Elastomer grid containing individual cushioning elements

Abstract

To provide a thermoplastic elastomer grid capable of providing a mattress with stability and a simple structure.SOLUTION: A thermoplastic elastomer grid may comprise a first zone including first and second cushion elements, a second zone including third and fourth cushion elements, and a third zone including fifth and sixth cushion elements. In certain examples, the first, second, and third zones may be disposed to respectively support a head / shoulder region, a hip joint region, and a leg region of a human body.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to mattress assemblies and, more particularly, to elastomeric grid layers for mattress assemblies. [Background technology]

[0002] Mattress construction is one factor that influences its unique feel. There are many different types of mattresses. One type includes pillow-top mattresses, which have a "floating" layer of upholstery, giving the feeling of having a giant pillow on top of the mattress. Pillow-top mattresses may range in feel from medium to very soft. Another type includes all-foam mattresses, which can be made using a combination of polyurethane foam, memory foam, and / or latex foam. The memory foam is usually located near the sleep surface for best results. A further type of mattress includes hybrid mattresses, which use an innerspring as a support core and add a layer of specialty foam (memory foam or latex foam) on top. Hybrid mattresses offer the active support of an innerspring with the unique feel of specialty foam materials.

[0003] As is well known, one of the challenges in the mattress industry is to create mattresses that provide comfortable support for all parts of the human body. It is desirable to achieve a level of comfort that relieves localized pressure points in areas of the human body, such as the shoulders, hips, back, and legs. In recent years, the mattress industry has developed mattress pads that incorporate a combination of gel, pillow-top padding, and foam layers that can conform to the contours of the human body to provide support. Typically, the gel layer extends across the entire width and length of the mattress. However, a drawback of incorporating a pillow-top padding, gel, and / or foam layer is that the mattress may be more prone to sagging or developing depressions. Additionally, the gel layer can increase the overall weight of the mattress.

[0004] Therefore, there is a need in the art for improved mattresses that provide increased stability, longer service life, and mattress comfort. The present disclosure solves this and other related and unrelated problems. Summary of the Invention

[0005] The present application relates to a thermoplastic elastomer grid designed to overcome the shortcomings of the prior art and provide a mattress with stability and simple construction.

[0006] The thermoplastic elastomer grid is designed for use in mattress assemblies, but may also be used in seat cushions, pet beds, etc. The thermoplastic elastomer grid includes a plurality of cushioning elements having buckled walls (e.g., cell walls, retractable walls) that define hollow or void cells. The buckled walls may be oriented in a variety of shapes (e.g., squares, rectangles, diamonds, triangles, ellipses, hexagons, pentagons, circles, etc.) to create a variety of patterns.

[0007] The thermoplastic elastomer grid may include a first region having first and second cushioning elements, a second region having third and fourth cushioning elements, and a third region having fifth and sixth cushioning elements. In certain examples, the cushioning elements in the first, second, and third regions may each be constructed with a different hardness on the Shore A scale.

[0008] One aspect of the present disclosure relates to a mattress assembly including a base layer having a base surface and a support layer having a first support surface and a second support surface, wherein the support layer may span the base surface such that the first support surface of the support layer contacts the base surface of the base layer.

[0009] The mattress assembly includes an elastomeric layer including a flexible foam panel defining a plurality of cutout portions and a plurality of discrete cushioning elements, each of the discrete cushioning elements positionable within one of the cutout portions of the flexible foam panel, the second support surface of the support layer contacting the elastomeric layer, and the elastomeric layer having a composition including graphene.

[0010] The mattress assembly also includes a memory foam layer, which may have a first surface and a second surface, and the memory foam layer may extend across the elastomeric layer such that the first surface of the memory foam layer contacts the elastomeric layer.

[0011] The mattress assembly may include a cover that may have a cover surface that extends over the memory foam layer such that the cover surface contacts the second surface of the memory foam layer.

[0012] The mattress assembly may also include a spring layer between two support layers, and the spring layer may include a plurality of coils each enclosed in a casing made of a nonwoven bag.

[0013] Another aspect of the present disclosure relates to a mattress assembly including a tri-fold mattress. The mattress assembly may include a first segment, a second segment, and a third segment. Each of the first, second, and third segments may include an elastomeric layer having a flexible foam panel defining a plurality of cutout portions and a plurality of individual cushioning elements positionable in one of the cutout portions of the flexible foam panel. The cutout portions and the plurality of individual cushioning elements may have the same shape.

[0014] Each of the first, second, and third segments of the mattress assembly includes a support layer, a first mattress cover, and a second mattress cover. The elastomeric layer, the support layer, and the first and second mattress covers are concealed in the first, second, and third segments, respectively, by zippers. The first, second, and third segments are connected to each other by a fabric cover. The first, second, and third segments may be pivotable and foldable along seams in the fabric cover of the mattress assembly.

[0015] A further aspect of the present disclosure relates to a mattress assembly including a base layer having a base surface and a support layer having a first support surface and a second support surface, wherein the support layer may span the base surface such that the first support surface of the support layer contacts the base surface of the base layer.

[0016] The mattress assembly also includes a gel layer having a first gel surface and a second gel surface, and the gel layer may extend across the support layer such that the first gel surface of the gel layer contacts the second support surface of the support layer.

[0017] The mattress assembly also includes an adaptive foam layer having a first foam surface and a second foam surface, and the adaptive foam layer may extend across the gel layer such that the first foam surface of the adaptive foam layer contacts the second gel surface of the gel layer.

[0018] The mattress assembly further includes an elastomer layer. The elastomer layer may include a flex foam encasement, a first thermoplastic elastomer grid region including a first cushioning element and a second cushioning element, a second thermoplastic elastomer grid region including a third cushioning element and a fourth cushioning element, and a third thermoplastic elastomer grid region including a fifth cushioning element and a sixth cushioning element. The flex foam encasement may define boundaries surrounding the first, second, and third thermoplastic elastomer grid regions. The first, second, and third thermoplastic elastomer grid regions of the elastomer layer may include a composition including graphene.

[0019] The elastomeric layer may have a first elastomeric surface and a second elastomeric surface, and may extend across the adaptive foam layer such that the first elastomeric surface of the elastomeric layer contacts the second foam surface of the adaptive foam layer.

[0020] Another aspect of the present disclosure relates to a graphite thermoplastic elastomer grid including a first region having first and second cushioning elements, a second region having third and fourth cushioning elements, and a third region having fifth and sixth cushioning elements.

[0021] Each of the first, second, third, fourth, fifth, and sixth cushioning elements includes two long sides that extend parallel to one another. The two long sides of each of the first, second, third, fourth, fifth, and sixth cushioning elements may be interconnected by two short sides that extend parallel to one another.

[0022] The first and second cushioning elements in the first region may be attached together at one of the short sides thereof, the third and fourth cushioning elements in the second region may be attached together at one of the short sides thereof, and the fifth and sixth cushioning elements in the third region may be attached together at one of the short sides thereof.

[0023] These and other features and advantages will become apparent upon reading the following detailed description and reviewing the associated drawings. Various additional aspects are set forth in the following description. These aspects may relate to individual features and 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 intended to limit the broad concepts underlying the embodiments disclosed herein. [Brief explanation of the drawings]

[0024] 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 follows: [Figure 1] 1 shows an example of an exploded schematic view of an exemplary mattress assembly including a base, a support layer, a gel layer, an adaptive foam layer, an elastomeric layer, and a cover according to the principles of the present disclosure. [Figure 2] 2 shows the mattress assembly of FIG. 1 with the base and cover removed. [Figure 3] 2 shows an example of an exploded view of a portion of the mattress assembly of FIG. 1. [Figure 4-5] 2 illustrates an example of a perspective view of the elastomeric layer of FIG. 1 including two dividers according to the principles of the present disclosure. [Figure 6-7] FIG. 1 shows an example of a perspective view of an elastomer layer without a divider. [Figure 8] 1 illustrates an example of a perspective view of an elastomeric layer including a single divider according to the principles of the present disclosure. [Figure 9]1 shows an example of a perspective view of an elastomeric layer including a single divider of different widths according to the principles of the present disclosure. [Figure 10] 1 illustrates an example of a plan view of an elastomeric layer including multiple cushioning elements according to the principles of the present disclosure. [Figure 11] 4 shows an example of an exploded view of FIG. 3 showing the stabilizing material. [Figure 12] 12 is an example of a plan view of the stabilizing material of FIG. 11. [Figure 13-15] 10A-10C illustrate examples of multiple views of cushioning element patterns and shapes according to the principles of the present disclosure. [Figure 16-17] 1 illustrates another exemplary mattress assembly including a memory foam layer and a spring layer according to the principles of the present disclosure. [Figure 18] 1 illustrates another example mattress assembly including a memory foam layer according to the principles of the present disclosure, a support layer, and an elastomeric layer including flex foam panels and a plurality of individual cushioning elements. [Figure 19] 19 shows an example of a perspective view of the elastomeric layer of FIG. 18. [Figure 20] 19 shows an example of a perspective view of the flex foam layer of FIG. 18 with the plurality of individual cushioning elements exploded. [Figure 21] 19 shows an example of a plan view of the elastomer layer of FIG. 18. [Figure 22] 1 illustrates another example mattress assembly including an elastomeric layer with an increased number of individual cushioning elements in a flex foam panel according to the principles of the present disclosure. [Figure 22A] 23 shows an example of a perspective view of the elastomeric layer of FIG. 22. [Figure 22B] 1 illustrates an example of another exemplary mattress assembly according to the principles of the present disclosure. [Figure 23] FIG. 22C shows an example of a top view of the elastomeric layer of FIG. 22B. [Figure 24] 21 is an example of an enlarged view of an individual cushioning element of FIG. 20. [Figure 25-28]1 illustrates another exemplary mattress assembly including a memory foam layer according to the principles of the present disclosure, a support layer, and an elastomeric layer including flex foam panels and a plurality of individual cushioning elements. [Figure 29-30] 10 illustrates another exemplary elastomeric layer example having an increased number of individual cushioning elements in a flex foam panel according to the principles of the present disclosure. [Figure 31-32] 1 shows an example of another exemplary mattress assembly according to the principles of the present disclosure. [Figure 33] 1 illustrates an example of an exemplary tri-fold mattress according to the principles of the present disclosure. [Figure 34] 34 illustrates an example of mattress components for the tri-fold mattress of FIG. 33 including an elastomeric layer, a support layer, a top mattress cover, and a bottom mattress cover according to the principles of the present disclosure. [Figure 35] 35 illustrates an example of the elastomeric layer of FIG. 34 including a flex foam panel and a plurality of individual cushioning elements according to the principles of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0025] This application relates to a thermoplastic elastomer grid for use in mattresses, seats, pet beds, etc. The thermoplastic elastomer grid is arranged to provide lateral stability by being formed from individual cushioning elements, i.e., the cushioning elements are separate pieces that can be separately placed within a mattress assembly as part of the thermoplastic elastomer grid.

[0026] The discrete cushioning elements may be arranged to provide different resilience properties in regions of the thermoplastic elastomer grid. That is, a first region may include cushioning elements having a desired firmness in the shoulder regions, a second region may include cushioning elements having a desired firmness in the hip regions, and a third region may include cushioning elements having a desired firmness in the leg regions. In certain examples, the resilient support of the cushioning elements in the hip regions may be stronger than the resilient support of the cushioning elements in the shoulder and / or leg regions.

[0027] 1 shows an example of an exploded view of an exemplary mattress assembly 100 according to the principles of the present disclosure. The mattress assembly 100 includes a multi-layer structure. 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 will be understood that one or more additional layers may be included as desired.

[0028] 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 be sized to provide a twin bed (generally referring to a length of about 75 inches and a width of about 38 inches), a full or double bed (generally referring to a length of about 75 inches and a width of about 53 inches), a queen bed (generally referring to a length of about 80 inches and a width of about 60 inches), or a king bed (generally referring to a length of about 80 inches and a width of about 76 inches).

[0029] The base 102 is typically the first layer in a mattress assembly. The base 102 is disposed at the bottom of the mattress assembly 100 and provides a foundation upon which the support layer 104, gel layer 106, foam layer 108, elastomeric layer 110, and cover 112 are disposed. In certain examples, the base 102 may comprise a foam material. The foam material may include polyurethane foam, latex foam, polyethylene foam, polypropylene foam, polystyrene, etc. The base 102 has a first end 114 (e.g., top end) and a second end 116 (e.g., 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 the mattress, and the second end 116 is associated with a footer portion of the mattress.

[0030] The base 102 may have a height or thickness T1 that can be varied as needed.

[0031] In certain examples, the thickness T1 of the base 102 may be approximately 12 inches. In certain examples, the thickness T1 of the base 102 may be 14 inches or less. In other examples, the thickness T1 of the base 102 may be from about 1 to about 18 inches, although alternatives are possible.

[0032] In the illustrated example, the base 102 has a sloped portion 120 (e.g., an inclined portion, a tapered portion) that tapers from a thickness T1 to a height or thickness T2. The thickness T2 of the base 201 may also be varied as desired. In a particular example, the thickness T2 may be approximately 1-9 inches, although alternatives are possible.

[0033] Referring to Figure 2, the mattress assembly 100 is shown with the base 102 and cover 112 removed. The support layer 104 may be designed to provide additional support and structural conformation to the mattress assembly 100. The support layer 104 may include a foam material that provides flexibility. The foam material may include polyurethane foam, latex foam, polyethylene foam, polypropylene foam, and / or combinations thereof. The support layer 104 may also include a flat foam or a complex foam.

[0034] In particular examples, the support layer 104 has a compressibility of about 1.5 to about 5 lb / ft 3 The support layer 104 may have a density of about 10 to about 25 lbs. The support layer 104 may also include an indentation load deflection (ILD) of about 10 to about 25 lbs. In certain examples, the indentation load deflection may be 20 to 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 1 to 10 inches, although alternatives are possible. In certain examples, the thickness T3 may be 7 inches.

[0035] 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 entire base surface 118. In this manner, the first support surface 122 of the support layer 104 may contact (e.g., engage, adhere) with the base surface 118 of the base 102. In certain examples, a water-based adhesive may be used to form a bond between the support layer 104 and the base 102.

[0036] Gel layer 106 may be formed from a liquid or solid gel, a foam gel, or a combination of liquid, solid, and / or foam gels. In the illustrated example, gel layer 106 comprises a liquid gel flexible foam layer. Example gels may include silicone gel, PVC gel, polyorganosiloxane gel, polyol gel, polyurethane gel, and polyisocyanate gel. Preferably, the gel is dimensionally stable.

[0037] In a particular example, the gel layer 106 has a resistance of 1.5 to about 5 lb / ft 3 The gel layer 106 may have a density of about 10 to about 25 pts. The gel layer 106 may also include an indentation load deflection (ILD) of about 10 to about 25 pts. In particular examples, the indentation load deflection may be 15 to about 60 pts. The gel layer 106 may have a height or thickness T4. The thickness T4 of the gel layer 106 may also vary. In particular examples, the thickness T4 may be 1 to 3 inches, although alternatives are possible. In particular examples, the thickness T4 may be about 1 inch. In particular examples, the thickness T4 may be about 2 inches.

[0038] 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 entire support layer 104. In this manner, the first gel surface 126 of the gel layer 106 may contact the second support surface 124 of the support layer 104. A water-based adhesive may be used to form a bond between the support layer 104 and the gel layer 106.

[0039] The adaptive foam layer 108 may provide rebound support; that is, the adaptive foam layer 108 may be designed to conform to the contours of the human body to relieve pressure points without trapping heat. The adaptive foam layer 108 may include a polyfoam open cell design that allows air to circulate and helps the mattress breathe. Exemplary adaptive foams may include polyurethane foam, memory foam, latex foam, and gel memory foam, although alternatives are possible.

[0040] In particular examples, the adaptive foam layer 108 has a compressibility of about 1.5 to about 5 lb / ft 3 The adaptive foam layer 108 may have a density of 100 psi to 100 psi. The adaptive foam layer 108 may also include an indentation load deflection (ILD). The indentation load deflection may be from about 5 to about 20 psi, although alternatives are possible. In particular examples, the indentation load deflection may be from 10 to about 30 psi. 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 particular examples, the thickness T5 may be from 1 to 5 inches, although alternatives are possible. In particular examples, the thickness T5 may be about 1.5 inches.

[0041] Adaptive foam layer 108 has a first foam surface 130 (e.g., lower surface, bottom surface) and an opposing second foam surface 132 (e.g., upper surface, top surface). During assembly, adaptive foam layer 108 may be placed on gel layer 106 and extend across gel layer 106. In this manner, first foam surface 130 of adaptive foam layer 108 may contact second gel surface 128 of gel layer 106. A water-based adhesive may be used to form a bond between adaptive foam layer 108 and gel layer 106.

[0042] Returning to Figure 3, a portion of mattress assembly 100 is depicted with elastomeric layer 110 and gel layer 106 shown. Elastomeric layer 110 may include a flex foam encasement 134 and a plurality of cushioning elements. The plurality of cushioning elements may include a first cushioning element 136, a second cushioning element 138, a third cushioning element 140, a fourth cushioning element 142, a fifth cushioning element 144, and a sixth cushioning element 146.

[0043] The flex foam encasement 134 has a rectangular shape and defines a central opening 148. The flex foam encasement 134 may include a foam material that provides flexibility. The foam material may include polyurethane foam, latex foam, polyethylene foam, polypropylene foam, and / or combinations thereof.

[0044] In certain examples, multiple portions together form flex form encasement 134 and define central opening 148. That is, flex form encasement 134 does not have to be made of a single, integral structure. For example, flex form encasement 134 may be comprised of four portions 134a, 134b, 134c, and 134d that together define central opening 148. The four portions 134a, 134b, 134c, and 134d may be fixedly coupled to one another by fasteners, adhesive, frictional engagement of the four pieces 134a, 134b, 134c, and 134d themselves, or a combination thereof. In other examples, flex form encasement 134 may be formed from more or fewer portions.

[0045] When assembled, the flex foam encasement 134 may provide a perimeter around the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 by surrounding them. That is, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may be received in a central opening 148 of the flex foam encasement 134 when assembled.

[0046] The flex foam encasement 134 and the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 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 and 3 inches, although alternatives are possible. In certain examples, the thickness T6 may be between 1 and 2 inches. The flex foam encasement 134 has a width W (see FIG. 4) of approximately 120 mm (millimeters), although alternatives are possible. In certain examples, the flex foam encasement 134 may have a density of between about 1.5 and about 5 lb / ft3. The flex foam encasement 134 may also include an indentation load deflection (ILD). The indentation load deflection may be between about 10 and about 60 lb / ft, although alternatives are possible. In a particular example, the indentation load deflection may be 20 to about 40 pts.

[0047] 3, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 each define an area within the central opening 148 of the flex foam encasement 134. For example, the first and second cushioning elements 136, 138 together define a first thermoplastic elastomer grid area 150, the third and fourth cushioning elements 140, 142 together define a second thermoplastic elastomer grid area 152, and the fifth and sixth cushioning elements 144, 146 together define a third thermoplastic elastomer grid area 154.

[0048] The first, second, and third thermoplastic elastomer grid regions 150, 152, 154 are separated at the central opening 148 of the flex foam encasement 134 by a divider 156 (e.g., a partition, wall, or barrier). The divider 156 may have a different material composition than the flex foam encasement 134. The divider 156 may be attached to the central opening 148 so as to be perpendicular to the long side 158 of the flex foam encasement 134 and parallel to the short side 160 of the flex foam encasement 134, although alternatives are possible. Thus, the divider 156 may be oriented perpendicular to the longitudinal axis X of the flex foam encasement 134 and attached to the long side 158 of the flex foam encasement 134, although alternatives are possible.

[0049] With reference to Figures 4-5, two dividers 156 are shown separating the first, second, and third thermoplastic elastomer grid regions 150, 151, and 154. The width W1 of the dividers 156 may vary based on, for example, the size of the bed. In certain examples, the width W1 of the dividers may be approximately 120-160 mm, although alternatives are possible. In other examples, dividers may not be used to separate the first, second, and third thermoplastic elastomer grid regions 150, 152, and 154 (see Figures 6-7).

[0050] In yet another example, a single divider 156a is provided to separate the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146, each extending along the longitudinal axis X (see FIGS. 8 and 9). The divider 156a may have a width W2 (see FIG. 9) that also varies based on the size of the bed. In a particular example, the divider 156a may have a width W2 of 50 mm for a queen-size bed, although alternatives are possible. In a particular example, the divider 156a may have a width W2 of 185 mm for a king-size bed, although alternatives are possible. The divider 156a is attached to the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146, respectively, with an adhesive.

[0051] The first, second, and third thermoplastic elastomer grid regions 150, 152, and 154 may be positioned along the longitudinal axis X of the flex form encasement 134 to provide the desired amount of lateral support. The first, second, and third thermoplastic elastomer grid regions 150, 152, and 154 may be arranged in a generally parallel array with respect to one another. The first, second, and third thermoplastic elastomer grid regions 150, 152, and 154 may laterally span the central opening 148 of the flex form encasement 134.

[0052] 10 , an example is shown of first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, and 146. When assembled into mattress assembly 100, first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, and 146 are separated from one another by two dividers 156.

[0053] Each of the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 includes a first long side 162 and a second long side 164 that extend parallel to one another. The first and second long sides 162, 164 of each of the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 are interconnected by a first short side 166 and a second short side 168 that also extend parallel to one another.

[0054] In the example shown in Figure 10, the second short side 168 of the first cushioning element 136 is attached to the first short side 166 of the second cushioning element 138 along the longitudinal axis X, although alternatives are possible. Also, the second short side 168 of the third cushioning element 140 is attached to the first short side 166 of the fourth cushioning element 142 along the longitudinal axis X, although alternatives are possible. Furthermore, the second short side 168 of the fifth cushioning element 144 is attached to the first short side 166 of the sixth cushioning element 146 along the longitudinal axis X, although alternatives are possible.

[0055] As shown in FIGS. 6 and 7 , when the elastomer layer 110 does not have a partition plate 156, the second long side 164 of the first cushion element 136 may also be attached to the first long side 162 of the third cushion element 140. The second long side 164 of the third cushion element 140 may also be attached to the first long side 162 of the fifth cushion element 144. The second long side 164 of the second cushion element 138 may also be attached to the first long side 162 of the fourth cushion element 142. The second long side 164 of the fourth cushion element 142 may also be attached to the first long side 162 of the sixth cushion element 146.

[0056] 8-9, when a single divider 156a is provided in the elastomeric layer 110, the first, third, and fifth cushioning elements 136, 140, 144 can be attached at their respective first and second long sides 162, 164. Also, the second, fourth, and sixth cushioning elements 138, 142, 146 can be attached at their respective first and second long sides 162, 164.

[0057] The size of the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may vary based on the bed size and the divider (if any) used. For example, if the mattress assembly 100 for a queen-size bed includes the divider 156, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may be approximately 500 mm by 642 mm. If the mattress assembly 100 for a king-size bed includes the divider 156, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may be approximately 500 mm by 845 mm.

[0058] 6-7, in the absence of dividers in the structure, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 are attached together at their respective long and short sides 162, 164, 166, and 168. For a queen-size bed without dividers, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may be approximately 600 mm by 642 mm in size. For a king-size bed without dividers, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may be approximately 600 mm by 845 mm in size.

[0059] 8-9, when the mattress assembly 100 includes the divider 156a, the divider 156a can be attached to the first and second short sides 166, 168 of each of the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146. For both queen and king size beds including the divider 156a, the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 can be approximately 645 mm by 690 mm in size.

[0060] In a particular example, each of the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may include A-B diblock copolymer and A-B-A reblock copolymer in proportions of 15% to 85%, a plasticizer (e.g., mineral oil) in proportions of 30% to 85%, polyethylene in proportions of 0.01% to 20%, antioxidant in proportions of 0.1% to 4%, erucylamide in proportions of 0.01% to 2%, and graphene in proportions of 1% to 10%, although alternatives are possible. As will be appreciated, the composition of each of the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may be different in each of the first, second, and third thermoplastic elastomer grid regions 150, 152, and 154 to achieve desired comfort and lateral stability. For example, the first and second cushioning elements 136, 138 in the first thermoplastic elastomer grid region 150 may have a composition to achieve desired firmness in the neck and shoulder regions. The third and fourth cushioning elements 140, 142 in the second thermoplastic elastomer grid region 152 may have a composition that is different or the same as the first thermoplastic elastomer grid region 150 to achieve desired firmness in the hip joint regions. The fifth and sixth cushioning elements 144, 146 in the third thermoplastic elastomer grid region 154 may have a composition that may be different or the same as the first and second thermoplastic elastomer grid regions 150, 152 to achieve the desired firmness in the leg region.

[0061] 11-12 , mattress assembly 100 may also include a stabilizing material 170 (e.g., scrim, fabric). During assembly, stabilizing material 170 may be attached to the underside 172 of each of first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 with an adhesive. In this manner, stabilizing material 170 and first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 may be bonded to adaptive foam layer 108. The undersides 172 of first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146 include stabilizing material 170 in contact with second foam surface 132 of adaptive foam layer 108. In certain examples, the stabilizing material 170 may be used to provide structural conformation to the first, second, third, fourth, fifth, and sixth cushioning elements 136 , 138 , 140 , 142 , 144 , and 146 in the adaptive foam layer 108 .

[0062] Stabilizing material 170 defines cutouts 174 (e.g., openings, voids) that, upon assembly, are disposed between first, second, and third thermoplastic elastomer grid regions 150, 152, and 154, respectively. Cutouts 174 may have a width W3 of approximately 66 mm, although alternatives are possible. Divider 156 may span cutouts 174 when assembled into central opening 148 of flex foam encasement 134. Divider 156 may be secured to stabilizing material 170 and adaptive foam layer 108 to enhance the stability of elastomeric layer 110.

[0063] The stabilizing material 170 does not extend into the flex foam encasement 134. The flex foam encasement 134 provides a perimeter surrounding the first, second, third, fourth, fifth, and sixth cushioning elements 136, 138, 140, 142, 144, and 146.

[0064] 13-15 illustrate exemplary cushioning elements 136, 136a, 136b having different patterns and shapes in accordance with the principles of the present disclosure. The cushioning elements 136, 136a, 136b can be arranged in a variety of shapes and sizes. In certain examples, the cushioning elements may have different patterns or shapes, such as square patterns or shapes, circular patterns or shapes, diamond patterns or shapes, triangular patterns or shapes, hexagonal patterns or shapes, rectangular patterns or shapes, pentagonal patterns or shapes, and / or any combination thereof.

[0065] The cushioning elements 136, 136a, 136b include walls 176 that form various patterns and shapes, as shown in FIGS. 13-15 . The walls 176 are designed to be interconnected to define voids 178 (e.g., holes, spaces, cavities). In certain examples, the walls 176 of the cushioning elements 136, 136a, 136b may have the same height, although alternatives are possible. The walls 176 define a grid structure of the patterns and shapes of the cushioning elements 136, 136a, 136b. The voids 178 help create airflow in the mattress assembly 100 by removing hot air from underneath the body. The walls 176 are designed to buckle and return to their original shape after deformation. The amount of deformation may vary depending on the desired stiffness based on the Shore A scale. The desired cushioning may be greater or less for each cushioning element arranged within the mattress assembly 100. In a particular example, the height or thickness of the wall 176 is 3 inches or less to allow the wall 176 to support the pattern or shape of the cushioning elements 136, 136a, 136b.

[0066] The cover 112 of the mattress assembly 100 includes a fabric that also has cooling properties. The cover may include a variety of materials and fabrics, including cotton, polyester, polymers, waterproof materials, synthetic fibers, and any combination thereof. In certain examples, the cover 112 may be flexible and elastic, stretching and returning to its original shape and / or size. The cover 112 may be positioned to at least partially surround the entire multi-layer structure. The cover 112 includes a mating sloped member 180 (see FIG. 1 ) that mates with the sloped member 120 of the base 102, thereby engaging the sloped members 120, 180 when attached together.

[0067] 16-17, another exemplary mattress assembly 200 is shown. Mattress assembly 200 is similar to mattress assembly 100 described previously, except that mattress assembly 200 includes a spring layer 212 between gel layer 206 and support layer 204, and a memory foam layer 214 between adaptive foam layer 208 and elastomeric layer 210. As such, only spring layer 212 and memory foam layer 214 will be described in detail. It will be understood that features described herein for mattress assembly 100 also apply to mattress assembly 200. Similar numbers to mattress assembly 100 will be used to refer to layers in mattress assembly 200, such as 200s.

[0068] The spring layer 212 may provide additional support and rigidity to the mattress assembly 100. The spring layer 212 includes a plurality of coils 216 each encased in a casing 218. In certain examples, the coils 216 may be cylindrical. The casing 218 may comprise a nonwoven bag. The spring layer 212 may include an indentation load deflection (ILD). The indentation load deflection may be from about 10 to about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be from 20 to about 40 lbs. The spring layer 212 may have a height or thickness T7 ranging from about 5 to about 10 inches, although alternatives are possible. The coils 216 form a coil unit in which the composition is encased by edge foam support 220, similar to the flexfoam encasement 134. In certain examples, the spring layer 212 includes a 15-gauge coil unit.

[0069] The memory foam layer 214 may comprise a polyurethane viscoelastic foam material. The memory foam layer 214 is configured to contour to the human body during use of the mattress assembly 100. In certain examples, the memory foam layer 214 has a stiffness of about 1.5 to about 5 lb / ft 3 The shape memory foam layer 214 may have a density of 10 to 15 lbs. The shape memory foam layer 214 may have a height or thickness T8 that may be 1 to 2 inches, although alternatives are possible. The shape memory foam layer 214 may include an indentation load deflection (ILD). The indentation load deflection may be about 10 to about 20 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be 5 to about 15 lbs.

[0070] 18-21 , another exemplary mattress assembly 300 is shown without a top mattress cover 301 (e.g., upper cover) and a bottom mattress cover 303 (e.g., lower cover). Mattress assembly 300 is similar to previously described mattress assemblies 100 and 200, except that mattress assembly 300 has a distinct elastomeric layer 302 positioned between memory foam layer 304 and support layer 306. As such, only elastomeric layer 302 will be described in detail. As will be appreciated, the features described herein for mattress assemblies 100 and 200 also apply to mattress assembly 300.

[0071] The elastomeric layer 302 includes a flex foam panel 308 and a plurality of individual cushioning elements 310. The flex foam panel 308 is a single piece, although alternatives are possible. The flex foam panel 308 may include a foam material that provides flexibility. The foam material may include polyurethane foam, latex foam, polyethylene foam, polypropylene foam, and / or combinations thereof.

[0072] The individual cushioning elements 310 may comprise a material different from that of the flex foam panel 308. The individual cushioning elements 310 may comprise a thermoplastic material (e.g., a thermoplastic elastomer). Each of the individual cushioning elements 310 may comprise an A-B diblock copolymer and an A-B-A reblock copolymer in a ratio of 15% to 85%, a plasticizer (e.g., mineral oil) in a ratio of 30% to 85%, polyethylene in a ratio of 0.01% to 20%, an antioxidant in a ratio of 0.1% to 4%, erucylamide in a ratio of 0.01% to 2%, and graphene in a ratio of 1% to 10%, although alternatives are possible. In certain examples, the individual cushioning elements 310 may comprise a gel and one or more non-gel materials.

[0073] The flex foam panel 308 may have dimensions of, for example, approximately 60 inches by 80 inches for a queen size bed, 76 inches by 80 inches for a king size bed, and 38 inches by 75 inches for a twin size bed. In certain examples, the flex foam panel 308 and the individual cushioning elements 310 may have the same height or thickness T9 (see FIG. 20), although alternatives are possible. That is, the individual cushioning elements 310 may have the same height. In other examples, the individual cushioning elements 310 may have varying heights within the flex foam panel 308. In certain examples, the height or thickness T9 may be between 1 and 3 inches, although alternatives are possible. In certain examples, the thickness T9 may be between 1 and 2 inches.

[0074] In a particular example, the flex foam panel 308 has a compressibility of about 1.5 to about 5 lb / ft 3 The flex foam panel 308 may have a density of 10 to 60 lbs. The flex foam panel 308 may also include an indentation load deflection (ILD). The indentation load deflection may be from about 10 to about 60 lbs, although alternatives are possible. In a particular example, the indentation load deflection may be from 20 to about 40 lbs.

[0075] 20, the flex foam panel 308 defines a plurality of cutout portions 312, each of which provides a recess or opening for receiving an individual cushioning element 310. Any suitable pattern may be used to cut out the cutout portions 312. The cutout portions 312 may be made by punching, cutting, die-cutting, or other process or suitable tooling.

[0076] The cutout portions 312 extend all the way through the flex foam panel 308. In other examples, the cutout portions 312 may be at a predetermined depth in the flex foam panel 308. The spacing and size of the cutout portions 312 may be the same, as shown in Figures 19, 21, and 23, although alternatives are possible.

[0077] In certain examples, the vertical or horizontal spacing S1 between each of the cutout portions 312 in the flex foam panels s308, 308a may be about 40 to about 50 mm, although alternatives are possible. In certain examples, the spacing S1 may be about 20 to about 60 mm. In certain examples, the spacing S1 may be about 80 to about 100 mm.

[0078] In certain examples, the number of cutout portions 312 defined in the flex foam panel 308 may be increased, as shown in FIGS. 22-23, while the spacing and size of the cutout portions 312 may remain the same. For example, FIG. 21 shows the cutout portions 312 defined in the flex foam panel 308 arranged in five columns and seven rows, although alternatives are possible. In another mattress assembly 300a shown in FIG. 22, the cutout portions 312 defined in the flex foam panel 308a (see FIGS. 22A and 23) are arranged in six columns and nine rows, although alternatives are possible. As shown, increasing the number of cutout portions 312 in the flex foam panel 308a of the mattress assembly 300a also increases the number of individual cushioning elements 310a in the flex foam panel 308a. In this manner, the overall density may be increased.

[0079] The cutout portions 312 may be sized and shaped to receive the individual cushioning elements 310. The cutout portions 312 may be various shapes, such as circular, square, rectangular, triangular, star, hexagonal, octagonal, pentagonal, oval, etc. In the example shown in FIGS. 19 and 22, the cutouts 312 are circular in shape. In other examples, cutout portions 312 defined in the same flex foam panel 308 may differ in shape, size, spacing, etc. from one another. Thus, in the flex foam panel 308, the individual cushioning elements 310 may differ in shape, size, spacing, etc. from one another.

[0080] The individual cushioning elements 310 are inserted into each of the cutout portions 312. No adhesive or glue is used to secure the individual cushioning elements 310 within the cutout portions 312. The individual cushioning elements 310 may have the same size and shape as the cutout portions 312 so that each individual cushioning element 310 is firmly but removably held within the appropriate cutout portion 312 by friction. Each individual cushioning element 310 may be positioned within the corresponding cutout portion 312 without creating uncomfortable ridges or creases felt by the user. The symmetrical and uniform design of the elastomer layer 302 allows for desired comfort, stability, and balance in the mattress assembly 300. For example, desired comfort may be achieved in the head region, hip region, and leg region of the mattress assembly 300.

[0081] 24 , each of the individual cushioning elements 310 includes a circular perimeter to complement the circular shape of the cutout portion 312. The individual cushioning elements 310 are shown as being isolated from one another in the flex foam panel 308. That is, the individual cushioning elements 310 are not interconnected to one another in adjacent columns or rows in the flex foam panel 308.

[0082] Each of the individual cushioning elements 310 includes a unique pattern. Each of the individual cushioning elements 310 may include a central cylindrical rod-shaped element 314 and a plurality of interconnected sidewall segments 316 extending from the cylindrical rod-shaped element 314 about its axis. The plurality of interconnected sidewall segments 316 also extend at various angles to a perimeter wall 318 of the individual cushioning element 310.

[0083] In certain examples, the multiple interconnected sidewall segments 316 can be angled relative to one another to provide multiple polygonal members. In the illustrated example, there is a pattern of multiple pentagonal members, in addition to other polygonal shapes. As will be appreciated, the interconnected sidewall segments 316 of the individual cushioning elements 310 may be arranged to form other shapes, such as squares, hexagons, heptagons, octagons, etc.

[0084] The pentagonal members and other shapes formed by the interconnected sidewall segments 316 of the individual cushioning elements 310 may be devoid of material, such that they are essentially empty cells or voids. That is, the interconnected sidewall segments 316 create a number of open cavities 320 that allow the individual cushioning elements 310 to flex. Additionally, the open cavities 320 of the individual cushioning elements 310 may provide ventilation in the mattress assembly 300.

[0085] 18 , the elastomeric layer 302 may be connected to the memory foam layer 304 and the support layer 306 by an adhesive or glue. In certain examples, a water-based adhesive may be present between the memory foam layer 304 and the elastomeric layer 302 to form a bond. A water-based adhesive may also be used to form a bond between the support layer 306 and the elastomeric layer 302. There is no fabric or connecting layer between the elastomeric layer 302 and the memory foam layer 304 or between the elastomeric layer 302 and the support layer 306.

[0086] In the illustrated example, memory foam layer 304 is positioned above elastomeric layer 302, and support layer 306 is positioned below elastomeric layer 302. Memory foam layer 304 and support layer 306 may each extend across elastomeric layer 302.

[0087] Memory foam layer 304 may be similar to memory foam layer 214 described above. Memory foam layer 304 is configured to contour to the human body during use of mattress assembly 300. In particular examples, memory foam layer 304 has a compressibility of about 1.5 to about 5 lb / ft 3 The memory foam layer 304 may have a density of 0.05 to 0.25 mm. The memory foam layer 304 may have a height or thickness T 10 The memory foam layer 304 may have an indentation load deflection (ILD). The indentation load deflection may be from about 10 to about 20 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be from 5 to about 15 lbs.

[0088] The support layer 306 has similar characteristics to the support layers 104, 204 described above. The support layer 306 may be designed to provide additional support and structural conformation to the mattress assembly 300. The support layer 306 may include a foam material that provides flexibility. The foam material may include polyurethane foam, latex foam, polyethylene foam, polypropylene foam, and / or combinations thereof. The support layer 306 may also include flat foam or complex foam.

[0089] The support layer 306 has a height or thickness T 11 The support layer 306 may have a thickness T 11 is the thickness T of the memory foam layer 304 10 In a particular example, the thickness T 11 may be 1 to 10 inches, although alternatives are possible.

[0090] The support layer 306a of the mattress assembly 300a has a height or thickness T greater than the support layer 306 of the mattress assembly 300. 11 In a particular example, the support layer 306a may have a thickness T 11a may be 5 inches, although alternatives are possible. In a particular example, the thickness T of the support layer 306a11a may be 5 to 10 inches, although alternatives are possible.

[0091] 22B illustrates another mattress assembly 300b according to the principles of the present disclosure. The support layer 306b of mattress assembly 300b has a similar height or thickness T 11b In a particular example, the support layer 306b may have a thickness T 11b The thickness of support layer 306b of mattress assembly 300b may be between 1 and 2 inches, although alternatives are possible. In another example, support layer 306b of mattress assembly 300b may be between about 1.2 and about 1.5 inches, although alternatives are possible. The mattress assembly 300b includes an elastomeric layer 302b similar to elastomeric layer 302a of mattress assembly 300a, and a memory foam layer 304b similar to memory foam layers 304, 304a.

[0092] 25-28 , another exemplary mattress assembly 400 is shown with a top mattress cover 401 (e.g., upper cover) and a bottom mattress cover 403. Mattress assembly 400 is similar to mattress assembly 300 described above, except that mattress assembly 400 has a distinct elastomeric layer 402 positioned between memory foam layer 404 and support layer 406. Memory foam layer 404 is similar to memory foam layer 304 described above, and support layer 406 is similar to support layer 306 described above. As such, only elastomeric layer 402 will be described in detail. As will be understood, the features described herein for mattress assembly 300 also apply to mattress assembly 400.

[0093] The elastomeric layer 402 includes a flex foam panel 408 and a plurality of individual cushioning elements 410. Each of the individual cushioning elements 410 may include an A-B diblock copolymer and an A-B-A reblock copolymer in proportions of 15% to 85%, a plasticizer (e.g., mineral oil) in proportions of 30% to 85%, polyethylene in proportions of 0.01% to 20%, antioxidants in proportions of 0.1% to 4%, erucylamide in proportions of 0.01% to 2%, and graphene in proportions of 1% to 10%, although alternatives are possible.

[0094] Flex foam panel 408 is similar to flex foam panel 308, but it has a greater height or thickness T 12 In a particular example, the height or thickness T 12 may be 1 to 10 inches, although alternatives are possible. In certain instances, the height or thickness T 12 may be about 2 inches. In a particular example, the height or thickness T 12 may be about 3 inches. In a particular example, the height or thickness T 12 may be about 4 inches. In a particular example, the height or thickness T 12 may be about 6 inches.

[0095] The flex foam panel 408 includes cutout portions 412, each having a shape that matches the shape of an individual cushioning element 410. In the illustrated example, each individual cushioning element 410 includes a plurality of interconnected sidewall segments 416 that intersect to form a pentagonal grid. The perimeters of the cutout portions 412 defined in the flex foam panel 408 generally form a star-shaped geometric shape that corresponds to the perimeter of the individual cushioning element 410. In this manner, the individual cushioning element 410 may be inserted into the cutout portions 412 of the flex foam panel 408 without gaps. That is, the contours of the individual cushioning element 410 perfectly match within the cutout portions 412. As will be appreciated, in other embodiments, the individual cushioning elements 410 may vary in shape and pattern. Accordingly, the cutout portions 412 may also vary in shape and pattern to correspond to the individual cushioning elements 410. As will be appreciated, any variation in the shape and pattern of the individual cushioning elements 310,410 or cut-out portions 312,412 will not alter or change the required performance of the mattress assemblies 300,400.

[0096] The cutouts 410 in the flex foam panel 408 may be approximately 150 mm wide in size. The cutouts 410 in the flex foam panel 408 may be spaced apart from each other in both the vertical and horizontal directions by approximately 100 to 106 mm.

[0097] As shown in Figures 29-30, the number of cutouts 412a in the flex foam panel 408a may be increased. The cutouts 412a in the flex foam panel 408a may each be approximately 150 mm wide. The cutouts 412a in the flex foam panel 408a may be spaced approximately 50 to 56 mm apart from each other in the vertical and horizontal directions.

[0098] 31-32, another exemplary mattress assembly 500 is shown. Mattress assembly 500 is similar to mattress assemblies 300, 400 described previously, except that mattress assembly 500 includes a spring layer 512 between first and second support layers 506a, 506b. Support layers 506a, 506b may be similar to support layers 306, 306, 306b described above, although alternatives are possible. Spring layer 512 may be similar to spring layer 212 in mattress assembly 200, although alternatives are possible.

[0099] Mattress assembly 500 also includes a memory foam layer 504 located between a top mattress cover 501 (e.g., upper cover) and an elastomeric layer 502. The elastomeric layer 502 includes a flex foam panel 508 and a plurality of individual cushioning elements 510. The memory foam layer 504 is directly connected to the flex foam panel 508 by an adhesive. Mattress assembly 500 further includes a bottom mattress cover 503 (e.g., lower cover) located below the second support layer 506b. As will be understood, features described herein for mattress assemblies 100, 200, 300, and 400 also apply to mattress assembly 500. Similar numbers as mattress assembly 300 are used to refer to layers in mattress assembly 500, but may also be 500s.

[0100] The spring layer 512 may provide additional support and rigidity to the mattress assembly 500. The spring layer 512 includes a plurality of coils 516. In certain examples, the coils 516 may be cylindrical. The plurality of coils 516 may each be encased in a casing 518. The casing 518 may comprise a nonwoven bag. The spring layer 512 may include an indentation load deflection (ILD). The indentation load deflection may be from about 10 to about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be from about 20 to about 40 lbs.

[0101] The spring layer 512 has a height or thickness T that ranges from about 5 to about 10 inches. 13 The spring layer 512 may have a thickness of 15 gauge, although alternatives are possible. The coils 516 comprise a coil unit in which the composition is encased by edge foam supports 520 similar to the flex foam panel 508. In a particular example, the spring layer 512 has a 15 gauge coil unit. The first support layer 506a is directly connected to the edge foam supports 520 of the spring layer 512.

[0102] FIG. 33 illustrates another exemplary mattress assembly 600 according to the principles of the present disclosure. The mattress assembly 600 is a tri-fold mattress including separate, individual components. For example, the tri-fold mattress includes a first segment 602, a second segment 604, and a third segment 606 connected together by a fabric cover 608. Each of the first, second, and third segments 602, 604, and 606 includes mattress components that are concealed by a corresponding zipper 603 or other alternative fastener used. The zipper may extend along one, both, or three sides of each of the first, second, and third segments 602, 604, and 606. The mattress components in the first, second, and third segments 602, 604, and 606 may remain attached together or may be detachable from one another when the zipper is unzipped.

[0103] Fabric divisions, seams, or stitches 605 may be provided in the fabric cover 608 to divide the mattress assembly 600 into first, second, and third segments 602, 604, 606. The fabric divisions, seams, or stitches 605 provide hub connections between the first, second, and third segments 602, 604, 606 to allow pivoting during folding. The mattress assembly 600 is shown divided into three equal-sized squares. As will be appreciated, the mattress assembly 600 may be divided into a different number of same-sized segments, multiple different-sized segments, and / or different-shaped segments.

[0104] 34 illustrates mattress components designed to be disposed within each of the first, second, and third segments 602, 604, and 606 of the mattress assembly 600. The mattress components include an elastomeric layer 610 including a flex foam panel 612 and a plurality of individual cushioning elements 614, a support layer 616, a top mattress cover 618 (e.g., upper cover), and a bottom mattress cover 620 (e.g., lower cover). Features of the elastomeric layer 610, support layer 616, top mattress cover 618, and bottom mattress cover 620 are similar to those described above. Within the flex foam panel 612, the plurality of individual cushioning elements 614 are arranged in two columns and four rows, although alternatives are possible.

[0105] Returning again to FIG. 33, the mattress assembly 600 also includes handles 622 suitably secured thereon and provided on the first and third segments 602, 606 for carrying the mattress assembly 600.

[0106] 35, in each of the first, second, and third segments 602, 604, 606, the elastomeric layer 610 has a length L and a width W. The length L of the elastomeric layer 610 may be approximately 900 mm, although alternatives are possible. The width W may be approximately 660 mm, although alternatives are possible. The total width W1 of the mattress assembly 600 may be approximately 1980 mm, although alternatives are possible.

[0107] The spacing S between each of the individual cushioning elements 614 from end to end (e.g., perimeter) of each row may be approximately 100 mm, although alternatives are possible. The spacing S1 between the individual cushioning elements 614 and their respective fabric divisions, seams, or stitches 605 may be approximately 140 mm, although alternatives are possible. The spacing S2 between the individual cushioning elements 614 and either the top edge 624 or bottom edge 626 may be 75 mm, although alternatives are possible. The top and bottom edges 624, 626 are generally perpendicular to the fabric divisions, seams, or stitches 605.

[0108] It will be understood that the measurements referred to herein are purely illustrative and not limiting.

[0109] From the foregoing detailed description, it will be apparent that modifications and variations can be made without departing from the spirit and scope of the disclosure.

Claims

1. 1. A mattress assembly comprising: a base 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 contacts the base surface of the base; an elastomeric layer in contact with the second support surface of the support layer, a flex foam panel defining a plurality of cutout portions, the plurality of cutout portions being arranged in a matrix, each row having a plurality of spaced apart cutout portions and each column having a plurality of spaced apart cutout portions; an elastomeric layer including a plurality of individual cushioning elements, each of the individual cushioning elements being disposed within one of the plurality of cutout portions of the flex foam panel, the plurality of individual cushioning elements comprising a composition that includes graphene; a shape memory foam layer having a first surface and a second surface, the shape memory foam layer extending over the elastomeric layer such that the first surface is in contact with the elastomeric layer; a cover having a cover surface in contact with the second surface of the shape memory foam layer, the cover surface adhering to the base; Mattress assembly.

2. the memory foam layer is connected to the elastomeric layer by an adhesive; 10. The mattress assembly of claim 1.

3. the support layer is directly connected to the elastomeric layer by an adhesive; 10. The mattress assembly of claim 1.

4. the plurality of individual cushioning elements are separated from one another by a flex foam panel; 10. The mattress assembly of claim 1.

5. the plurality of cutout portions are formed to match the size and shape of the plurality of individual cushioning elements.

10. The mattress assembly of claim 1.

6. There is no fabric between the elastomer layer and the memory foam layer or between the elastomer layer and the support layer.

10. The mattress assembly of claim 1.

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