Mattresses including a variable coil layer and an elastomeric cushioning element

Abstract

A mattress assembly includes a coil layer including a first plurality of coils with a first height and a second plurality of coils with a second height greater than the first height. The mattress assembly also includes an elastomeric cushioning element at least partially supported by the coil layer and including a plurality of interconnected buckling walls that define a plurality of hollow columns.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. App. No. 63 / 762,500, filed Feb. 24, 2025, which is incorporated herein by reference in its entirety and for all purposes.TECHNICAL FIELD

[0002] Embodiments and aspects of this disclosure relate generally to cushion elements, such as mattresses including a pocketed coil layer, and to methods of making such cushion elements, such as mattresses.BACKGROUND

[0003] Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and / or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well suited to different applications.

[0004] In mattresses, springs may be preferable to foam for their durability and ability to withstand compression. Springs may also impart a feel that may be more desirable to users than that of foam, while providing structure for maintaining the shape of the mattress. Despite these advantages, springs may not provide a positive aesthetic and / or tactile experience if they are seen or felt through the mattress, prompting manufacturers to conceal the feel of springs. One solution includes layering a different cushioning material on top of the springs.SUMMARY

[0005] One embodiment relates to a mattress assembly. The mattress assembly includes a coil layer including a first plurality of coils with a first height and a second plurality of coils with a second height greater than the first height. The mattress assembly also includes an elastomeric cushioning element at least partially supported by the coil layer and including a plurality of interconnected buckling walls that define a plurality of hollow columns.

[0006] Another embodiment relates to a mattress assembly. The mattress assembly includes a coil layer including a first plurality of coils with a first height and a second plurality of coils with a second height greater than the first height. The second plurality of coils may extend around an outer peripheral edge of the first plurality of coils to define a receptable. The mattress assembly also includes an elastomeric cushioning element at least partially supported by the coil layer and including a plurality of interconnected buckling walls that define a plurality of hollow columns. The elastomeric cushioning element may be disposed at least partly within the receptacle. The mattress assembly may also include an intermediate layer positioned at least partly within the receptacle.

[0007] Still another embodiment relates to a cushion assembly. The cushion assembly includes a coil layer including a first coil layer with a first height and a second coil layer with a second height greater than the first height. The second coil layer may extend around an outer peripheral edge of the first coil layer to define a receptable. The cushion assembly may also include an elastomeric cushioning element at least partially supported by the coil layer and disposed at least partly within the receptacle. A top surface of the elastomeric cushioning element may be one of substantially coplanar with or extends vertically above a top surface of the second coil layer.

[0008] Numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. The described features of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In this regard, one or more features of an aspect of the invention may be combined with one or more features of a different aspect of the invention. Moreover, additional features may be recognized in certain embodiments and / or implementations that may not be present in all embodiments or implementations.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of a cross-section of a mattress assembly, according to an exemplary embodiment;

[0010] FIG. 2 is an exploded view of a mattress assembly, according to an exemplary embodiment;

[0011] FIG. 3 is a cross-sectional view of the mattress assembly, according to an exemplary embodiment;

[0012] FIG. 4 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0013] FIG. 5 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0014] FIG. 6 is a cross-sectional view of an elastomeric cushioning element of a mattress assembly, according to an exemplary embodiment;

[0015] FIG. 7 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0016] FIG. 8 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0017] FIG. 9 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0018] FIG. 10 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0019] FIG. 11 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0020] FIG. 12 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0021] FIG. 13 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment;

[0022] FIG. 14 is a cross-sectional view of the mattress assembly, according to another exemplary embodiment; and

[0023] FIG. 15 is a flowchart of a method of forming a mattress assembly, according to an exemplary embodiment.DETAILED DESCRIPTION

[0024] Numerous specific details are given to impart a thorough understanding of embodiments of the subject matter of the present disclosure. The described features of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In this regard, one or more features of an aspect of the invention may be combined with one or more features of a different aspect of the invention. Moreover, additional features may be recognized in certain embodiments and / or implementations that may not be present in all embodiments or implementations.

[0025] FIG. 1 shows a mattress or mattress assembly 100 (or cushion or cushion assembly), according to an exemplary embodiment. FIG. 2 shows an exploded view of the mattress assembly 100, according to an exemplary embodiment. FIG. 3 shows a cross-sectional view of the mattress assembly 100, according to an exemplary embodiment. Referring to FIGS. 1-3, the mattress assembly 100 may include a variable coil layer 104 and an elastomeric cushioning element 116 at least partially supported by coil layer 104. As shown in FIG. 2, the mattress assembly 100 may also include an intermediate layer 124 positioned between variable coil layer 104 and the elastomeric cushioning element 116 whereby the elastomeric cushioning element 116 is positioned vertically above, at least partly both of the variable coil layer and the intermediate layer 124.

[0026] In some embodiments, an elastomeric cushioning material may be too soft to define an edge of the mattress when having a height also thick enough for a desired cushioning effect, such that a second, firmer, cushioning material may be add to the edges. Such a combination of cushioning materials typically includes a seam between the two different cushioning materials which may be felt through the mattress. Beneficially, the elastomeric cushioning element over the variable coil layer 104 as described herein may mask the feel of the coil layer 104 while still providing a stiff edge for the mattress assembly 100. These and other features and benefits are described more fully herein below.

[0027] The elastomeric cushioning element 116 may be disposed over an upper surface of variable coil layer 104 and may extend over at least a portion of coil layer 104. In some embodiments, an outer covering may extend around and substantially encase the variable coil layer 104 and the elastomeric cushioning element 116. In some embodiments, the mattress assembly 100 may include one or more side panels. The one or more side panels may extend along outer perimeters the variable coil layer 104 and / or the elastomeric cushioning element 116 and within a place perpendicular or substantially perpendicular to a plane defined by a ground surface (a substantially flat or horizontal surface). In some embodiments, the outer covering may at least substantially encase the one or more side panels. In FIGS. 1-3, many parts of the mattress assembly 100 (e.g., the outer covering, the one or more side panels, etc.) are removed or not shown to better illustrate select parts of the mattress assembly 100.

[0028] The variable coil layer 104 may include a first plurality of coils 108 and a second plurality of coils 112. Each of the first plurality of coils 108 and the second plurality of coils 112 may be encased in at least one respective casing 109 (e.g., polypropylene socks or bags). For example, each casing 109 may form a pocket for a respective coil 110. In other words, the first plurality of coils 108 and the second plurality of coils 112 may include a plurality of pocketed coils 110. In some embodiments, each coil 110 may include a relatively thin-gauge, barrel-shaped (e.g., helical-shaped), knotless coil. Furthermore, in one or more embodiments, each coil 110 may be encased in multiple casings 109. For instance, each coil 110 may be double bagged or triple bagged. In some embodiments, the casings 109 may include a polypropylene material. The casings 109 may include a two-ply polypropylene non-woven material. In some embodiments, each ply of the casings 109 may have a thickness within a range of about 0.10 mm and about 0.40 mm. As an example, each ply of the casings 109 may have a thickness within″ a range of about 0.15 mm and about 0.30 mm. However, any suitable material may be used. Each coil 110 of the variable coil layer 104 may also extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to a ground surface. Furthermore, the coil 110 in the variable coil layer 104 may be spaced next to each other in an array (e.g., rows and columns or a grid pattern) to form coil layer 104.

[0029] In some embodiments, each casing 109 of each coil 110 of the plurality of coils 110 may be individual and discrete. In additional embodiments, the casings 109 of the plurality of coils 110 may be connected (i.e., joined) and may form a single body. Furthermore, each coil 110 of the plurality of coils 110 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to a ground surface beneath the mattress assembly 100. Furthermore, the plurality of coils 110 may be oriented next to each other in an array (e.g., rows and columns or a grid pattern) to form the coil layer 104.

[0030] Still referring to FIGS. 1-3, in some embodiments, a pocketed coil 110 includes a casing 109 encasing a coil 110 and a coil topper positioned vertically over a coil 110. In some embodiments, the coil topper comprises a compressible, resilient material (e.g., polyurethane foam, a memory foam, a latex rubber foam, or any other suitable foam). In some embodiments, the coil topper comprises an elastomeric material (e.g., a gelatinous elastomer, plasticized block copolymers, etc.). In some embodiments, a casing 109 encases a coil 110 and a plurality of coil toppers. Each coil topper may have any suitable shape (e.g., cylinder, puck, rectangular, etc.). In some embodiments, a pocket coil is configured according to the teachings of U.S. Pat. No. 10,098,474, the entire disclosure of which is incorporated by reference herein.

[0031] The first plurality of coils 108 may extend within a central region 111 of the mattress assembly 100. The second plurality of coils 112 may extend in a perimeter region 113 and may laterally surround an outer periphery, or the sides, of the first plurality of coils 108 in the central region 111. The variable coil layer 104 may be a variable coil layer, wherein the first plurality of coils 108 may vary in one or more characteristics relative to the second plurality of coils 112. The characteristics may include a coil height, a coil diameter, a wire gauge, a pitch, a coil angle, and / or a material. For example, the first plurality of coils 108 may have a first coil height, h1, and the second plurality of coils 112 may have a second coil height, h2, greater than the first coil height, h1 (see FIG. 3). The second plurality of coils 112 in the perimeter region 113 may define an edge of the mattress assembly 100 while the first plurality of coils 108 disposed or positioned in the central region 111 may define a lower, central portion or region 111 of the mattress assembly 100. The edge may be a peripheral edge or region of the mattress assembly 100 and, as such, may extend around the mattress assembly 100. The second plurality of coils 112 may extend a distance, d1, above the first plurality of coils 108, wherein the distance, d1, is the difference between the coil height, h1, of the first plurality of coils 108 and the coil height, h2, of the second plurality of coils 112. Thus and due to the height difference between the coil layers or sections, the variable coil layer 104 including the first plurality of coils 108 and the second plurality of coils 112 may define a receptacle 114.

[0032] The receptacle 114 (e.g., cavity, inset, etc.) may receive one or more layers of cushioning materials, including the elastomeric cushioning element 116 and / or the intermediate layer 124. The elastomeric cushioning element 116 may include a singly molded elastomeric cushioning element 116, in some embodiments. For example, the entire elastomeric cushioning element 116 may be formed via a single molding process. In other embodiments, the cushioning element 116 may be molded via more than a single molding process. In some embodiments, the elastomeric cushioning element 116 may include buckling walls 117. The buckling walls 117 of the elastomeric cushioning element 116 may be interconnected to one another and may define hollow columns 118 or voids in an expanded form. As used herein, the term “expanded form” means and includes a state in which an elastomeric cushioning element 116 has its original size and shape and wherein the buckling walls 117 are separated and define hollow columns 118. The buckling walls 117 may extend in two directions, intersecting at right or substantially right angles, and defining square columns 118. However, in some embodiments, the buckling walls 117 may intersect at other angles and define columns 118 of other shapes, such as triangles, parallelograms, hexagons, etc., or any other polygonal or circular shape.

[0033] The elastomeric cushioning element 116 may comprise more structures and configurations such as those structures and configurations described in, for example, U.S. Pat. No. 8,434,748, titled “Cushions Comprising Gel Springs,” issued May 7, 2013; U.S. Pat. No. 8,628,067, titled “Cushions Comprising Core Structures and Related Methods,” issued Jan. 14, 2014; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014; and U.S. Pat. No. 8,932,692, titled “Cushions Comprising Deformable Members and Related Methods,” issued Jan. 13, 2015, the entire disclosure of each of which is incorporated herein by this reference.

[0034] The elastomeric cushioning element 116 may be formed of an elastomeric material. Elastomeric materials are described in, for example, U.S. Pat. No. 5,994,450, titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom,” issued Nov. 30, 1999 (“the '450 patent”); U.S. Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW in Mid-Block” issued Jun. 21, 2011; U.S. Pat. No. 4,369,284, titled “Thermoplastic Elastomer Gelatinous Compositions” issued Jan. 18, 1983; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014 (“the '750 patent”); the disclosures of each of which are incorporated herein in their entirety by this reference. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc.

[0035] The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). For example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc., of Houston, Tex., under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, Tex., under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651. In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene / propylene or ethylene / butylene or ethylene / ethylene / propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers.

[0036] The elastomeric material may include one or more plasticizers, such as hydrocarbon fluids. For example, elastomeric materials may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, N.J., under the trade names BLANDOL® and CARNATION®.

[0037] In some embodiments, the elastomeric material may have a plasticizer-to-polymer ratio from about 0.1:1 to about 50:1 by weight. For example, elastomeric materials may have plasticizer-to-polymer ratios from about 1:1 to about 30:1 by weight, or even from about 1.5:1 to about 10:1 by weight. In further embodiments, elastomeric materials may have plasticizer-to-polymer ratios of about 4:1 by weight.

[0038] The elastomeric material may have one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. For example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer. As another example, metal particles (e.g., aluminum, copper, etc.) may increase the thermal conductivity of the resulting elastomeric material because such particles may have greater thermal conductivity than the plasticizer or polymer. Microspheres filled with wax or another phase-change material (i.e., a material formulated to undergo a phase change near a temperature at which a cushioning element may be used) may provide temperature stability at or near the phase-change temperature of the wax or other phase-change material within the microspheres (i.e., due to the heat of fusion of the phase change). The phase-change material may have a melting point from about 20° C. to about 45° C.

[0039] The elastomeric material may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, pentaerythritol tetrakis (3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate), commercially available as IRGANOX® 1010, from BASF Corp., of Iselin, N.J. or as EVERNOX®-10, from Everspring Corp. USA, of Los Angeles, Calif. ; octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, commercially available as IRGANOX® 1076, from BASF Corp. or as EVERNOX® 76, from Everspring Chemical; and tris(2,4-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® 168, from BASF Corp. or as EVERFOS® 168, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of elastomeric material. The use of antioxidants in mixtures of plasticizers and polymers is described in columns 25 and 26 of the '450 patent. The elastomeric material may include up to about 5 wt % antioxidants. For example, the elastomeric material may include from about 0.10 wt % to about 1.0 wt % antioxidants.

[0040] In some embodiments, the elastomeric material may include a resin. The resin may be selected to modify the elastomeric material to slow a rebound of the elastomeric cushioning element 116 after deformation. The resin, if present, may include a hydrogenated pure monomer hydrocarbon resin, such as those commercially available from Eastman Chemical Company, of Kingsport, Tenn., under the trade name REGALREZ®. The resin, if present, may function as a tackifier, increasing the stickiness of a surface of the elastomeric material.

[0041] In some embodiments, the elastomeric material may include a pigment or a combination of pigments. Pigments may be aesthetic and / or functional. That is, pigments may provide the elastomeric cushioning element 116 with an appearance appealing to consumers. In addition, an elastomeric cushioning element 116 having a dark color may absorb radiation differently than an elastomeric cushioning element 116 having a light color.

[0042] The elastomeric material may include any type of gelatinous elastomer. For example, the elastomeric material may include a melt-blend of one part by weight of a styrene-ethylene-ethylene-propylene-styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® 4055) with four parts by weight of a 70-weight straight-cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and / or other additives.

[0043] The elastomeric material may include a material that may return to its original shape after deformation, and that may be elastically stretched. The elastomeric material may be rubbery in feel but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5. While referred to herein as the elastomeric cushioning element 116, it should be understood that the elastomeric cushioning element 116 may alternatively be made of another material such as a foam (e.g., of a memory polyurethane foam, a latex foam rubber, or any other suitable foam), plastic reticulated material, polymer material, or other type of cushioning material.

[0044] In some embodiments, the mattress assembly 100 may include stacked elastomeric gels and foam layers in various configurations. The elastomeric gels may have the structure and function described above, and may also define an array of buckling columns. Various stacking arrangements are shown and described in U.S. application Ser. No. 19 / 019,306, which is incorporated herein by reference in its entirety and for all purposes. The stackable arrangements, which may include a combination of buckling layers (e.g., elastomeric gel layers) and intermediate layers (e.g., foam layers) may be at least partly disposed in the receptacle 114. In this way, it should be appreciated that the relative heights and number of layers are configurable to either completely fit in the receptacle and not extend above the second coil layer 112 or may extend vertically above the second coil layer 112.

[0045] With reference to FIG. 3, in some embodiments, a microgrid layer 160 may be included with the mattress or cushion assembly 100. The microgrid layer 160 may be formed from an elastomeric gel material as described herein. However, it will be appreciated that the plasticizer to polymer ratios for the microgrid layer 160 may vary from the cushioning element layer 116 (e.g., elastomeric gel layer) which may make the microgrid layer 160“softer.” In some embodiments, the microgrid layer 160 includes elastomeric cushioning elements made with a generally planar top and bottom surfaces. In other embodiments, the microgrid layer 160 may include at least one non-planar or substantially non-planar (e.g., non flat) top or bottom surface. The top and bottom surfaces refer to the vertically opposing substantially horizontally planar surfaces, not the vertical height or thicknesses. In some embodiments, the microgrid layer 160 may include walls. The walls of the microgrid layer 160 may be interconnected to one another and may define an array of voids when the microgrid layer 160 is in an uncompressed form. As used herein, the term “uncompressed form” means and includes a state in which the microgrid layer 160 has its original size and shape and wherein the walls are separated and define voids. Each void and the walls that define it may together define a hollow column. In some embodiments, the voids are defined by a three-dimensional shape (e.g., tetrahedron, rectangular prism, etc.). In some embodiments, the walls of the microgrid layer 160 form two-dimensional shapes (e.g., triangular, diamond, rhombus, hexagon, etc.) hollow columns. In some embodiments, the microgrid layer 160 is one inch thick. In some embodiments, the microgrid layer 160 has thickness between approximately 0.25-2.0 inches (about 0.64-5.1 cm). The geometry of the buckling columns as well as other features of the microgrid layer 160 are shown and described in the U.S. application Ser. No. 19 / 019,306, which is incorporated herein by reference in its entirety. As described, in some embodiments, the microgrid layer 160 has a buckling point, and buckles similar to the cushioning element 116. Furthermore, it is contemplated that the microgrid layer 160 may be disposed directly over the cushioning element 116; in other embodiments and intermediate layer, like intermediate layer 124, is disposed between the microgrid layer 160 and the cushioning element 116. In the example shown and consistent with U.S. application Ser. No. 19 / 019,306, the microgrid layer 160 is an elastomeric cushioning element with buckling columns defining diamond voids. Each buckling column has a buckling point characteristic (i.e., a threshold pressure after which the buckling column will buckle). In the example shown, each buckling column has a height or a thickness between 0.5-1 inch (about 1.3-2.5 cm) (e.g., ⅞ in). In some embodiments, the diamond voids of the microgrid 160 are smaller than the voids of the buckling layer 116. In some embodiments, from a top down view of the microgrid layer 160 on top a buckling layer such as the buckling layer 116, the walls of the microgrid layer 160 are not aligned with the walls of the voids of the buckling or cushioning layer 116. In some embodiments, the walls of the microgrid layer 160 are offset at an angle from the walls of the buckling layer 116.

[0046] The microgrid layer 160 may further include a stabilization layer, which may include or be a relatively thin material (e.g., a cotton spandex blend “scrim”) and may be used to provide a surface for adhering (e.g., gluing, fusing, etc.) the elastomeric cushioning element to adjacent layers, such as an upper surface of the elastomeric cushioning element 116 (e.g., the stabilization material 150 of the elastomeric cushioning element 116 may be adhered via glue, fusing, etc. to the stabilization material of the microgrid layer 160 to couple these adjacent layers together) and / or a surface of the intermediate layer 124. In some embodiments and as described herein, the material of the stabilization layer of the microgrid layer 160 may include a scrim fabric (e.g., a woven or non-woven fabric material) and portions of an elastomeric cushioning element may seep through (e.g., be melt fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric. In embodiments where an elastomeric cushioning element includes a gel material, portions of the gel material of the elastomeric cushioning element 160 that extend through the scrim fabric may define non-slip features or reduced slip features that create a non-slip surface or reduced slip surface on a surface of the stabilization layer. Where disposed, the non-slip surface or reduced slip surface may help the elastomeric cushioning element stay in place, such as relative to the coil layer 116, an intermediate layer, and other components of the cushion assembly 100.

[0047] With continued reference to FIG. 3, the microgrid layer 160 is shown to extend edge-to-edge. In this way, the microgrid layer 160 is disposed above each of the second coil layer 112 and the elastomeric cushion element 116. This configuration may provide a uniform upper layer to cushion assembly 100. In another embodiment, the elastomeric cushion element 116 is less than the distance, d1, such that a gap exists between the vertical top of the cushion element 116 and the second coil layer 112. In this embodiment, the microgrid layer 160 may be disposed in this gap and create a flush or generally flush upper surface with an upper surface of the second coil layer 112. Thus, in this embodiment, the microgrid layer 160 and the elastomeric cushioning element 116 may each be completely or substantially completely disposed in the receptacle 114. In other embodiments, the microgrid layer 160 may be disposed over the cushioning element 116, and be vertically above the upper surface of the second coil layer 112 without extending over the coil layer 112. Thus, it should be appreciated, the microgrid layer 160 may be positioned or disposed at least partly above and over the various components of the assemblies 100 shown herein, such as over and above the cushioning element 116 of FIGS. 5-7, over and above the intermediate layer of FIGS. 8 and 12 as well as the combination of intermediate layer and cushioning element of FIGS. 13-14, and over the cushioning element 116 of FIGS. 9-11. In still other embodiments, the microgrid layer 160 may be disposed one or more components of the assemblies 100 (e.g., between the intermediate layer 124 and cushioning element 116 of FIG. 12). All such variations are intended to fall within the spirit and scope of the present disclosure.

[0048] FIGS. 3-5 and 7-14 show schematic side cross-sectional views of a side portion of mattress assemblies, according to one or more embodiments. Mirror images of the same views represent an opposing side portion of the mattress assemblies. Referring to FIG. 3, the elastomeric cushioning element 116 may be positioned in or substantially within the receptacle 114. The first plurality of coils 108 may have a generally planar top surface, and the elastomeric cushioning element 116 may be disposed over and may at least substantially extend over the top surface of the first plurality of coils 108 within the receptacle 114. The elastomeric cushioning element 116 may have a height, h3, in a direction parallel with a longitudinal axis of the columns 118. In some embodiments, the height, h3, equals the difference in height between the coil height, h1, of the first plurality of coils 108 and the coil height, h2, of the second plurality of coils 112 such that a top surface of the elastomeric cushioning element 116 is flush or substantially flush (co-planar) with a top surface of the second plurality of coils 112. The second plurality of coils 112 may laterally surround an outer periphery, or the sides, of the elastomeric cushioning element 116 such that the second plurality of coils 112 stabilize the sides and define a stiff edge of the mattress assembly 100 without additional cushioning materials, such as foam (e.g., polyurethane foam) being disposed or positioned adjacent the sides of the elastomeric cushioning element 116.

[0049] The receptacle 114 may further include one or more other layers of cushioning material superimposed or layered with the elastomeric cushioning element 116. Referring to FIG. 2, in some embodiments the intermediate layer 124 is positioned within the receptacle 114 between the first plurality of coils 108 and the elastomeric cushioning element 116. The intermediate layer 124 may include a polyurethane foam and / or an elastomeric material as described above with reference to the elastomeric cushioning element 116. In additional embodiments, the intermediate layer 124 may include one or more of a memory polyurethane foam, a latex foam rubber, or any other suitable foam. In some embodiments, the intermediate layer 124 may have non-planar upper surface including a texture or pattern, such as a convoluted pattern or an egg crate pattern. In additional embodiments, the intermediate layer 124 may have a planar or generally planar upper surface. While only a single intermediate layer 124 is shown, it should be understood that there may be additional layers disposed on the coil layer 104, which may be made of an elastomeric material, a foam, and / or another type of cushioning material as discussed herein.

[0050] Referring to FIG. 4, the intermediate layer 124 may be positioned on top or above of the elastomeric cushioning element 116 in the receptacle 114. The top surface 125 of the intermediate layer 124 (the surface of the layer 124 positioned furthest from the first plurality of coils 108 based on the view in FIG. 4) may be coplanar or substantially coplanar with the top surface of the second plurality of coils 112. In such embodiments, the elastomeric cushioning element 116 may have a height, h3, less than the distance, d1, such that a top surface of the elastomeric cushioning element 116 is lower than the top surface of the second plurality of coils 112 when the elastomeric cushioning element 116 is received within the receptacle 114.

[0051] Referring now to FIG. 5, and according to another embodiment, the elastomeric cushioning element 116 may be disposed over and may at least substantially extend over the first plurality of coils 108 and the second plurality of coils 112. Thus, the elastomeric cushioning element 116 may have a T-shaped or substantially T-shaped cross section as shown in FIG. 6 and in FIG. 5. Referring to FIGS. 5 and 6, the T-shaped cross section includes a web 119 corresponding the vertical stroke of the T and a flange 120 corresponding to the horizontal stroke of the T. The web 119 may have a height, h4, and a width, w1, while the flange may have a height, h5, and a width, w2. The height, h3, of the elastomeric cushioning element 116 may be the sum of h4 and h5. The height, h4, may correspond to the distance, d1, representing the difference between the coil height, h1, of the first plurality of coils 108 and the coil height, h2, of the second plurality of coils 112, such that a bottom surface of the flange 120 may be disposed at on or at least partially on the top surface of the second plurality of coils 112. The flange width, w2, may be greater than the web width, w1, by a distance, d2, on each side of the web 119, such that w2 is the sum of w1 and two d2. In some embodiments, the distance d2 is equal or substantially equal to a width of the second plurality of coils 112 such that the flange 120 may extend out to the outer periphery or edge of the mattress assembly 100. In other embodiments, the flange 120 may extend only partially across the second plurality of coils 112 (i.e., not completely cover / over the top of the coils 112). The flange 120 of the elastomeric cushioning element 116 allows the elastomeric cushioning element 116 to mask a feel of the second plurality of coils 112 to a user, while benefitting from the strength and stiffness of a coil, relative to the web 119 of the elastomeric cushioning element 116 in the central region 111.

[0052] Referring to FIG. 7, the intermediate layer 124 may be positioned beneath the T-shaped elastomeric cushioning element 116, such that the intermediate layer 124 is between the first plurality of coils 108 and the elastomeric cushioning element 116. In an additional embodiment as shown in FIG. 8, the intermediate layer 124 may be T-shaped or substantially T-shaped, and the elastomeric cushioning element 116 may be positioned below the intermediate layer 124, such that the elastomeric cushioning element 116 is between the first plurality of coils 108 and the intermediate layer 124.

[0053] Referring to FIG. 9, the elastomeric cushioning element 116 may have a rectangular or substantially rectangular cross section where the height h3 is greater than the distance d1 such that a top surface of the elastomeric cushioning element 116 is above a top surface of the second plurality of coils 112. In such embodiments, the elastomeric cushioning element 116 may protrude from the receptacle 114 defined by the first plurality of coils 108 and the second plurality of coils 112 of the coil layer 104. Referring now to FIG. 10, the intermediate layer 124 may be positioned beneath the elastomeric cushioning element 116. In other embodiments, the positions of the elastomeric cushioning element 116 and the intermediate layer 124 may be switched, such that the elastomeric cushioning element 116 is beneath the intermediate layer 124.

[0054] Referring now to FIG. 11, the intermediate layer 124 may have a height h6 equal to the difference d1 between the coil height h1 of the first plurality of coils 108 and the coil height h2 of the second plurality of coils 112 such that a top surface of the intermediate layer 124 is flush or substantially flush with the tops of the second plurality of coils 112. The elastomeric cushioning element 116 / may be disposed on and extend at least partially over the intermediate layer 124 and the second plurality of coils 112. In such embodiments, the elastomeric cushioning element 116 may extend such that an edge or side of the elastomeric cushioning element 116 is substantially coplanar with an edge or side of the second plurality of coils 112. In other embodiments, the elastomeric cushioning element 116 may extend only partially across the second plurality of coils 112. In some embodiments, the positions of the elastomeric cushioning element 116 and the intermediate layer 124 may be switched, as shown in FIG. 12.

[0055] Referring to FIG. 13, the intermediate layer 124 may be substantially L-shaped, with a flange extend at least partially over the second plurality of coils 112. In such embodiments, the intermediate layer 124 may extend only partially onto the first plurality of coils 108 in the central region 111 of the mattress assembly 100. The elastomeric cushioning element 116 may extend within the central region 111 between opposing rails of intermediate layer 124 on the sides of the central region 111, such that the elastomeric cushioning element 116 extends at least partially across the central region 111. In such embodiments, a total height of the elastomeric cushioning element 116 may be equal or substantially equal to a total height of the intermediate layer 124.

[0056] Referring to FIG. 14, the elastomeric cushioning element 116 protrudes from the receptacle 114 define by the variable coil layer 104 and is at least partially surrounded on the outer periphery by the second plurality of coils 112 and the intermediate layer 124. In such embodiments, the intermediate layer 124 may extend across or substantially across the second plurality of coils 112 in the perimeter region 113, while the elastomeric cushioning element 116 may extend across or substantially across the first plurality of coils 108 in the central region 111. The intermediate layer 124 may provide a firm border while concealing or masking a feel of the second plurality of coils 112. The elastomeric cushioning element 116 in the central region 111 may similarly mask the feel of the first plurality of coils 108 while providing additional cushioning for a user.

[0057] FIG. 15 shows a schematic flowchart of a method 1500 of forming a mattress assembly 100, according to an example embodiment. It should be understood that the order of the steps may change in other embodiments. Further, a depicted step may be omitted and / or another step added to the method 1500 in still other embodiments. All such variations are intended to fall within the scope of the present disclosure.

[0058] In some embodiments, the method 1500 may include an act 1510 of providing a coil layer defining a receptacle. For example, act 1510 may include disposing a first plurality of coils 108 in a central region 111 and disposing a second plurality of coils 112 in a perimeter region 113 at least partially surrounding an outer periphery of the first plurality of coils 108 in the central region 111. The second plurality of coils 112 may have one or more characteristics which differ from the first plurality of coils 108. The characteristics may include a coil height, a coil diameter, a wire gauge, a pitch, a coil angle, and / or a material. For example, the first plurality of coils 108 may have a first coil height h1 and the second plurality of coils 112 may have a second coil height h2 greater than the first coil height h1. The second plurality of coils 112 in the perimeter region 113 may define an edge of the mattress assembly 100 while the first plurality of coils 108 in the central region 111 may define a central portion of the mattress assembly 100. In some embodiments, the central portion 111 may be vertically lower than the perimeter region 113. The second plurality of coils 112 may extend a distance d1 above the first plurality of coils 108, wherein the distance d1 is the difference between the coil height h1 of the first plurality of coils 108 and the coil height h2 of the second plurality of coils 112. Thus, the variable coil layer 104 including the first plurality of coils 108 and the second plurality of coils 112 may define a receptacle 114 according to any of the embodiments of FIGS. 1-14.

[0059] The method 1500 may optionally include the act 1510 of disposing an intermediate layer 124 over the variable coil layer 104 and / or in the receptacle 114. In some embodiments, the intermediate layer 124 may be an elastomeric material or a foam. The intermediate layer 124 may also include an upper surface with a texture or pattern, such as top surface 125 with a convoluted or egg crate pattern. The act 1510 may include disposing the intermediate layer 124 over the variable coil layer 104 according to any of the embodiments in FIGS. 2, 4, and 7-14.

[0060] The method 1500 may include an act 1515 of disposing an elastomeric cushioning element 116 in the receptacle 114. The elastomeric cushioning element 116 may be made of an elastomeric material. In some embodiments, the elastomeric cushioning element 116 may include buckling walls 117. The buckling walls 117 of the elastomeric cushioning element 116 may be interconnected to one another and may define hollow columns 118 or voids in an expanded form. As used herein, the term “expanded form” means and includes a state in which an elastomeric cushioning element 116 has its original size and shape and wherein the buckling walls 117 are separated and define hollow columns 118. The buckling walls 117 may extend in two directions, intersecting at right angles, and defining square columns 118. However, in some embodiments, the buckling walls 117 may intersect at other angles and define columns 118 of other shapes including any other polygonal shape, such as triangles, parallelograms, hexagons, etc., or even circular shapes. The act 1515 may include disposing the elastomeric cushioning element 116 in the receptacle 114 according to any of the embodiments of FIGS. 1-14.

[0061] In some embodiments and referring back to FIG. 2 as an example, the elastomeric cushioning element 116 may include a stabilization material 150. In some instances, the stabilization material 150 may include a relatively thin material (e.g., cotton spandex blend “scrim”) and may be used to provide a surface for adhering (e.g., gluing) the elastomeric cushioning element 116 to surrounding materials, such as another elastomeric cushioning element 116, coil layer 104, and / or the intermediate layer 124. In some embodiments, the stabilization material 150 may be or comprise a scrim fabric (e.g., a woven or non-woven fabric material) and portions of the elastomeric cushioning element 116 may seep through (e.g., be melt fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric of the stabilization material 150. For example, when the elastomeric cushioning element 116 includes a gel material, portions of the gel material may be heat fused through the stabilization material 150. The portions of the elastomeric cushioning element 116 that extend through the scrim fabric of the stabilization material may create a non-slip surface or reduced slip surface on a lower surface of the stabilization material 150 (e.g., surface that would contact an upper surface of coil layer 104). The nonslip surface or reduced slip surface created by the elastomeric cushioning element 116 may help the cushioning materials stay in place relative to one another. Furthermore, in one embodiment, an adhesive may be disposed between the stabilization material and coil layer 104. An adhesive may be disposed between the intermediate layer 124 and the scrim or stabilization material of cushioning element 116. While shown in FIG. 2 as being disposed on a vertical top of the cushioning element 116, the stabilization material may also be disposed on a vertical bottom side or surface of the cushioning element 116 as well (e.g., proximate the coils 108).

[0062] The stabilization or scrim 150 may be used in manufacturing to add stability to the mattress assembly. In one example, the scrim 150 atop the cushioning element 150 may extend relatively wider than the gel cushioning material 150, such that the scrim 150 at least partly overlays, covers, and / or otherwise extends over a top of the surrounding second coil layer 112. In one embodiment and due to the woven nature of the scrim, the scrim 150 may then be adhered (e.g., glued, melt fused, etc.) to at least part of the top surface of the second coil 112 layer. This connection may help to retain the second coil layer 112 proximate to the cushion element 116 so as to avoid gaps that may be noticeable to users of the mattress assembly. In another example and as shown, a piece 152 (e.g., portion, etc.) of the scrim 150 may extend at least partly vertically down along an outer side / surface of at least some of the sections of the second coil layer 112. In this way, at least two connection points (on a vertical top and on a side) may be used to couple the stabilization material 150 to the surrounding second coil layer 112 (e.g., via glue, melt fused, a fastener(s), etc.). The multiple connection points may further strength the retention of the cushioning element 116 to the surrounding second coil layer 112 to reduce the formation of gaps therebetween and provide an enhanced comfort to a user of the mattress.

[0063] It should be understood that while the stabilization material 150 is only shown in FIG. 2, the stabilization material may be applied to the gel cushioning elements that are shown in each of the configurations herein. The stabilization material 150 may be used to not only stabilize the elastomeric gel layer, but also be used to couple to surrounding components (e.g., the first coil layer 108, the second coil layer 112, the intermediate layer 124, a combination thereof, etc.). The coupling may be via glue, melt-fused, a fastener(s), and or another methodology. Due to the elasticity of the scrim 150, the scrim 150 may expand and contrast as the mattress 100 is used without or substantially without the bond(s) between the stabilization material 150 and the coils 112 becoming undone. This adds the benefit of longevity in the assembly of the mattress 100.

[0064] The following description provides specific details, such as material types, manufacturing processes, uses, and structures in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without using these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional manufacturing techniques and materials employed in the industry.

[0065] As used herein, the terms “approximately,”“about,”“substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims. For example, a parameter that is substantially met may be at least about 90% met, at least about 95% met, or even at least about 99% met.

[0066] The terms “coupled” as used herein means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable, or releasable). Such joining may be achieved with the two members, or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0067] References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms. References to at least one of a conjunctive list of terms may be construed as an inclusive OR to indicate any of a single, more than one, and all of the described terms. For example, a reference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only ‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunction with “comprising” or other open terminology can include additional items.

[0068] References herein to the positions of elements (e.g., “top,”“bottom,”“above,”“below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0069] As used herein, the term “elastomeric polymer” means and includes a polymer capable of recovering its original size and shape after deformation. In other words, an elastomeric polymer is a polymer having elastic or viscoelastic properties. Elastomeric polymers may also be referred to as “elastomers” in the art. Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).

[0070] As used herein, the term “elastomeric block copolymer” means and includes an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B).

[0071] As used herein, the term “plasticizer” means and includes a substance added to another material (e.g., an elastomeric polymer) to increase a workability of the material. For example, a plasticizer may increase the flexibility, softness, or extensibility of the material. Plasticizers include, without limitation, hydrocarbon fluids, such as mineral oils. Hydrocarbon plasticizers may be aromatic or aliphatic.

[0072] As used herein, the term “elastomeric material” means and includes elastomeric polymers and mixtures of elastomeric polymers with plasticizers and / or other materials. Elastomeric materials are elastic (i.e., capable of recovering size and shape after deformation). Elastomeric materials include, without limitation, materials referred to in the art as “elastomer gels,”“gelatinous elastomers,” or simply “gels.”

[0073] The construction and arrangement of the elements of the assembly as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied.

[0074] Additionally, the word “exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). Rather, use of the word “exemplary” is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

[0075] Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. For example, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Also, for example, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes, and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

Claims

1. A mattress assembly, comprising:a coil layer comprising a first plurality of coils with a first height and a second plurality of coils with a second height greater than the first height; andan elastomeric cushioning element at least partially supported by the coil layer and comprising a plurality of interconnected buckling walls that define a plurality of hollow columns.

2. The mattress assembly of claim 1, wherein the second plurality of coils extend around an outer peripheral edge of the first plurality of coils to define a receptable.

3. The mattress assembly of claim 2, wherein the elastomeric cushioning element is positioned at least partially within the receptacle.

4. The mattress assembly of claim 3, wherein a cross-section of the elastomeric cushioning element is substantially T-shaped.

5. The mattress assembly of claim 4, wherein the substantially T-shaped cross-section of the elastomeric cushioning element comprises a web corresponding to a vertical stroke of a T and a flange corresponding to a horizontal stroke of the T.

6. The mattress assembly of claim 5, wherein the web is at least partially supported by the first plurality of coils and the flange is at least partially supported by the second plurality of coils.

7. The mattress assembly of claim 5, wherein the flange extends at least partially over the second plurality of coils extending around the outer peripheral edge of the first plurality of coils.

8. The mattress assembly of claim 2, wherein the elastomeric cushioning element extends at least partially over the first plurality of coils and the second plurality of coils.

9. The mattress assembly of claim 1, wherein each of the first plurality of coils and the second plurality of coils comprise a plurality of pocketed coils arranged in an array and spaced apart.

10. The mattress assembly of claim 1, further comprising a stabilization layer comprising a scrim fabric between the coil layer and the elastomeric cushioning element.

11. The mattress assembly of claim 1, wherein an elastomeric material of the elastomeric cushioning element seeping through a stabilization layer secures an upper surface of the stabilization layer to the elastomeric cushioning element, the elastomeric material exposed and defining a reduced slip surface or a non-slip surface on a lower surface of the stabilization layer.

12. A mattress assembly, comprising:a coil layer comprising a first plurality of coils with a first height and a second plurality of coils with a second height greater than the first height, wherein the second plurality of coils extend around an outer peripheral edge of the first plurality of coils to define a receptable;an elastomeric cushioning element at least partially supported by the coil layer and comprising a plurality of interconnected buckling walls that define a plurality of hollow columns, the elastomeric cushioning element disposed at least partly within the receptacle; andan intermediate layer positioned at least partly within the receptacle.

13. The mattress assembly of claim 12, wherein the intermediate layer is an at least partly foam layer.

14. The mattress assembly of claim 13, wherein the intermediate layer is disposed between the elastomeric cushioning element and the first plurality of coils.

15. The mattress assembly of claim 13, wherein the intermediate layer is disposed above the elastomeric cushioning element.

16. The mattress assembly of claim 15, wherein the intermediate layer is one of substantially coplanar with a top surface of the second plurality of coils or extends vertically above the top surface of the second plurality of coils.

17. A cushion assembly, comprising:a coil layer comprising a first coil layer with a first height and a second coil layer with a second height greater than the first height, wherein the second coil layer extends around an outer peripheral edge of the first coil layer to define a receptable; andan elastomeric cushioning element at least partially supported by the coil layer and disposed at least partly within the receptacle, wherein a top surface of the elastomeric cushioning element is one of substantially coplanar with or extends vertically above a top surface of the second coil layer.

18. The cushion assembly of claim 17, wherein the top surface of the elastomeric cushioning element is substantially coplanar with the top surface of the second coil layer, and wherein the cushion assembly further comprises a stabilization layer coupled to the top surface of the elastomeric cushioning element.

19. The cushion assembly of claim 18, wherein the stabilization material extends at least partly over the second coil layer.

20. The cushion assembly of claim 19, wherein at least some of the stabilization material is adhered to at least part of the second coil layer.

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