Mattress with a stable upper surface

Abstract

A mattress assembly having a stabilized top surface to prevent separation of rails (e.g., side rails, end rails) from the edges of the primary cushion of the mattress assembly. A strip of scrim fabric can overlap each rail and adjacent portion of the primary cushion to stabilize the interface or seam between the edge of the primary cushion and the rail positioned relative to that edge. A method for stabilizing the top surface of a mattress assembly is also disclosed, as is an adjustable bed including a mattress with the stabilized top surface.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS A claim of priority to U.S. Provisional Patent Application No. 63 / 440,591, entitled "MATTRESSES WITH STABILIZED UPPER SURFACES," filed January 23, 2023 (the "'591 Provisional Application"), is hereby made pursuant to 35 U.S.C. § 119(e). The entire disclosure of the '591 Provisional Application is hereby incorporated herein.

[0002] The present disclosure relates generally to mattresses, and more particularly to mattresses having a stabilized surface to prevent separation of the mattress's side rails from the side edges of the mattress's primary cushion. More specifically, the present disclosure relates to mattresses having a top surface stabilized with a scrim positioned over the interface between the mattress's side rails and the sides of the primary cushion. A method for stabilizing the mattress top surface is also disclosed, as is an adjustable bed including a mattress with the stabilized top surface. [Background technology]

[0003] Purple Innovation manufactures mattresses that include a primary cushion surrounded by rails, including side rails and end rails. The primary cushion of such mattresses includes interconnected walls, or hollow columns, that define an array of cells. The interconnected walls are formed of a high-density gel material that could cause the primary cushion to sink, sag, or "collapse" if not confined at its periphery. The rails of such mattresses are typically formed from polyurethane foam that is sufficiently rigid to define the periphery of the mattress and, when held in place with an adhesive material and a mattress cover, confine the primary cushion at its periphery, preventing it from sinking, sagging, or collapsing when the mattress is placed on a flat surface.

[0004] When a mattress is placed on the adjustable platform and the adjustable platform is moved to give the mattress a particular contour or shape, portions of the mattress do not fully sink into the concavely angled joints between adjacent portions of the adjustable platform. The side rails of the mattress may become elevated above the concavely angled joints on the adjustable platform, which can cause the high-density gel of the mattress's primary cushion to fall into the concavely angled joints, potentially separating the mattress's primary cushion from the side rails and causing premature wear of the mattress. Summary of the Invention

[0005] In one aspect, a mattress having a stable surface is disclosed. Such a mattress includes a primary cushion adjacent to an upper surface and a rail at least partially surrounding the primary cushion. The primary cushion may be formed from a material having a density greater than that of the rail. In some embodiments, the primary cushion may include interconnected walls defining a plurality of cells. Each cell and the walls defining each cell may together define a hollow column comprising a buckling column. The interconnected walls may be formed as a lattice defining an array of cells.

[0006] An embodiment of a mattress assembly having a stable surface includes a primary cushion, side rails, and strips of scrim fabric. The mattress assembly may also include end rails.

[0007] The primary cushion includes an upper surface and an opposite lower surface. The primary cushion also includes a periphery including a first edge (e.g., a head edge), a second edge (e.g., a foot edge), and side edges. In some embodiments, the primary cushion may include an elastomeric gel. The elastomeric gel may define interconnected walls that define a plurality of cells. Each cell and the walls defining each cell may together define a hollow post with buckling posts. The interconnected walls may be formed as a lattice that defines an array of cells.

[0008] Each side rail may include an upper surface and a lower surface. Additionally, each side rail may include outer and inner edges and ends. The inner edges of each side rail may be positioned adjacent to the side edges of the primary cushion. The upper surfaces of the side rails may be substantially flush with or substantially coplanar with the upper surface of the primary cushion. The side rails may include a compressible, resilient foam material. The stiffness or hardness of the material forming the side rails may exceed the stiffness or hardness of the material forming the primary cushion.

[0009] In embodiments in which the mattress assembly includes end rails, each end rail may include upper and lower surfaces, an outer edge, an inner edge, and an end. The inner edge of each end rail may be positioned adjacent to the edge of the primary cushion. The upper surface of the end rail may be substantially flush with or substantially coplanar with the upper surface of the primary cushion. The end rail may comprise a compressible, resilient foam material. The stiffness or hardness of the material forming the end rail may exceed the stiffness or hardness of the material forming the primary cushion.

[0010] Each strip of scrim fabric may comprise a material that can receive (e.g., interlock, impregnate) an adhesive material (e.g., glue), a material that forms a primary cushion, etc. In some embodiments, the scrim fabric may comprise cotton, for example, a blend of cotton and a synthetic material (e.g., a cotton-spandex blend, etc.). The scrim fabric may be a woven or nonwoven fabric.

[0011] Each strip of scrim fabric may include an outer edge, an inner edge, and an end. The scrim fabric strip may be positioned over the interface or seam between each side rail and the side portion of the top surface of the primary cushion adjacent to the side rail, and over at least a portion of the top surface of the side rail and the side portion of the top surface of the primary cushion. The outer edge of the scrim fabric strip may be positioned over or adjacent to the outer edge of the side rail. The inner edge of the scrim fabric strip may be positioned over the side portion of the top surface of the primary cushion. In some embodiments, the inner edge of the scrim fabric strip is located about 2 inches to about 6 inches inward from the side edge of the primary cushion. A central portion of the top surface of the primary cushion may be exposed beyond the scrim fabric strip.

[0012] In embodiments where the mattress assembly also includes one or more end rails, at least a portion of the end portion of each strip of scrim fabric that extends over the side rails may be positioned over a portion of the top surface of the end rail. In addition, another strip of scrim fabric may be positioned over the interface or seam between the end rail and the edge of the primary cushion, as well as over portions of the top surface of the end rail and primary cushion adjacent the interface. Optionally, the ends of such strips of scrim fabric may be positioned over a portion of the end portions of the side rails of the mattress assembly.

[0013] Each strip of scrim fabric may be secured directly or indirectly (e.g., through an overlapping portion of another strip of scrim fabric) to the portion of the upper surface of the side and / or end rail on which it sits and to the portion of the upper surface of the primary cushion on which it sits. Without limitation, each strip of scrim fabric may be glued or otherwise adhesively secured to the portion of the upper surface of the side and / or end rail on which it sits. Each strip of scrim fabric may be secured directly or indirectly (e.g., through an overlapping portion of another strip of scrim fabric) to the portion of the upper surface of the primary cushion on which it sits with an adhesive material such as glue, or by being bonded by a material on the upper surface of the primary cushion that interlocks with (e.g., is impregnated with) the strip of scrim fabric (e.g., a melt bond in which an elastomeric material of the primary cushion may penetrate or impregnate the strip of scrim fabric).

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

[0015] In situations where the mattress assembly includes one or more end rails, the strip of scrim fabric may be positioned over the interface between the edge of the primary cushion (e.g., head edge, foot edge, etc.) and the end rail adjacent the edge of the primary cushion, as well as over portions of the end rail and top surface of the primary cushion adjacent the interface. The strip of scrim fabric may be secured to the top surface of the end rail and the top surface of the primary cushion.

[0016] In some embodiments, the primary cushion may include an elastomeric gel. The elastomeric gel may define interconnected walls that define a plurality of cells. Each cell and the walls that define each cell may together define a hollow post with buckling posts. The interconnected walls may be formed as a lattice that defines an array of cells.

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

[0018] Positioning the scrim fabric strip may include positioning an exterior side of the scrim fabric strip on or adjacent to an outer edge of the side rail and an interior side of the scrim fabric strip on a side portion of the primary cushion. Positioning the scrim fabric strip may include leaving a central portion of the elastomeric cushioning element exposed beyond the scrim fabric strip. Positioning the scrim fabric strip may include positioning an interior side of the scrim fabric strip about 2 inches to about 6 inches inward from a side edge of the elastomeric cushioning element.

[0019] In embodiments in which the mattress assembly includes side rails and at least one end rail adjacent at least one edge of the primary cushion, positioning the strip of scrim fabric along the side rails includes positioning at least one end portion of the strip of scrim fabric on or over a portion of the at least one end rail, and / or positioning the strip of scrim fabric along the end rails includes positioning an end portion of the strip of scrim fabric over a portion of the side rail.

[0020] Securing the strip of scrim fabric to the portion of the top surface of the side and / or end rail overlying the strip of scrim fabric may include securing the strip of scrim fabric directly to the portion of the top surface of the side and / or end rail overlying the strip of scrim fabric, or indirectly (e.g., through an overlapping portion of another strip of scrim fabric, etc.). The strip of scrim fabric can be secured to the portion(s) of the top surface of the side and / or end rail overlying the strip of scrim fabric with an adhesive material, such as glue.

[0021] Securing the scrim fabric strip to the portion of the upper surface of the primary cushion over which the scrim fabric strip is located may include securing the scrim fabric strip directly or indirectly (e.g., through an overlapping portion of another strip of scrim fabric) to the portion of the upper surface of the primary cushion over which the scrim fabric strip is located. The scrim fabric strip may be secured to the portion of the upper surface of the primary cushion with an adhesive material such as glue. Alternatively, the scrim fabric strip may be bonded to the upper surface of the primary cushion. In embodiments where the material on the upper surface of the primary cushion may reflow when heated (i.e., the material is thermoplastic) (e.g., in embodiments where the primary cushion includes an elastomeric gel), the scrim fabric strip may be melt-bonded to the upper surface of the primary cushion. The scrim fabric strip may be melt-bonded to the upper surface of the primary cushion by heating the upper surface of the elastomeric cushioning element (e.g., through the scrim fabric) to a temperature that causes the elastomeric material on the upper surface of the elastomeric cushioning element to melt and penetrate or impregnate the scrim fabric strip.

[0022] In some embodiments, strips of scrim fabric may be secured in parallel to the side / end rails and the top surface of the primary cushion. In embodiments where the mattress assembly includes multiple strips of scrim fabric, two or more strips of scrim fabric (e.g., side rails and strips of scrim fabric on side portions of the primary cushion, etc.) may be secured simultaneously to the side / end rails and / or the primary cushion.

[0023] 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 skilled in the art from consideration of the foregoing disclosure, the accompanying images, and the appended claims. [Brief explanation of the drawings]

[0024] [Figure 1]FIG. 1 is a schematic diagram of the top surface of an embodiment of a mattress assembly including a primary cushion, rails (e.g., side rails, end rails, etc.) surrounding the periphery of the primary cushion, and a strip of scrim fabric positioned over the interface or seam between the primary cushion and one or more of the side rails of the mattress assembly. [Figure 2] FIG. 2 is a perspective view of the mattress assembly, again showing the strips of scrim fabric covering the top surfaces of the primary cushion and rails of the mattress assembly, as well as adjacent side portions of the side rails and primary cushion of the mattress assembly. [Figure 3] FIG. 3 is a partial close-up view of a strip of scrim fabric located over the interface or seam between the rail of the mattress assembly and the peripheral portion of the primary cushion of the mattress assembly. [Figure 4] FIG. 4 is a schematic diagram of the top view of another embodiment of a mattress assembly including a primary cushion, rails (e.g., side rails, end rails, etc.) that surround the periphery of the primary cushion, and strips of scrim fabric positioned over the interfaces or seams between the sides of the primary cushion and one or more of the side rails of the mattress assembly, and over the interfaces or seams between the edges of the primary cushion and one or more end rails of the primary cushion. DETAILED DESCRIPTION OF THE INVENTION

[0025] 1 and 2, an embodiment of a mattress assembly 10 is illustrated that includes a primary cushion 20, side rails 30, optional end rails 35, and strips of scrim fabric 50. The side rails 30 are positioned adjacent side edges 22 and 23 of the primary cushion 20. The end rails 35, if present, are positioned adjacent end edges 24 and 25 of the primary cushion 20. For simplicity, each side rail 30 and each end rail 35 may also be referred to as a "rail" (i.e., "rail 30," "rail 35," or "rails 30, 35"). Each strip of scrim fabric 50 is positioned over an interface or seam 42, 43 between the side edges 22, 23 of the primary cushion 20 and the rails 30 positioned relative to the side edges 22, 23. Thus, each strip of scrim fabric 50 overlaps a portion of the primary cushion 20 and at least a portion of the corresponding side rail 30. In embodiments in which the mattress assembly 10 includes end rails 35 , each strip of scrim fabric 50 may overlap a portion of one or both end rails 35 .

[0026] In addition to including side edges 22, 23 and end edges 24, 25 (e.g., end edge 24 may include a first or head edge, end edge 25 may include a second or foot edge, etc.), primary cushion 20 includes an upper surface 26 and a lower surface (not shown) opposite upper surface 26. Each side rail 30 and end rail 35 may similarly include an upper surface 31, 36, respectively, and a lower surface 33, 38 opposite upper surfaces 31, 36, respectively. While FIGS. 1 and 2 show scrim strip 50 positioned on and secured to upper surfaces 26 and 31 of primary cushion 20 and side rail 30, respectively, embodiments of mattress assemblies in which scrim strip 50 overlaps and is secured to lower surfaces 28 and 33 of primary cushion 20 and side rail 30, respectively, are also within the scope of this disclosure.

[0027] The primary cushion 20 may include a plurality of resilient compressible walls 102 defining an array of resilient buckling posts 104, and a void 106 within each resilient buckling post 104. Embodiments of such a primary cushion 20 are disclosed by U.S. Patent Nos. 7,060,213, 7,076,822, and 8,919,750, the disclosures of which are hereby incorporated in their entireties. The resilient compressible walls 102, buckling posts 104, and voids 106 may extend completely through the thickness of the primary cushion 20, substantially through the thickness of the primary cushion 20 (e.g., a film of material from which the primary cushion 20 is formed may extend over a major surface (e.g., top surface 26, bottom surface 28, etc. of the primary cushion 20)), or partially through the thickness of the primary cushion 20 (e.g., from one major surface of the primary cushion 20 partially into the thickness of the primary cushion 20, etc.).

[0028] The resilient compressible wall 102 of the primary cushion 20 may be formed from any suitable material, including, but not limited to, an elastomeric material. The elastomeric material may include a gel-like material, an elastomeric gel, or a gel elastomer. Examples of elastomeric materials, including gel-like materials, include, but are not limited to, plasticized block copolymers, diblock copolymers, and triblock copolymers. U.S. Patent Nos. 6,413,458, 6,797,765, and 7,964,664, the disclosures of which are incorporated herein in their entireties, disclose various embodiments of plasticized AB-A3 block copolymers that can be used to form the primary cushion.

[0029] A scrim fabric (not shown) may be secured to the bottom surface (not shown) of the primary cushion 20. The scrim fabric may comprise the same type of fabric as the fabric from which the strips of scrim fabric 50 are formed, or a similar type of fabric, a fabric similar to the fabric from which the strips of scrim fabric 50 are formed, or any other suitable fabric. The scrim fabric may be secured to the bottom surface of the primary cushion 20 by an elastomeric material of the primary cushion 20 that impregnates the scrim fabric, by an adhesive material, or by any other suitable method. In embodiments in which the mattress assembly 10 includes a cushioning element (e.g., a layer of foam, etc.) below the primary cushion 20 (not shown), the scrim fabric or an elastomeric material exuded from the scrim fabric may be positioned against an intermediate cushioning element. In some embodiments, the scrim fabric may be secured to the intermediate cushioning element (e.g., by an adhesive material, etc.). In some embodiments, the primary cushion 20 may be provided on a coil (not shown; see, for example, U.S. Patent No. 11,317,733, issued May 3, 2022, the disclosure of which is incorporated herein in its entirety), on one or more pressurizable chambers (not shown; see, for example, U.S. Patent Application Publication US2021 / 0251393A1 (the "'393 Publication"), published August 19, 2021, the disclosure of which is incorporated herein in its entirety, and U.S. Patent Application Publication US2022 / 0273113A1, published September 1, 2022, the disclosure of which is incorporated herein in its entirety), or on a combination of a coil and one or more pressurizable chambers (see, for example, the '393 Publication).

[0030] Each rail 30, 35 may include an outer edge 30o, 35o and an inner edge 30i, 35i, as well as ends 30e, 35e. The inner edge 30i, 35i of each rail 30, 35 may be positioned adjacent to the side edges 22, 23 or the edges 24, 25 of the primary cushion 20. The top surface 31, 36 of each side rail 30, 35 may be substantially flush with or substantially coplanar with the top surface 26 of the primary cushion 20. Each rail 30, 35 may comprise a compressible, resilient foam material. The stiffness or hardness of the material forming the rails 30, 35 may exceed the stiffness or hardness of the material forming the primary cushion 20. In some embodiments, the rails 30, 35 may prevent the side edges 22, 23 and edges 24, 25 of the primary cushion 20 from bulging outward.

[0031] Each strip of scrim fabric 50 may include a fabric that can receive (e.g., interlock, impregnate, etc.) an adhesive material (e.g., glue), or material that forms the primary cushion 20, etc. In some embodiments, the fabric of the strip of scrim fabric 50 may include cotton, for example, a blend of cotton and a synthetic material (e.g., a cotton-spandex blend, etc.). The fabric of the strip of scrim fabric 50 may be woven or nonwoven. In a particular embodiment, each strip of scrim fabric 50 may include a 90% cotton / 10% spandex blend weighing 100 GSM (grams per square meter).

[0032] Each strip of scrim fabric 50 may include an outer edge 50o, an inner edge 50i, and an end 50e. The strip of scrim fabric 50 may be positioned over the interface or seam 42, 43 between each side rail 30 and the side portion 26s of the top surface 26 of the primary cushion 20 adjacent to the side rail 30, as well as over at least a portion of the top surface 31 of the side rail 30 and the side portion 26s of the top surface 26 of the primary cushion 20. The outer edge 50o of the strip of scrim fabric 50 may be positioned on or adjacent to the outer edge 30o of the side rail 30. The inner edge 50i of the strip of scrim fabric 50 may be positioned over the side portion 26s of the top surface 26 of the primary cushion 20.

[0033] In some embodiments, the inner edge 50i of the strip of scrim fabric 50 is located about 2 cm (about 0.75 inches) to about 15 cm (about 6 inches) inward from the side edges 22, 23 of the primary cushion 20. FIG. 3 shows an embodiment in which the inner edge 50i of the strip of scrim fabric 50 overlaps the side portions 26s of the top surface 26 of the primary cushion 20 by about four buckling posts 104, or by about 10 cm (about 4 inches) to about 15 cm (about 6 inches). It will be understood that each strip of scrim fabric 50 may extend a shorter or longer distance over the side portions 26s of the top surface 26 of the primary cushion 20, or may extend a shorter distance over each side rail 30. The distance that each strip of scrim fabric 50 extends over the side portions 26s of the top surface 26 of the primary cushion 20 can vary depending on the width of the top surface 26 of the primary cushion 20. A central portion 26 c of the top surface 26 of the primary cushion 20 may remain exposed beyond the strip of scrim fabric 50 .

[0034] 1 and 2, in embodiments in which mattress assembly 10 also includes one or more end rails 35, at least a portion of end portion 50e of each strip of scrim fabric 50 extending over side rail 30 may be positioned over a portion of top surface 36 of end rail 35. As shown in FIG. 1, each strip of scrim fabric 50 extending over top surface 31 of side rail 30 and adjacent side portions 26s of top surface 26 of primary cushion 20 may extend over end rails 35 positioned adjacent opposite edges 24 and 25 of primary cushion 20.

[0035] 4, there is shown an embodiment of a mattress assembly 10' that includes a primary cushion 20, side rails 30, end rails 35, and strips of scrim fabric 50. In addition, the mattress assembly 10' of FIG.

[0036] Each strip of scrim fabric 55 may include a fabric capable of receiving (e.g., interlocking, impregnating, etc.) an adhesive material (e.g., glue), material forming primary cushion 20, etc. In some embodiments, the fabric of the strip of scrim fabric 55 may include cotton, for example, a blend of cotton and a synthetic material (e.g., a cotton-spandex blend, etc.). The fabric of the strip of scrim fabric 55 may be woven or nonwoven. In a particular embodiment, each strip of scrim fabric 55 may include a 90% cotton / 10% spandex blend weighing 100 GSM (grams per square meter).

[0037] Each strip of scrim fabric 55 may include an outer edge 55o, an inner edge 55i, and an end 55e. The strip of scrim fabric 55 may be positioned over the interface or seam 44, 45 between each end rail 35 and the end portion 26e of the top surface 26 of the primary cushion 20 adjacent the end rail 35, as well as over at least a portion of the top surface 36 of the end rail 35 and the end portion 26e of the top surface 26 of the primary cushion 20. The outer edge 55o of the strip of scrim fabric 55 may be positioned over or adjacent the outer edge 35o of the end rail 35. The inner edge 55i of the strip of scrim fabric 55 may be positioned over the end portion 26e of the top surface 26 of the primary cushion 20.

[0038] In some embodiments, the inner edge 55i of the strip of scrim fabric 55 is located about 2 cm (about 0.75 inches) to about 15 cm (about 6 inches) inward from the end edges 24, 25 of the primary cushion 20. More specifically, the inner edge 55i of the strip of scrim fabric 55 may overlap the end portion 26e of the top surface 26 of the primary cushion 20 by about four buckling posts 104, or by about 10 cm (about 4 inches) to about 15 cm (about 6 inches) (see FIG. 3 ). It will be understood that each strip of scrim fabric 55 may extend a lesser or greater distance above the end portion 26e of the top surface 26 of the primary cushion 20, or may extend a lesser distance above each end rail 35. The distance that each strip of scrim fabric 55 extends above the end portion 26e of the top surface 26 of the primary cushion 20 can vary depending on the length of the top surface 26 of the primary cushion 20. A central portion 26 c of the top surface 26 of the primary cushion 20 may remain exposed beyond the strip of scrim fabric 55 .

[0039] In other embodiments, a single sheet of scrim fabric extending across and / or beyond the entire width and / or length of the upper surface 26 of the primary cushion 20 may be used in place of two or more strips of scrim fabric 50, 55.

[0040] 4, at least a portion of the end portion 55e of each strip of scrim fabric 55 extending over end rail 35 may be positioned over a portion of top surface 31 of side rail 30. As shown in FIG. 4, each strip of scrim fabric 55 extending over top surface 36 of end rail 35 and adjacent end portion 26e of top surface 26 of primary cushion 20 may extend over side rail 30 positioned adjacent both side edges 22, 23 of primary cushion 20 and / or over end portion 50e of strip of scrim fabric 50 over adjacent side portions 26s of side rail 30 and top surface 26 of primary cushion 20.

[0041] 1-4, each strip of scrim fabric 50, 55 may be secured directly or indirectly (e.g., through an overlapping portion of another strip of scrim fabric 50, 55, etc.) to the upper surfaces 31, 36 of the rails 30, 35 on which the strip of scrim fabric 50, 55 rests, respectively, and to the portions 26s, 26e of the upper surface 26 of the primary cushion 20 on which it rests. Without limitation, each strip of scrim fabric 50, 55 may be secured to the upper surfaces 31, 36 of the rails 30, 35 on which it rests, respectively, by glue or other adhesive means. Each strip of scrim fabric 50, 55 may be secured to the portion 26s, 26e of the upper surface 26 of the primary cushion 20 that it overlies, either directly (e.g., through an overlapping portion of another strip of scrim fabric 50, 55), by an adhesive material such as glue, or by being joined by a material of the upper surface 26 of the primary cushion 20 that interlocks with (e.g., is impregnated with, etc.) the strip of scrim fabric 50, 55 (e.g., a melt bond in which the elastomeric material of the primary cushion 20 may be impregnated into the strip of scrim fabric 50, 55, etc.), or indirectly (e.g., through an overlapping portion of another strip of scrim fabric 50, 55, etc.).

[0042] The mattress assemblies 10, 10' of the present disclosure may be incorporated into mattresses that may be used in adjustable beds. Each strip of scrim fabric 50, 55 of such mattress assemblies 10, 10' maintains the upper surfaces 31, 36 of the rails 30, 35, respectively, substantially flush with the upper surface 26 of the primary cushion 20 of the mattress assemblies 10, 10' while the mattress of which the mattress assemblies 10, 10' are a part is adjusted (e.g., the contour of the mattress is changed, etc.).

[0043] While this disclosure provides many details, these should not be construed as limiting the scope of any of the following claims, but merely as providing illustrations of some embodiments of the elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, their elements and features, may be devised 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 its plain language and legal equivalents.

Claims

1. a primary cushion including an upper surface, a lower surface opposite the upper surface, and a periphery including a first edge, a second edge, and side edges; side rails adjacent each side edge of the primary cushion, each side rail including an upper surface that is substantially flush with the upper surface of the primary cushion; a strip of scrim fabric positioned on the top surface of each side rail and on a side portion of the top surface of the primary cushion adjacent the side rail, each strip of scrim fabric secured to the side portion of the top surface of the primary cushion and secured to the top surface of the side rail; A mattress assembly comprising:

2. 2. The mattress assembly of claim 1, wherein an outer edge of the strip of scrim fabric is positioned on or adjacent to an outer edge of the side rail and an inner edge of the strip of scrim fabric is positioned on the side portion of the primary cushion.

3. 3. The mattress assembly of claim 2, wherein the inner edge of the strip of scrim fabric is located from about 2 inches to about 6 inches inward from the side edge of the primary cushion.

4. 4. The mattress assembly of claim 1, wherein the strip of scrim fabric does not extend over a central portion of the primary cushion.

5. 5. The mattress assembly of claim 1, wherein the strips of scrim fabric are adhered to the side rails.

6. 6. The mattress assembly of claim 1, wherein the primary cushion comprises an elastomeric gel.

7. 7. The mattress assembly of claim 6, wherein the strip of scrim fabric is melt bonded to the primary cushion.

8. 8. The mattress assembly of claim 7, wherein the primary cushion material impregnates the strips of scrim fabric.

9. 9. The mattress assembly of claim 1, further comprising a first end rail adjacent a first edge of the primary cushion, a first end rail over which a first end of the strip of scrim fabric extends and is secured.

10. 10. The mattress assembly of claim 9, further comprising a second end rail adjacent a second edge of the primary cushion, the second end of the strip of scrim fabric extending over and secured to the second end rail.

11. 1. A method of assembling a mattress, comprising: positioning a strip of scrim fabric over an interface between a side edge of a primary cushion and a side rail adjacent the side edge of the primary cushion, the top surface of the side rail being substantially flush with the top surface of the primary cushion; securing the strip of scrim fabric to the top surface of the side rail; securing the strip of scrim fabric to the top surface of the primary cushion; A method comprising:

12. 12. The method of claim 11, wherein positioning the strip of scrim fabric comprises positioning an outer edge of the strip of scrim fabric on or adjacent to an outer edge of the side rail and positioning an inner edge of the strip of scrim fabric on a side portion of the primary cushion.

13. 13. The method of claim 12, wherein positioning the strip of scrim fabric comprises positioning the inner edge of the strip of scrim fabric about 2 inches to about 6 inches inward from the side edge of the primary cushion.

14. 14. The method of any one of claims 11 to 13, wherein positioning the strip of scrim fabric includes leaving a central portion of the primary cushion exposed beyond the strip of scrim fabric.

15. 15. The method of any one of claims 11 to 14, wherein securing the strip of scrim fabric comprises gluing the strip of scrim fabric to the top surface of the side rail.

16. 16. The method of any one of claims 11 to 15, wherein the primary cushion comprises an elastomeric gel.

17. 17. The method of claim 16, wherein securing the strip of scrim fabric to the top surface of the primary cushion comprises melt-bonding the strip of scrim fabric to the top surface of the primary cushion.

18. 20. The method of claim 17, wherein the melt-bonding step includes heating the top surface of the primary cushion through the scrim fabric to a temperature that causes material on the top surface of the primary cushion to melt and infiltrate into the strips of scrim fabric.

19. 19. The method of any one of claims 11 to 18, wherein the steps of securing the strip of scrim fabric to the top surface of the side rail and securing the strip of scrim fabric to the top surface of the primary cushion are performed concurrently.

20. positioning the strip of scrim fabric includes positioning at least one end portion of the strip of scrim fabric on or over a portion of at least one end rail adjacent an edge of the primary cushion and an edge of the side rail; 20. The method of any one of claims 11 to 19, further comprising the step of securing a strip of the scrim fabric to the portion of the at least one end rail.

21. positioning the strip of scrim fabric includes positioning end portions of the strip of scrim fabric over portions of end rails adjacent each end of the primary cushion; 21. The method of claim 20, wherein securing the strip of scrim fabric to the at least one end rail comprises securing the portion of the end rail.

Images