality of differently configured upper mattress assemblies. The present disclosure also relates to a method of assembling a lower mattress assembly and an upper mattress assembly together to provide a completed mattress.

Background Art

[0003] In recent years, online mattress companies have become extremely popular. Online mattress companies enable individuals to select and order mattresses from a website and then directly deliver the mattresses to consumers. Most online mattress companies offer customers a trial period during which customers can try out the mattresses. If the mattress does not meet the customer's expectations, the customer usually sends a return request to the online mattress company, and then the online mattress company arranges for the shipping carrier to pick up the mattress from the customer at no cost.

[0004] Online mattress companies have made it easier for consumers to select, purchase, try, and return mattresses as desired, but packaged mattresses can be bulky and heavy. Therefore, the delivery and installation of mattresses can be cumbersome for both delivery providers and consumers. To reduce the burden, some online mattress companies have developed compact packaging technologies (such as compressed and rolled mattresses) and packages (such as cylindrical packages with effectively positioned handles) that reduce the size and facilitate the movement of mattresses during storage, shipping, delivery, and installation. Nevertheless, the weight of the mattress cannot be reduced, and some compactly packaged mattresses are still very large. SUMMARY OF THE INVENTION MEANS FOR SOLVING THE PROBLEM

[0005] The mattress according to the present disclosure includes a lower mattress assembly and an upper mattress assembly. The lower mattress assembly and the upper mattress assembly can be assembled with each other and, optionally, can be disassembled from each other. The mattress can include a cover, and the cover includes a lower cover on the base and sides of the lower mattress assembly and an upper cover disposed on the upper portion of the upper mattress assembly and connectable to the lower mattress assembly. The mattress can also include an inner overlapping portion that extends around the sides of the upper mattress assembly and the lower mattress assembly. In some embodiments, the inner overlapping portion can be fixed to the lower cover.

[0006] The lower mattress assembly can include a lower core. The lower core can include a base for receiving and supporting one or more lower cushioning elements. The lower cushioning elements can include a column of coils, one or more pressurizable cells (e.g., including air, gas, liquid, etc.), memory foam, other cushioning structures suitable for use in a mattress, or combinations thereof. The lower core of the lower mattress assembly can also include an intermediate layer. The intermediate layer of the lower core can cover the lower cushioning elements.

[0007] In some embodiments, a non-slip surface can be provided on the upper surface of the upper portion of the lower core. The non-slip surface can at least partially define the base of a container portion defined by an inner overlapping portion. The non-slip surface can include non-slip features defined from an elastomeric material. In some embodiments, the non-slip features can be printed on the upper surface of the upper portion of the lower core (e.g., the upper surface of a lower core cover, etc.). The non-slip features together can include a pattern of shapes on the upper surface of the upper portion of the lower core.

[0008] The inner overlapping portion can laterally surround the perimeter or sides of the lower core of the lower mattress assembly. Additionally, the inner overlapping portion can project beyond the upper portion of the lower core by a first distance to define a container portion capable of receiving at least the base of the upper mattress assembly. Thus, the first distance can be less than or equal to the thickness of the upper core. The inner overlapping portion can align the upper mattress assembly with the lower mattress assembly. In some embodiments, the inner overlapping portion can have sufficient rigidity to prevent the upper core of the upper mattress assembly from bulging laterally outward when a force is applied to the upper portion of the assembled mattress (e.g., when one or more people lie on the mattress, etc.). The rigidity of the inner overlapping portion can exceed the rigidity of the sides of the cover (e.g., the sides of the upper cover, the sides of the lower cover, etc.).

[0009] Once the upper mattress assembly is positioned within the container portion defined by the inner overlapping portion, the configuration of the inner overlapping portion allows the inner overlapping portion to be tightened around the upper mattress assembly. In some embodiments, the inner overlapping portion can extend at least below the peripheral portion of the base of the lower core of the lower mattress assembly. The inner overlapping portion can be fixed to the lower cover. The lower edge of the inner overlapping portion can be connected to the base of the lower cover. The lower cover can include a base covering the base of the lower core and a side portion surrounding at least the lower part of the side of the inner overlapping portion.

[0010] The upper mattress assembly including a base that can be inserted into the container portion defined by the inner overlapping portion can include an upper core and an upper core cover. The upper core can include an intermediate layer and one or more upper cushioning elements on the intermediate layer. Examples of upper cushioning elements include, but are not limited to, gel cushions, foams, memory foams, other cushioning structures, or any combination of the above. Without limitation, a gel cushion can include a gel cushion of the type disclosed by U.S. Patent Nos. 7,060,213, 7,076,822, and 8,919,750, the entire disclosures of which are hereby incorporated herein by reference. Such a gel cushion can include a plurality of elastic compression interconnecting walls defining rows of interconnected elastic buckling columns, with voids in each column. Such a gel cushion can be formed from any of a variety of compression elastic materials including a cushioning foam and an elastomeric material such as a stretched A-B-A triblock copolymer disclosed by U.S. Patent Nos. 6,413,458, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein by reference. The upper core can also include one or more lateral support portions surrounding the perimeter of the upper cushioning elements.

[0011] The upper core cover can enclose the upper core. Thus, the upper core cover can include an upper portion on the upper part of the upper core, a base portion below the base of the upper core, and a side portion extending around the outer periphery of the upper core. In some embodiments, a non-slip surface can be provided on the lower surface of the base of the upper core cover. Such a non-slip surface can include non-slip features formed from an elastomeric material. The non-slip features can be printed on the lower surface of the base of the upper core cover. The non-slip features can together include a pattern of shapes on the lower surface of the base of the upper core.

[0012] The mattress cover can include a lower cover portion, an upper cover portion, and a fastener. The lower cover portion can include a base under the lower core of the lower mattress assembly and side portions extending around the sides of the inner overlapping portion of the lower mattress assembly. The side portions of the lower cover portion can extend over the upper portion of the lower core. More specifically, the side portions of the lower cover portion can extend over the upper portion of the lower core by a second distance. In some embodiments, the second distance by which the side portions of the lower cover portion project over the upper portion of the lower core is less than the first distance by which the side portions of the inner overlapping portion project over the upper portion of the lower core, and thus, the side portions of the inner overlapping portion can project further than the side portions of the lower cover portion. In other embodiments, the second distance can be the same as or greater than the first distance. In some embodiments, the lower cover portion can include a part of the lower mattress assembly.

[0013] The upper cover portion can include an upper portion and side portions. The upper portion of the upper cover portion can be disposed on the upper core of the upper mattress assembly. In some embodiments, the upper portion of the upper cover portion can be positionable on the upper portion of the upper core cover of the upper mattress assembly. In other embodiments, the upper portion of the upper cover portion and the upper portion of the upper cover can include the same elements. The side portions of the upper cover portion can extend around the side portions of the upper core cover. The upper portion of the inner overlapping portion projecting over the upper portion of the lower core can be inserted or received between the side portions of the upper cover portion and the side portions of the upper core cover so that the side portions of the upper cover portion and the side portions of the upper core cover can be associated with each other.

[0014] The fastener can include a lower fastener positioned along the upper edge of the side of the lower part of the cover and an upper fastener positioned along the lower edge of the side of the upper part of the cover. In embodiments where the inner overlapping part is fixed to the lower part of the cover, the combination of the inner overlapping part and the fastener can provide a high tensile strength to the mattress, and in some embodiments, the mattress can have the same or higher tensile strength than a mattress with the same internal structure but an integral side wall.

[0015] A plurality of additional fasteners can also be used. For example, the fastener can fix the periphery of the upper part of the lower mattress assembly to the periphery of the lower part of the upper mattress assembly. As another example, the fastener can fix the upper edge of the side of the lower part of the cover to the middle part of the side of the inner overlapping part. Such fasteners can be shifted vertically from each other and / or from the fasteners of the cover of the mattress assembly. By using such shifted fasteners, a high tensile strength can be provided to the mattress, and in some embodiments, the mattress can have the same or higher tensile strength than a mattress with the same internal structure but an integral side wall.

[0016] In some embodiments, the mattress assembly can comprise a modular mattress assembly. The modular mattress assembly can comprise a lower mattress assembly selectable from or selected from a plurality of lower mattress assemblies of different configurations, and / or an upper mattress assembly selectable from and / or selected from a plurality of upper mattress assemblies of different configurations. In some embodiments, two upper mattress assemblies that can be arranged side by side can be selected from a plurality of upper mattress assemblies of different configurations. Such a modular mattress can enable one or two consumers to select from a plurality of lower mattress assemblies of different configurations and / or a plurality of upper mattress assemblies of different configurations.

[0017] The lower mattress assembly and each upper mattress assembly can be packaged and shipped separately from each other, providing two or more packages that are each significantly lighter and significantly smaller than a single package in the case where the lower mattress assembly and the upper mattress assembly are assembled into a mattress and shipped together.

[0018] In another aspect, a method of assembling a mattress is disclosed. Such a method includes providing an inner overlapping portion that defines a container portion on a lower core in the lower mattress assembly. The base of the upper mattress assembly can be inserted into the container portion of the lower mattress assembly. In some embodiments, at least one anti-slip surface can be provided between the lower core and the upper mattress assembly. With the upper mattress assembly in a predetermined position, the inner overlapping portion can be tightened laterally around the upper mattress assembly. Thereafter, the cover upper can be placed on the upper mattress assembly and fixed to a cover lower of the lower mattress assembly, and this cover lower can be provided as part of the lower mattress assembly.

[0019] Such a method can be used by a consumer, and the consumer can assemble separately shipped parts of the mattress. Such a method can also enable a consumer to select and assemble parts of a modular mattress. More specifically, one or two consumers can select a lower mattress assembly from a plurality of lower mattress assemblies of different configurations and / or select an upper mattress assembly from a plurality of upper mattress assemblies of different configurations. In some embodiments, one or two consumers can select at least two upper mattress assemblies arranged side by side on the lower mattress assembly. One or two consumers can further select a cover upper from a plurality of cover uppers of different configurations.

[0020] Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, will become apparent to those of ordinary skill in the art upon consideration of the following description, the accompanying drawings, and the appended claims.

Brief Description of the Drawings

[0021]

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[0022] FIGS. 1 - 4 illustrate an embodiment of a mattress assembly 10 including a lower mattress assembly 20, an inner overlap portion 40, an upper mattress assembly 60, and a cover 80. The configurations of the lower mattress assembly 20, the inner overlap portion 40, the upper mattress assembly 60, and the cover 80 allow the lower mattress assembly 20 and the upper mattress assembly 60 to be provided (e.g., selected, purchased, shipped, etc.) separately from each other and assembled and secured to each other.

[0023] As shown in FIG. 1, the cover 80 of the mattress assembly 10 can include a cover lower portion 82 and a cover upper portion 86. The cover lower portion 82 includes a base 83 (FIG. 2) and side portions 84, each side portion 84 including an upper edge portion 85. The cover upper portion 86 includes an upper portion 87 and side portions 88, each side portion 88 including a lower edge portion 89.

[0024] Any of a variety of suitable materials can be used to define the lower cover 82 and the upper cover 86. For example, the upper portion 87 of the upper cover 86, and optionally, the side portion 88 of the upper cover 86, the side portion 84 of the lower cover 82, and / or the base portion 83 of the lower cover 82 can be at least partially formed from a stretchable fabric. Some non-limiting examples of suitable fabrics are disclosed by U.S. Patent Application Publication No. 2017 / 0251825 (A1) (e.g., the base portion 83 of the lower cover 82, the side portion 84 of the lower cover 82, the side portion 88 of the upper cover 86, and / or the upper portion 87 of the upper cover 86), U.S. Patent Application Publication No. 2017 / 0254003 (A1) (e.g., the upper portion 87 of the upper cover 86, the side portion 88 of the upper cover 86, the side portion 84 of the lower cover 82, etc.), U.S. Patent No. 10,555,618 (e.g., the upper portion 87 of the upper cover, etc.), and U.S. Patent No. 10,881,217 (e.g., the side portion 84 of the lower cover 82, the side portion 88 of the upper cover 86, etc.), the entire disclosure of which is hereby incorporated herein by reference.

[0025] As shown, one or more properties (e.g., texture / design, color, fabric, etc.) of the materials of the lower cover 82 and the upper cover 86 and their features (e.g., the base portion 83 and the upper portion 87 respectively, the side portion 84 and the side portion 88 respectively, etc.) may be different. Alternatively, various features (e.g., one, part, all, etc.) of the materials of the lower cover 82 or a part thereof (e.g., the side portion 84, etc.) and the upper cover 86 or a part thereof (e.g., the side portion 88, the upper portion 87, etc.) may be the same.

[0026] The cover 80 can also include at least one fastener 90. The at least one fastener 90 can include a lower element 95 and an upper element 99, which may have a configuration that allows them to be connected to each other. In some embodiments, the lower element 95 and the upper element 99 of the fastener 90 can be reversibly connected to each other. The lower element 95 of the fastener 90 can be associated with (e.g., fixed to, including an integral part of, etc.) the side portion 84 of the cover lower 82 at or adjacent to the upper edge 85 of the side portion 84. The upper element 99 of the fastener 90 can be associated with (e.g., fixed to, including an integral part of, etc.) the side portion 88 of the cover upper 86 at or adjacent to the lower edge 89 of the side portion 88. In various embodiments, the lower element 95 and the upper element 99 of the fastener 90 can include the sides of a zipper (in which case the fastener 90 also includes at least one zipper pull), the sides of a touch fastener (e.g., a hook-and-loop fastener, or a "VELCRO (registered trademark)" fastener, a hook-hook fastener, etc.), buttons and buttonholes, complementary snap-fitting elements, or a "snap", etc.

[0027] In addition to the illustrated features of the cover 80, FIGS. 2-4 generally show the internal configuration of a mattress assembly 10 comprising a lower mattress assembly 20, an inner overlapping portion 40, and an upper mattress assembly 60. The lower mattress assembly 20 can include a lower core 22. Although FIGS. 2-4 do not show the details of the lower core 22, the lower core 22 can include a base for receiving and supporting one or more lower cushioning elements. The lower cushioning elements can include a column of coils (see, e.g., U.S. Patent Application Publication No. US2019 / 0150632(A1), which is hereby incorporated by reference in its entirety), one or more pressurizable cells (e.g., including air, gas, liquid, etc.) (see, e.g., U.S. Patent No. 11,213,139, which is hereby incorporated by reference in its entirety), memory foam, other cushioning structures suitable for use in a mattress, or combinations thereof. The intermediate layer of the lower core 22 can cover the lower cushioning elements. The intermediate layer can include a foam (e.g., a compression elastic foam, memory foam, etc.).

[0028] In some embodiments, the lower mattress assembly 20 can also include a lower core cover 32 that covers, surrounds, and / or encloses the elements (e.g., the base, coils, pressurizable cells, intermediate layer, etc.) that define the lower core 22. The lower core cover 32 can include fasteners (e.g., zippers, touch fasteners, buttons and buttonholes, snaps, etc.) for holding the elements that define the lower core 22 within the lower core cover 32.

[0029] The upper surface 38 of the lower core 22 or the lower core cover 32 can include an anti-slip surface 50 as shown in FIG. 5A. The anti-slip surface 50 can include anti-slip features 52 formed from an elastomeric material. Without limitation, the elastomeric material can include silicone, an A-B-A triblock copolymer that can be extended by a plasticizer (e.g., a plasticizer-extended A-B-A triblock copolymer disclosed by U.S. Patent Nos. 6,413,458, 6,797,765, and 7,964,664, etc.), or any other elastomeric material that prevents two surfaces positioned in contact with each other from sliding relative to each other.

[0030] Figure 5B shows a non-limiting but specific example of the anti-slip feature 52. The anti-slip feature 52 shown in Figure 5B has a regular cross shape including two cross members 54 and a center 56. Each cross member has a length of about 15 mm and a width of about 1 mm to about 1.5 mm. The center 56 is slightly enlarged relative to the width of the cross member 54 and has a width of about 3 mm. Of course, other shapes and sizes of the anti-slip feature 52 are also included within the scope of the present disclosure.

[0031] Referring again to FIGS. 2-4, the inner overlapping portion 40 extends around at least a part of the outer periphery or side portion 26 of the lower core 22. More specifically, the side portion 46 of the inner overlapping portion 40 can extend around at least a part of the side portion 26 of the lower core 20. The side portion 46 of the inner overlapping portion 40 can be fixed to the side portion 84 of the lower cover 82 (e.g., at a plurality of spaced positions by stitching during the knitting of the side portion 84, using an adhesive, etc.).

[0032] The upper portion 48 of the inner overlapping portion 40 can protrude beyond the upper portion 28 of the lower core 22. Thus, the upper portion 48 of the inner overlapping portion 40 can define a container portion 50 on the lower core 22. The container portion 50 can receive the base 61 of the upper mattress assembly 60.

[0033] The inner overlapping portion 40 can include a lower corner portion 44 at the lower part of the side portion 46. The lower corner portion 44 is positioned under the lower corner portion 24 of the lower core 22 and can wrap around the lower corner portion 24. The inner overlapping portion 40 having the lower corner portion 44 can also include a lower portion 42. The lower portion 42 can extend horizontally inward and thus can be positioned under the peripheral portion of the lower portion 23 of the lower core 22. The lower cover 82 can receive and cover the side portion 46 and the lower portion 44 of the inner overlapping portion 40 and the side portion 26 and the lower portion 23 of the lower core 22.

[0034] In some embodiments, the inner overlap portion 40 can extend along the entire outer periphery of the lower core 22 or around the entire side portion 26 of the lower core 22. As shown in FIG. 6, in an embodiment where the inner overlap portion 40 extends around the entire outer periphery of the lower core 22, the inner overlap portion 40 can include end portions 41, 49, and by pulling these end portions 41, 49 in opposite directions and fixing them at a predetermined position relative to each other, the inner overlap portion 40 can be tightened (e.g., around the base 61 of the upper mattress assembly 60).

[0035] The inner overlap portion 40 can include a material that has little or no lateral stretchability (e.g., less than 2 percent, less than 1 percent, etc.) or does not stretch laterally. In some such embodiments, the inner overlap portion 40 can include a non-woven fabric (e.g., felt, a fabric-like material made from staple fibers (short) and long fibers (continuous length) bonded to each other, etc.). The non-woven fabric can include a reinforced non-woven fabric and / or can include a backing. In other embodiments, the inner overlap portion 40 can include a somewhat rigid element (e.g., a plastic sheet, etc.).

[0036] Referring again to FIGS. 2-4, the base 61 of the upper mattress assembly 60 can be inserted into the container portion 50 defined by the upper portion 48 of the inner overlapping portion 40 and can be within the container portion 50. The upper mattress assembly 60 can include an upper core 62 and an upper core cover 72. Although FIGS. 2-4 do not show the details of the upper core 62, the upper core 62 can include an intermediate layer and one or more upper cushioning elements on the intermediate layer. The intermediate layer can include a foam (e.g., a compression elastic foam, a memory foam, etc.). Examples of the upper cushioning elements include, but are not limited to, gel cushions, foams, memory foams, other cushioning structures, or any combination of the above. Without limitation, the gel cushion can include a gel cushion of the type disclosed by U.S. Pat. Nos. 7,060,213, 7,076,822, and 8,919,750, the entire disclosures of which are hereby incorporated herein by reference. Such a gel cushion can include a plurality of elastic compression interconnected walls defining rows of interconnected elastic buckling columns, with voids in each column. Such a gel cushion can be formed from any of a variety of compression elastic materials including a cushioning foam and an elastomeric material such as a stretched A-B-A triblock copolymer disclosed by U.S. Pat. Nos. 6,413,458, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein by reference. The upper core 62 can also include one or more lateral support portions surrounding the upper cushioning elements.

[0037] The upper core cover 72 can enclose the upper core 62. The upper core cover 72 can cover, surround, and / or encapsulate elements that define the upper core 62 (such as a layer of foam, memory foam, upper cushioning elements (such as gel cushions, etc.)). The upper core cover 72 can include an upper portion 74 on the upper 64 of the upper core 62, a base portion 78 below the base 68 of the upper core 62, and a side portion 76 extending around the outer periphery or side 66 of the upper core 62. Additionally, the upper core cover 72 can include fasteners (such as zippers, touch fasteners, buttons and buttonholes, snaps, etc.) for holding the elements that define the upper core 62 within the upper core cover 72.

[0038] In some embodiments, the lower surface 79 of the base 78 of the lower core cover 72 can include a non-slip surface 50 having non-slip features 52. The non-slip features 52 can be formed from any suitable material (such as an elastomeric material, etc.) and can have any suitable shape and size. In embodiments where one or both of the lower mattress assembly 20 and the upper mattress assembly 60 include the non-slip surface 50, the non-slip surface 50 can prevent the upper mattress assembly 60 from sliding laterally relative to the lower mattress assembly 20.

[0039] The cover upper 86 can be positioned on the upper core cover 72. More specifically, the upper 87 of the cover upper 86 can be positioned on the upper 74 of the upper core cover 72, and the side 88 of the cover upper 86 can overlap at least the upper portion of the side 76 of the upper core cover 72. The side 88 of the cover upper 86 and the side 76 of the upper core cover 72 can be associated with each other such that the upper 48 of the inner overlap portion 40 can be positioned between the side 88 and the side 76.

[0040] Referring now to FIG. 7, an embodiment of a mattress assembly 10' having a cover 80' is shown, which is different from that illustrated and described with reference to FIGS. 1 - 4. The cover 80' includes a cover lower 82' and a cover upper 86'. The lower cover 82' includes a base 83' and corner portions 84', and each corner portion 84' includes an upper edge portion 85'. The corner portions 84' of the lower cover 82' extend only slightly above the side portions 26' of the lower core 22'.

[0041] The upper cover 86' includes an upper portion 87' and side portions 88', and each side portion 88' includes a lower edge portion 89'. The height of the side portions 88' is equal to the sum of the height of the side portions 26' of the lower core 22' and the height of the side portions 66' of the upper core 62'. Thus, when the upper core 62' and the lower core 22' are assembled and the upper cover 86' is disposed on the assembly, the side portions 88' of the upper cover 86' extend onto the side portions 66' of the upper core 62' and, although not completely, generally onto the side portions 26' of the lower core 22' to a position where the lower edge portion 89' of the upper cover 86' can be joined to the upper edge portion 85' of the lower cover 82'.

[0042] FIG. 8 shows an embodiment of a mattress assembly 10" including an embodiment of a cover 80". The cover 80" shown in FIG. 8 includes a lower cover 82" and an upper cover 86". The lower cover 82" includes a base 83" having a peripheral edge portion 85". The dimensions of the lower cover 82" are smaller than the lower portion 23" of the lower core 22". Thus, the peripheral edge portion 85" of the lower cover 82" can be positioned under the lower portion 23" of the lower core 22".

[0043] The upper cover 86" includes an upper portion 87' and side portions 88", and a lower portion 88b" extends inwardly to the lower edge portion 89". The height of the side portions 88" is equal to the sum of the height of the side portions 26" of the lower core 22" and the height of the side portions 66" of the upper core 62". Thus, when the upper core 62" and the lower core 22" are assembled and the upper cover 86" is disposed on the assembly, the side portions 88" of the upper cover 86" extend onto the side portions 66" of the upper core 62" and the side portions 26" of the lower core 22". In addition, the lower portion 88b" of the side portions 88" of the upper cover 86" extends under the peripheral portion of the lower portion 23" of the lower core 22" to a position where the lower edge portion 89" of the upper cover 86" can be joined to the peripheral edge portion 85" of the lower cover 82".

[0044] Referring to FIG. 9, the elements 92', 94' of the fastener 90' can be provided at or adjacent to the respective corners 39, 79 of the lower core cover 32 and the upper core cover 72. When the upper core 62 is positioned and aligned with the lower core 22, as shown in FIG. 10, the adjacent corners 39, 79 and the associated elements 92', 94' of the fastener 90' are close to each other. Thereafter, the elements 92', 94' of the fastener 90' can be fixed to each other, fixing the upper core 22 to the lower core 62 and preventing the upper core 22 from sliding laterally or moving in other ways relative to the lower core 62.

[0045] As shown in FIGS. 11 and 12, the element 92'' of the fastener 90'' can be provided at or adjacent to the corner 39 of the lower core cover 32, and the element 94'' can be provided at an intermediate position along the height of the inner surface 41 of the inner overlapping portion 40. When the elements 92'', 94'' of the fastener 90' are close to each other and connected to each other, the inner overlapping portion 40 can be fixed at a predetermined position relative to the side portion 26 of the lower core 22. In an embodiment where the lower core 22 can also be connected to the upper core 62 as shown in FIG. 11, using the embodiment of the fastener 90'' shown in FIGS. 11 and 12, the inner overlapping portion 40 can be fixed at a predetermined position relative to the entire internal assembly of the mattress assembly 10.

[0046] In an embodiment where a connection provided by the fastener 90 shown in FIGS. 1 - 4 between the lower cover 82 and the upper cover 86 is provided in either or both of the types of connections shown by FIGS. 9 and 10 and the types of connections shown by FIGS. 11 and 12, the positions where the various elements of the various parts of the mattress assembly are connected to each other may be offset perpendicular to each other. Such an arrangement can provide a high tensile strength to the mattress, and in some embodiments, the mattress can have a tensile strength equal to or higher than that of a mattress having the same internal configuration but an integral side wall.

[0047] Although not limited thereto, a method of assembling and disassembling the components of the mattress assembly 10 according to the present disclosure will become apparent from the foregoing description and the accompanying drawings.

[0048] While the present disclosure provides many details, these should not be construed as limiting the scope of any of the following claims, but merely as exemplifying some embodiments of the elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, their elements and features can be conceived without departing from the spirit or scope of any of the claims. Features of different embodiments may be used in combination. Accordingly, the scope of each claim is limited only by plain terms and legal equivalents.

Claims

1. A lower mattress assembly comprising a lower core, and an inner overlapping portion including a base extending under the lower core and a side portion extending along the outer periphery of the lower core and protruding beyond the upper portion of the lower core by a first distance to define a container portion ; a lower mattress assembly; an upper mattress assembly insertable into the container portion defined by the inner overlapping portion of the lower mattress assembly, an upper core, and an upper core cover wrapping the upper core and including an upper portion above the upper portion of the upper core, a base portion below the base portion of the upper core, and a side portion extending around the outer periphery of the upper core ; an upper mattress assembly; a mattress cover comprising a lower cover portion including the base under the lower core of the lower mattress assembly, an upper cover portion positionable above the upper portion of the upper core cover of the upper mattress assembly and including a side portion extending around the side portion of the upper core cover, and a reversible fastener including a lower fastener positioned along an edge of the lower cover portion and an upper fastener positioned along an edge of the side portion of the upper cover portion ; a mattress cover ; a mattress comprising the same.

2. The mattress according to claim 1, wherein the first distance is smaller than the thickness of the upper core.

3. The mattress according to claim 2, wherein the lower cover portion further includes a side portion extending around the side portion of the inner overlapping portion of the lower mattress assembly and protruding beyond the upper portion of the lower core by a second distance.

4. The mattress according to claim 3, wherein the second distance by which the side portion of the lower cover portion protrudes beyond the upper portion of the lower core is smaller than the first distance by which the side portion of the inner overlapping portion protrudes beyond the upper portion of the lower core.

5. The mattress according to claim 3, wherein the side portion of the inner overlapping portion is fixed to the side portion of the lower cover portion.

6. The mattress according to any one of claims 1 to 5, wherein another reversible fastener fixes the inner overlapping portion to the lower core.

7. The mattress according to any one of claims 1 to 5, wherein the inner overlapping portion is laterally adjustable.

8. a non-slip surface between the lower mattress assembly and the upper mattress assembly The mattress according to any one of claims 1 to 5, further comprising

9. The mattress according to claim 8, wherein the anti-slip surface is at least one of the bases of the upper core covers of the upper mattress assembly.

10. The mattress according to claim 8, wherein the anti-slip surface includes an anti-slip feature formed of an elastomer material.

11. The mattress according to any one of claims 1 to 5, wherein the upper core includes a gel cushion including intersecting walls formed of an elastomer material and defining a row of voids.

12. The mattress according to claim 11, wherein the lower core includes a row of coils.

13. The mattress according to claim 11, wherein the lower core includes at least one pressurizable cell.

14. Providing an inner overlapping portion on the lower core that defines a container portion on the lower mattress assembly; Inserting the base of the upper mattress assembly into the container portion of the lower mattress assembly; Fixing the upper cover of the upper mattress assembly to the lower cover of the lower mattress assembly A method of assembling a mattress, including

15. The method according to claim 14, further including the step of laterally tightening the inner overlapping portion around the upper mattress assembly.

16. The method according to claim 14, further including the step of placing the upper cover on top of the upper part of the upper mattress assembly.

17. The method according to claim 16, wherein the step of providing on the lower mattress assembly includes the step of providing on a lower mattress assembly in which the lower cover is assembled together with the lower mattress assembly.

18. The method according to any one of claims 14 to 17, further including the step of selecting the lower mattress assembly from a plurality of lower mattress assemblies of different configurations.

19. The method according to any one of claims 14 to 18, further including the step of selecting the upper mattress assembly from a plurality of upper mattress assemblies of different configurations.

20. The method according to claim 19, wherein the step of selecting the upper mattress assembly includes the step of selecting at least two upper mattress assemblies arranged side by side on the lower mattress assembly.

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