Mattresses including gel supports and related methods

Abstract

A mattress assembly includes a base layer; a support layer disposed over the base layer; an upper layer disposed over the support layer; and an outer covering encasing the base layer, the support layer, and the upper layer; wherein the support layer includes a plurality of gel support units attached to one another in an array of rows and columns, wherein each of the gel support units includes a plurality of gel members. Methods of making mattress assemblies and support layers for mattresses are also described.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 778,197, filed Mar. 26, 2025, the contents of which are incorporated herein by reference in their entirety for any and all purposesTECHNICAL FIELD

[0002] Embodiments of the disclosure relate generally to mattresses and more specifically to supporting elements used in mattresses, and to methods of making such mattresses.BACKGROUND

[0003] Sleep is an important bodily function. Sleep allows the body to repair and supports bodily functions such as, among other things, brain development, mental function and concentration, and stress reduction. Sleep also helps lower the risk of conditions such as high blood pressure, stroke, and diabetes.

[0004] Mattresses can help improve sleep quality and therefore overall health. However, different people often have different mattress preferences and requirements. Factors such as a person's body type, preferred sleeping position, and personal comfort preferences can each affect an individual's requirements for a mattress.

[0005] Therefore, a need exists to develop technologies to provide mattresses that can be customized to fit an individual's requirements in a mattress.SUMMARY

[0006] The present disclosure is directed to mattress assemblies that use a support layer comprising a plurality of gel support units that each comprise a plurality of gel members, where individual gel support units are attached to one another in an array (e.g., rows and columns) to form a support layer. The gel support units may be manufactured with different materials and / or dimensions to provide different levels of support. Therefore, gel support units with varying levels of support can be arranged within the array to provide a support layer of a mattress that offers customizable levels of support in different locations across the mattress based on the user's needs and preferences. Therefore, the presently disclosed technology overcomes technological barriers that previously limited customization of mattresses in this way.

[0007] In one aspect, the present technology is directed towards a support layer for a mattress, where the support layer comprises a plurality of gel support units comprising a plurality of gel members, where individual gel support units are attached to one another in an array (e.g., rows and columns) to form a support layer. In some embodiments, adjacent gel members of a gel support unit are separated from one another and attached to one another using gel member connecting walls. In any embodiments, all gel member connecting walls adjoining adjacent gel members may have approximately the same length and width. In any embodiments, gel members within a gel support unit may have different gel member wall thicknesses and different widths or diameters than other gel members within the same gel support unit. In any embodiments, a piece of adhesion material such as scrim fabric may be attached to one or more outer walls of a gel support unit using a heat fusion process. In any embodiments, gel support units may be attached to one another using adhesive to adhere pieces of adhesion material such as scrim fabric that have been attached to the outer walls of gel support units.

[0008] In another aspect, the present technology is directed towards mattress assemblies comprising a base layer; support layer (as described above) disposed over the base layer; an upper layer disposed over the support layer; and an outer covering encasing the base layer, the support layer, and the upper layer. In some embodiments, the upper layer may comprise foam such as a memory polyurethane foam and / or a latex foam rubber. In any embodiments, the upper lay may have a thickness between about 0.1 inches and about 1.0 inches.

[0009] In another aspect, the present technology is directed towards methods of forming support layers for mattress assemblies. In some embodiments, the method comprises forming a support layer comprising a plurality of gel support units that comprise a plurality of gel members. In any embodiments, a plurality of gel support units may be attached to one another in an array (e.g., rows and columns) to form a grid. In any embodiments, gel support units may be attached to one another using adhesive to adhere pieces of adhesion material such as scrim fabric that have been attached to the outer walls of gel support units. In any embodiments, the adhesion material may be attached to the gel support units through heat fusion.

[0010] In another aspect, the present technology is directed towards methods of forming a mattress assembly. In any embodiments, the method of forming a mattress assembly comprises forming a support layer; disposing the support layer over a base layer; disposing an upper layer over the support layer; and encasing the base layer, support layer, and upper layer in an outer covering. In any embodiments, the upper layer may be attached to the support layer using an adhesive.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:

[0012] FIG. 1 is a perspective view of a mattress assembly according to the present disclosure.

[0013] FIGS. 2A-2B are a simplified perspective view of the mattress assembly of FIG. 1, where FIG. 2A includes gel member connecting walls 126 (see also FIGS. 3A-3B) between gel members 124 and FIG. 2B omits gel member connecting walls 126.

[0014] FIG. 3A is a schematic of a top view of a gel support unit according to one or more embodiments of the present disclosure.

[0015] FIG. 3B is a schematic of a top view of subset of a gel support unit according to one or more embodiments of the present disclosure, zoomed to show gel member walls and gel member connecting walls.

[0016] FIG. 4A is a perspective view of a gel support unit according to one or more embodiments of the present disclosure.

[0017] FIG. 4B is a perspective view of the gel support unit of FIG. 4A after adhesion material has been attached to the gel support unit.

[0018] FIG. 5A is a top view of two gel support units before adhesion.

[0019] FIG. 5B is a top view of the gel support units of FIG. 6A after adhesion, forming the support layer.

[0020] FIG. 6 is a top view of a support layer after gel support units have been attached in an array (e.g., rows and columns to form a grid) of three columns by five rows, with an inset showing a single gel support unit. The dashed line in both the entire support layer and single support unit inset depicts where one or more gel support units of the support layer may be trimmed to conform to desired support layer dimensions.

[0021] FIG. 7 is a flowchart of a method of forming a mattress assembly according to one or more embodiments of the present disclosure.DETAILED DESCRIPTION

[0022] 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 employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional manufacturing techniques and materials employed in the industry.

[0023] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice the disclosure. However, other embodiments may be utilized, and structural, procedural, and other changes may be made without departing from the scope of the disclosure. The illustrations presented herein are not meant to be actual views of any particular system, device, structure, or process, but are idealized representations that are employed to describe the embodiments of the disclosure. The drawings presented herein are not necessarily drawn to scale. Similar structures or components in the various drawings may retain the same or similar numbering for the convenience of the reader; however, the similarity in numbering does not mean that the structures or components are necessarily identical in size, composition, configuration, or other property.

[0024] The following terms are used throughout as defined below.

[0025] As used herein and in the appended claims, singular articles such as “a” and “an” and “the” and similar referents in the context of describing the elements (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

[0026] As used herein, “about” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” will mean up to plus or minus 10% of the particular term—for example, “about 10% by volume” would be understood to mean “9% by volume to 11% by volume.” It is to be understood that when “about” precedes a term, the term is to be construed as disclosing “about” the term as well as the term without modification by “about”—for example, “about 10% by volume” discloses “9% by volume to 11% by volume” as well as disclosing “10% by volume.”

[0027] The phrase “and / or” as used in the present disclosure will be understood to mean any one of the recited members individually or a combination of any two or more thereof—for example, “A, B, and / or C” would mean “A or B or C; A and B; A and C; B and C; or the combination of A, B, and C.”

[0028] Unless otherwise indicated, numeric ranges, for instance as in “from 2 to 10,” are inclusive of the numbers defining the range (e.g., 2 and 10).

[0029] As used herein, any relational term, such as “first,”“second,”“top,”“bottom,”“upper,”“base,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise. For example, these terms may refer to an orientation of elements of a mattress when oriented for sleeping in a conventional manner. Furthermore, these terms may refer to an orientation of elements of a mattress assembly as illustrated in the drawings.

[0030] As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. 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.

[0031] 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).

[0032] 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.

[0033] 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.”

[0034] Unless otherwise indicated or obvious from the context, any reference to a two-dimensional shape may also be a reference to the corresponding three-dimensional shape, and any reference to a three-dimensional shape may also be a reference to the corresponding two dimensional shape. For example, any reference to a “circle” may also be a reference to a “cylinder;” likewise, any reference to a “cylinder” may also be a reference to a “circle.” As another example, any reference to a “rectangle” may also be reference to a “rectangular prism;” likewise, any reference to a “rectangular prism” may also be a reference to a “rectangle.”

[0035] Embodiments of the present disclosure include a mattress assembly 100 comprising a base layer 110; a support layer 120 disposed over the base layer 110; an upper layer 130 disposed over the support layer 120; and an outer covering 112 encasing the base layer 110, the support layer 120, and the upper layer 130; wherein the support layer 120 comprises a plurality of gel support units 122 attached to one another in an array of rows and columns, wherein each of the gel support units 122 comprises a plurality of gel members 124.

[0036] FIG. 1 shows a mattress assembly 100 according to one or more embodiments of the present disclosure. FIGS. 2A-2B show a simplified top perspective view of the mattress assembly 100 of FIG. 1, where FIG. 2A includes gel member connecting walls 126 (see also FIGS. 3A-3B) between gel members 124 and FIG. 2B omits gel member connecting walls 126. In FIGS. 2A-2B, various portions of the mattress assembly 100 are removed to provide a cutaway view and to better show internal components of the mattress assembly 100. Referring to FIG. 1 and FIGS. 2A-2B together, in one or more embodiments, the mattress assembly may include a base layer 110, a support layer 120, an upper layer 130, an elastomeric cushioning element 140, an edge portion 118, one or more side panels 114, and an outer covering 112.Gel Support Units

[0037] The support layer 120 may include a plurality of gel support units 122. The gel support units 122 may be made of any suitable material, including, for example, gel. Gel supports are described in U.S. Pat. No. 8,434,748 to Pearce et al., the entire disclosure of which is incorporated herein by reference. Notably, gel supports such as gel springs may be designed to buckle at predetermined pressure thresholds, which can relieve pressure hot spots and redistribute pressure so that no part of the object being supported by the gel support receives pressure above a predetermined threshold.

[0038] In one or more embodiments, the gel supports units 122 may comprise an elastomeric material. Such elastomeric materials are described in U.S. Pat. No. 11,317,733, to Pearce et al., the entire disclosure of which is incorporated herein by reference. Moreover, U.S. Pat. No. 11,317,733, to Pearce et al. references U.S. Pat. Nos. 5,994,450; 7,964,664; 4,369,284; and 8,919,750; the entire disclosures of each of which are incorporated herein by 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.

[0039] Gel support units 122 may be produced by any process that results in the desired dimensional specifications and desired material. Manufacturing methods are described in U.S. Pat. No. 8,434,748 to Pearce et al., the entire disclosure of which is incorporated herein by reference. For example, the gel support units may be manufactured using injection molding, compression molding, rotational molding, extrusion, screed molding, or any other suitable manufacturing process.

[0040] The design of the gel support units 122 must factor in several variables, including but not limited to the spacing of the gel members 124, the stiffness of the gel, the width / diameter of the gel members 124, the height of the gel members 124, the thickness of the gel member walls 125, the durometer of the gel from which the gel support units 122 are made, the expected weight of the person to use the mattress, the expected surface area of the person to contact the mattress, and the degree to which other materials and / or parts in the mattress assembly affect the behavior of the gel members 124. Generally, test data and experience may dictate the dimensional variables, and the composition of the gel may be varied experimentally to optimize the desired support features.

[0041] In some embodiments, the support layer 120 may comprise multiple gel support units 122, wherein each gel support unit 122 comprises a plurality of gel members 124. The gel members 124 may be connected to each other at two or more points by gel member connecting walls 126 and arranged in an array (e.g., rows and columns) to form a grid pattern. The gel members 124 can be of any shape, and in any embodiment may be rectangular or circular (or, in three dimensions, each gel member may be a rectangular prism or a cylinder). The gel members 124 may be hollow (and therefore have gel member walls 125) or solid.

[0042] FIG. 3A and FIG. 3B demonstrate an example embodiment of a gel support unit 122. FIG. 3A shows a gel support unit 122 consisting of ninety hollow, circular gel members 124 (9 rows×10 columns) separated from and connected to one another by gel member connecting walls 126. As shown by FIG. 3A, the gel members 124 may be arranged in an array (e.g., rows and columns) to form a grid pattern, wherein the gel members 124 may be spaced by gel member connecting walls 126. As can be seen by FIG. 3A and in detail in FIG. 3B, the gel members 124 may be spaced by gel member connecting walls 126 of a uniform thickness (e.g., width), regardless of the gel member wall 125 thickness. Referring still to FIG. 3A and FIG. 3B, gel support unit attachment walls 127 may extend about perpendicularly from an outer edge of a gel member wall 125 when said gel member 124 is located in an outer row or outer column of the gel support unit 122. For example, for a gel support unit 122 with an array of gel members 124 consisting of 9 rows and 10 columns, row 1, row 9, column 1, and column 10 of the gel support unit 122 may have gel support unit attachment walls 127 extending about perpendicularly from an outer edge of each gel member wall 125. Referring again to FIG. 3A, the gel support units 122 may optionally incorporate an indicator 128 to indicate the proper orientation for the gel support units 122 when the gel support units 122 are adjoined to form the support layer 120 (see discussion below).

[0043] While the thickness of the gel member walls 125 in any single gel support unit 122 may remain constant, the thickness of gel member walls 125 may vary within a single gel support unit 122 and / or from one gel support unit 122 to another gel support unit 122 within a support layer. For example, referencing FIG. 3B, the gel member 124 in the bottom right has a thicker gel member wall 125 than the other three gel members 124 shown in the schematic. The differences in the thickness of gel member walls 125 may allow for some zones of the support layer 120 to provide more support with thicker gel member walls 125 whereas some zones of the support layer 120 with thinner gel member walls 125 may provide less support, thereby enabling customizable mattress support combinations. In some embodiments, the thickness of the gel member walls 125 may be about 0.05 inches, about 0.06 inches, about 0.07 inches, about 0.08 inches, about 0.09 inches, about 0.095 inches, about 0.1 inches, about 0.105 inches, about 0.11 inches, about 0.1125 inches, about 0.1150 inches, about 0.1175 inches, about 0.12 inches, about 0.1225 inches, about 0.1250 inches, about 0.1275 inches, about 0.13 inches, 0.1325 inches, about 0.1350 inches, about 0.1375 inches, about 0.14 inches, about 0.15 inches, about 0.16 inches, about 0.17 inches, about 0.18 inches, about 0.19 inches, about 0.20 inches, or any range including and / or in-between any two of these values.

[0044] The gel support units 122 may have any suitable dimensions. For example, in some embodiments, the gel support units 122 may have a length of about 6 inches, about 8 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, about 14 inches, about 15 inches, about 16 inches, about 17 inches, about 18 inches, about 19 inches, about 20 inches, about 21 inches, about 22 inches, about 23 inches, about 24 inches, about 26 inches, about 28 inches, about 30 inches, or any range including and / or in-between any two of these values. Additionally, in some embodiments, the gel support units 122 may have a width of about 6 inches, about 8 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, about 14 inches, about 15 inches, about 16 inches, about 17 inches, about 18 inches, about 19 inches, about 20 inches, about 21 inches, about 22 inches, about 23 inches, about 24 inches, about 26 inches, about 28 inches, about 30 inches, or any range including and / or in-between any two of these values.

[0045] Similarly, the gel members 124 of the gel support units 122 may have any suitable dimensions. For example, in some embodiments, the gel members 124 may be circular and have a diameter of about 0.90 inches, about 0.91 inches, about 0.92 inches, about 0.93 inches, about 0.94 inches, about 0.941 inches, about 0.942 inches, about 0.943 inches, about 0.944 inches, about 0.945 inches, about 0.946 inches, about 0.947 inches, about 0.948 inches, about 0.949 inches, about 9.95 inches, about 0.96 inches, about 0.961 inches, about 0.962 inches, about 0.963 inches, about 0.964 inches, about 0.965 inches, about 0.966 inches, about 0.967 inches, about 0.968 inches, about 0.969 inches, about 0.97 inches, about 0.98 inches, about 9.99 inches, about 0.991 inches, about 0.992 inches, about 0.993 inches, about 0.994 inches, about 0.995 inches, about 0.996 inches, about 0.997 inches, about 0.998 inches, about 0.999 inches, about 1.0 inches, about 1.01 inches, about 1.02 inches, about 1.03 inches, about 1.04 inches, about 1.05 inches, or any range including and / or in-between any two of these values. In some embodiments, the gel members 124 may be rectangular and have lengths and / or widths of about 0.5 inches, about 0.6 inches, about 0.7 inches, about 0.8 inches, about 0.9 inches, about 1.0 inches, about 1.1 inches, about 1.2 inches, about 1.3 inches, about 1.4 inches, about 1.5 inches, about 2.0 inches, about 2.5 inches, about 3.0 inches, about 3.5 inches, about 4.0 inches, or any range including and / or in-between any two of these values. In any embodiments, the shape and dimensions of gel members 124 may not necessarily be uniform across all gel members 124 within a single gel support unit 122.

[0046] Similarly, in embodiments that incorporate gel member connecting walls 126, the gel member connecting walls 126 spacing adjacent gel members 124 from one another and connecting adjacent gel members 124 to one another may be of any suitable length. For example, in some embodiments, the gel member connecting walls 126 may have a length of about 0.1 inches, about 0.15 inches, about 0.2 inches, about 0.25 inches, about 0.3 inches, about 0.35 inches, about 0.4 inches, about 0.45 inches, about 0.5 inches, about 0.55 inches, about 0.6 inches, about 0.65 inches, about 0.7 inches, about 0.75 inches, about 0.8 inches, about 0.85 inches, about 0.9 inches, about 0.95 inches, about 1.0 inches, about 1.05 inches, about 1.1 inches, about 1.15 inches, about 1.2 inches, about 1.25 inches, about 1.3 inches, about 1.35 inches, about 1.4 inches, about 1.55 inches, about 1.5 inches, or any range including and / or in-between any two of these values.

[0047] Similarly, the gel member connecting walls 126 may be of any suitable width.

[0048] In some embodiments, the length of the gel support unit attachment walls 127 that form the outer edges of a gel support unit 122 may be about half the length of the gel member connecting walls 126 connecting two or more gel members 124 within a single gel support unit 122. For example, FIG. 3B shows that the gel support unit attachment walls 127 extend perpendicularly from the outer edge of the circular gel members 124. Still referring to FIG. 3B, the gel support unit attachment walls 127 are about one half the length of the gel member connecting walls 126.

[0049] Therefore, in some embodiments, the width of the gel support units 122 may be about 1 gel member 124, about 2 gel members 124, about 3 gel members 124, about 4 gel members 124, about 5 gel members 124, about 6 gel members 124, about 7 gel members 124, about 8 gel members 124, about 9 gel members 124, about 10 gel members 124, about 11 gel members 124, about 12 gel members 124, about 13 gel members 124, about 14 gel members 124, about 15 gel members 124, or any range including and / or in-between any two of these values. Similarly, in some embodiments, the length of the gel support units 122 may be about 1 gel member 124, about 2 gel members 124, about 3 gel members 124, about 4 gel members 124, about 5 gel members 124, about 6 gel members 124, about 7 gel members 124, about 8 gel members 124, about 9 gel members 124, about 10 gel members 124, about 11 gel members 124, about 12 gel members 124, about 13 gel members 124, about 14 gel members 124, about 15 gel members 124, or any range including and / or in-between any two of these values. In preferred embodiments, the gel support units 122 may be about 9 gel members 124 in width by about 10 gel members 124 in length.

[0050] In some embodiments, the thickness (i.e., height) of the gel support units 122 (and therefore also of the support layer-see discussion below) may be about 6.0 inches, about 6.5 inches, about 7.0 inches, about 7.5 inches, about 8.0 inches, about 8.5 inches, about 9.0 inches, or any range including and / or in-between any two of these values.Support Layer Formation

[0051] The gel support units 122 may be connected to one another in any suitable manner. In some embodiments, an adhesion material 150 may be used. The adhesion material 150 may be, for example, a cotton spandex blend “scrim.” This scrim fabric 151 may be used to provide a surface for adhering (e.g., gluing) the gel support unit 122 to surrounding materials, such as another gel support unit 122 or a surface of the upper layer 130 disposed over the support layer. The scrim fabric 151 may be attached to the gel support unit 122 in any suitable manner. In some embodiments, the scrim fabric 151 may be attached to the gel support unit 122 using heat fusion, such as by heating the gel support unit 122 to where the surface of the gel support unit 122 begins to melt without significantly deforming, so that portions of the gel support unit 122 may seep through (i.e., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric 151. In other words, an adhesion material 150 can be fused into the gel of a gel support unit 122. Referring now to FIG. 4A and FIG. 4B together, FIG. 4A shows a gel support unit 122 with protruding gel support unit attachment walls 127 before any adhesion material 150 has been attached to the gel support unit 122, while FIG. 4B shows the same gel support unit 122 after a scrim fabric 151 has been adhered to the gel support unit attachment walls 127 through heat fusion.

[0052] After attachment of the adhesion material 150 to the gel support unit 122, the gel support unit 122 may be attached by any suitable means to another gel support unit 122 and / or a surface of the upper layer 130 disposed over the support layer 120. For example, in some embodiments, the adhesion material 150 that has been attached to a gel support unit 122 may be attached using an adhesive to a second piece of adhesion material 150 that has been attached to a second gel support unit 122. As another example, in some embodiments, the adhesion material 150 that has been attached to a gel support unit 122 may be attached using an adhesive to a surface of the upper layer 130 disposed over the support layer 120. The adhesive may comprise latex, synthetic rubber (e.g., styrene-butadiene rubbers (SBR), polyisoprene, neoprene, nitrile rubber, silicone rubber, or a combination of any two or more thereof), acrylic resin, ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, the adhesive may include a latex water-based adhesive. For example, the adhesive may include a dispersion of acrylic resin and synthetic rubber in water. For example, the adhesive may include a thermoplastic adhesive (e.g., hot melt glue or hot glue), which may include ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, in one or more embodiments, the adhesive may comprise one or more of SIMALFA® 338, SIMALFA® 310, and SIMALFA 350-R. The process of attaching gel support units 122 to one another may be repeated to form an array (e.g., rows and columns) of gel support units 122 until the desired support layer 120 dimensions (e.g., mattress dimensions) are achieved.

[0053] The gel support units 122 may be connected to one another in any suitable manner. In some embodiments, an adhesion material 150 may be used. The adhesion material 150 may be, for example, one or more portions of the gel support units 122 attached via heat fusion. The adhesion material 150 may be for example, one or more portions of gel members 124, gel member connecting walls 126, gel support unit attachment walls 127, or a combination of any two or more thereof from each gel support unit 122 at the point of connection via heat fusion, such as by heating a portion of the gel support unit 122 at a temperature where the surface of the portion of the gel support unit 122 begins to melt without significantly deforming, so that the portion of the gel support unit 122 may fuse with (i.e., be melt-fused with) another gel support unit 122. For example, one gel support unit 122 may be heated for heat fusion or both gel support units 122 may be heated for heat fusion. Heat fusion may be by any suitable manner, such as with a hot knife or hot wire cutter. Referring now to FIG. 5A and FIG. 5B together, FIG. 5A shows a top view of two gel support units 122A and 122B before adhesion, while FIG. 5B shows a top view of the gel support units after adhesion, forming a support layer 120. Gel support unit attachment walls 127A of the gel support unit 122A may adhere to a gel support unit attachment walls 127B of the gel support unit 122B via the adhesion layer 150. The adhesion layer 150 may not include a scrim layer.

[0054] The gel support unit 122 may be attached by any suitable means to another gel support unit 122 and / or a surface of the upper layer 130 disposed over the support layer 120. For example, a gel support unit 122 may be attached to one another gel support unit 122 via heat fusion without a scrim layer. As another example, a gel support unit 122 may be attached to one another gel support unit 122 via an adhesive, and the adhesion layer 150 may include the adhesive. The adhesive may include latex, synthetic rubber (e.g., styrene-butadiene rubbers (SBR), polyisoprene, neoprene, nitrile rubber, silicone rubber, or a combination of any two or more thereof), acrylic resin, ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, the adhesive may include a latex water-based adhesive. For example, the adhesive may include a dispersion of acrylic resin and synthetic rubber in water. For example, the adhesive may include a thermoplastic adhesive (e.g., hot melt glue or hot glue), which may include ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, in one or more embodiments, the adhesive may comprise one or more of SIMALFA® 338, SIMALFA® 310, and SIMALFA 350-R. The process of attaching gel support units 122 to one another may be repeated to form an array (e.g., rows and columns) of gel support units 122 until the desired support layer 120 dimensions (e.g., mattress dimensions) are achieved.

[0055] As noted above, in some embodiments of gel support units 122, the length of the gel support unit attachment walls 127 (i.e., the distance that the gel support unit attachment walls 127 extend away from the outer edge of gel member walls 125) may be about half the length of the gel member connecting walls 126. In these embodiments, a first gel support unit attachment wall 127 of a first gel support unit 122 may be attached to a second gel support unit attachment wall 127 of a second gel support unit 122, thereby creating a wall that spans the two gel support units 122 and is the same length as the gel member connecting walls 126 connecting two or more gel members 124 within a single gel support unit 122. For example, FIG. 3A, FIG. 3B, and FIG. 6 show embodiments of a gel support unit 122 with gel support unit attachment walls 127 of about half the length of gel member connecting walls 126 in the same gel support unit 122. FIG. 6 also demonstrates that once the gel support units 122 are attached to form a support layer 120, a gel support unit attachment wall 127 of a first gel support unit 122 may be attached to a gel support unit attachment wall 127 of a second gel support unit 122, thereby creating a wall that spans the two gel support units 122 and is the same length as the gel member connecting walls 126 connecting two or more gel members 124 within a single gel support unit 122.

[0056] In some embodiments, it may be desirable to trim (i.e., remove) some portion of one or more gel support units 122. The trimming may occur either before or after gel support units 122 have been attached to one another to create a support layer 120. Trimming may be desirable, for example, to conform the support layer 120 to dimensions suitable for standard mattress sizes (e.g., twin, queen, king). As an example, FIG. 6 shows a support layer 120 formed from attaching fifteen gel support units 122 in an array (i.e., grid) of 5 rows by 3 columns, with each gel support unit 122 consisting of an array (i.e., grid) of 9 rows by 10 columns of gel members 124. Still referring to FIG. 6, the dashed line indicates where the gel support units 122 may be trimmed, indicating that four rows of gel members 124 may be trimmed from each of the three gel support units 122 in the fifth row of the array of gel support units 122.Mattress Assembly

[0057] In some embodiments, a mattress assembly comprises a base layer 110; a support layer 120 disposed over the base layer 110; an upper layer 130 disposed over the support layer 120; and an outer covering 112 encasing the base layer 110, the support layer 120, and the upper layer 130; wherein the support layer 120 comprises a plurality of gel support units 122 attached to one another in an array of rows and columns, wherein each of the gel support units 122 comprises a plurality of gel members 124.

[0058] The base layer 110 may have generally planar top and bottom surfaces. The support layer 120 (described in detail above) may be disposed on the top surface of the base layer 110 and between the base layer 110 and the upper layer 130. In particular, the upper layer 130 may be disposed over and may at least substantially extend over the support layer 120. The elastomeric cushioning element 140 may be disposed over an upper surface of the upper layer 130 and may extend over at least a portion of the upper layer 130. The edge portion 118 may extend around an outer peripheral edge of the elastomeric cushioning element 140. The one or more side panels 114 may extend along outer perimeters of the base layer 110 and the upper layer 130 and may be disposed between the upper layer 130 and the base layer 110.

[0059] Furthermore, the one or more side panels 114 may extend within a plane perpendicular to a plane defined by the top surface of the base layer 110. The outer covering 112 may extend from the base layer 110 and may at least substantially encase the support layer 120, upper layer 130, and elastomeric cushioning element 140.

[0060] In some embodiments, the mattress assembly 100 may include an adhesion material 150 between the elastomeric cushioning element 140 and the upper layer 130. In some instances, the adhesion material 150 may include a relatively thin material (e.g., cotton spandex blend “scrim”) and may be used to provide a surface for attaching the elastomeric cushioning element 140 to surrounding materials, such as another elastomeric cushioning element 140 and / or an upper surface of the upper layer 130. In some embodiments, the adhesion material 150 may comprise a scrim fabric 151 (e.g., a woven or non-woven fabric material) and portions of the elastomeric cushioning element 140 may seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric 151 of the adhesion material 150. For example, when the elastomeric cushioning element 140 includes a gel material, portions of the gel material may be heat fused through the adhesion material 150. The portions of the elastomeric cushioning element 140 that extend through the scrim fabric 151 of the adhesion material 150 may create a non-slip surface or reduced slip surface on a lower surface of the adhesion material 150 (e.g., surface that would contact an upper surface of the upper layer 130). The non-slip surface or reduced slip surface created by the elastomeric cushioning element 140 may help the cushioning materials stay in place relative to one another.

[0061] Furthermore, in some embodiments, an adhesive may be disposed between the adhesion material 150 and the upper surface of the upper layer 130. However, an adhesive may not be disposed between the edge portion 118 and the upper layer 130. Furthermore, an adhesive may be disposed between the base layer 110 and the support layer 120. Moreover, an adhesive may be disposed between the support layer 120 and the upper layer 130. Additionally, an adhesive may be disposed between the one or more side panels 114 and the support layer 120. In some embodiments the adhesive(s) may include a latex water-based adhesive. For instance, in one or more embodiments, the adhesive(s) may include one or more of SIMALFA® 338 and SIMALFA® 310.

[0062] In one or more embodiments, the mattress assembly 100 may not include an adhesion material 150 between the support layer 120 and the upper layer 130 of the mattress assembly 100. However, in some instances, an adhesive may be disposed between the adhesion material 150 and the upper surface of the upper layer 130. For example, the adhesive may include any of the adhesives described above.

[0063] In some embodiments, the outer covering 112 may comprise a stretchable material that may be secured to or be integral with the elastomeric cushioning element 140. Such a stretchable material is described in U.S. Pat. No. 11,793,322 to Pearce, the entire disclosure of which is incorporated herein by reference.

[0064] In one or more embodiments, the base layer 110 and the upper layer 130 may include a polyurethane foam. In additional embodiments, the base layer 110 and the upper layer 130 may include one or more of a memory polyurethane foam, a latex foam rubber, or any other suitable foam. In some embodiments, the base layer 110 may include a polyurethane foam having a nominal density of about 2.0 lb / ft3 and an indention load deflection (ILD) of 55 (i.e., 55 ILD). Additionally, the upper layer 130 may include a polyurethane foam having a nominal density of about 2.0 lb / ft3 and 18 ILD. The one or more side panels 114 may also include a polyurethane foam or any other spacer fabric known in the art. For example, the one or more side panels 114 may include any of the side panels 114 described in U.S. Pat. No. 10,881,217 to Moon et al., the entire disclosure of which is incorporated herein by reference.

[0065] As shown in FIG. 1 and FIG. 2, in some embodiments, the upper layer 130 of the mattress assembly 100 may have a thickness (e.g., height) of about 0.20 inches, about 0.25 inches, about 0.30 inches, about 0.35 inches, about 0.40 inches, about 0.45 inches, about 0.50 inches, about 0.55 inches, about 0.60 inches, about 0.65 inches, about 0.70 inches, about 0.75 inches, about 0.8 inches, or any range including and / or in-between any two of these values.

[0066] Still referring to FIG. 2, in some embodiments, the base layer 110 of the mattress assembly 100 may have a thickness (e.g., height) of about 0.50 inches, about 0.60 inches, about 0.70 inches, about 0.80 inches, about 0.90 inches, about 1.00 inches, about 1.10 inches, about 1.20 inches, about 1.30 inches, about 1.40 inches, about 1.50 inches, or any range including and / or in-between any two of these values.

[0067] Still referring to FIG. 2, in some embodiments, the elastomeric cushioning element 140 disposed over the upper layer 130 may comprise between about 15.0%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 30.2%, about 30.4%, about 30.6%, about 30.8%, about 31.0%, about 31.2%, about 31.4%, about 31.6%, about 31.8%, about 32.0%, about 33%, about 34%, about 35%, or any range including and / or in-between any two of these values.

[0068] FIG. 7 shows a schematic flowchart of a method 1000 of forming a mattress assembly 100. In some embodiments, the method 1000 may include an act 1010 of disposing a support layer 120 over a base layer 110.

[0069] Additionally, the method 1000 may include an act 1020 of disposing an upper layer 130 over the support layer 120. In some embodiments, act 1020 may not include disposing an adhesion material 150 between the support layer 120 and the upper layer 130. However, in some embodiments, act 1020 may include disposing an adhesive between the support layer 120 and the upper layer 130. For example, act 1020 may include disposing any of the adhesives described above between the support layer 120 and the upper layer 130.

[0070] Moreover, the method 1000 may include an act 1030 of disposing an elastomeric cushioning element 140 over the upper layer 130.

[0071] Additionally, the method 1000 may include act 1040 of disposing an outer covering 112 over at least the upper layer 130. For example, act 1040 can include disposing an outer covering 112 over the mattress assembly 100 such that the outer covering 112 covers at least substantially an entirety of the upper layer 130 and side panels 114 of the mattress assembly 100. In one or more embodiments, the method 1000 can include disposing an adhesive between any of the layers of the mattress assembly 100.EXAMPLES

[0072] The examples herein are provided to illustrate advantages of the present technology and to further assist a person of ordinary skill in the art with preparing or using the compositions of the present technology. The examples herein are also presented to more fully illustrate the present technology. The examples should in no way be construed as limiting the scope of the present technology, as defined by the appended claims. The examples can include or incorporate any of the variations or aspects of the present technology described above. The variations or aspects described above may also further each include or incorporate the variations of any or all other variations or aspects of the present technology.Example 1. Manufacturing of Gel Support Units

[0073] Gel support units 122 were manufactured using a molding process. While gel support units 122 may be manufactured with gel members 124 of any suitable shape, the gel support units 122 of the present embodiments were manufactured to have hollow, circular gel members 124 (i.e., cylinders).

[0074] Several embodiments of gel support units 122 were manufactured. In at least one embodiment, the diameter of each gel member 124 and the thickness of each gel member wall 125 was the same across all gel members 124 within the gel support unit 122 (see Gel Support Unit 122 Embodiment R). In some embodiments, the diameter of gel members 124 and the thickness of gel member walls 125 varied across gel members 124 of the gel support unit 122 (see Gel Support Unit 122 Embodiments A-Q). Gel support units 122 were manufactured with gel member wall 125 thicknesses of about 0.090 inches, about 0.100 inches, about 0.1125 inches, about 0.125 inches, about 0.130 inches, and about 0.1375 inches. The gel support units 122 were manufactured with cylindrical gel members 124 with diameters of about 0.949 inches, about 0.964 inches, about 0.969 inches, about 0.995 inches, and about 1.02 inches. The gel support unit 122 embodiments described below comprised an array of gel members 124 with 9 rows and 10 columns, where all gel members 124 in a given row had about the same diameter and about the same gel member wall 125 thickness.

[0075] The following tables disclose gel member 124 diameter and gel member wall 125 thickness for exemplary gel support unit 122 embodiments.Gel Support Unit 122 Embodiment AGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9640.13020.9640.13030.9640.13040.9690.12550.9690.12560.9950.112571.020.10081.020.10091.020.100Gel Support Unit 122 Embodiment BGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)11.020.10020.9950.112530.9950.112540.9950.112550.9690.12560.9690.12570.9950.112580.9950.112591.020.100Gel Support Unit 122 Embodiment CGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)11.020.10021.020.10031.020.10041.020.10050.9950.112560.9950.112570.9950.112580.9690.12590.9690.125Gel Support Unit 122 Embodiment DGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9690.12520.9640.13030.9640.13040.9640.13050.9640.13060.9640.13070.9640.13080.9690.12590.9690.125Gel Support Unit 122 Embodiment EGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9950.112520.9950.112530.9950.112540.9950.112550.9950.112560.9950.112570.9950.112580.9950.112590.9950.1125Gel Support Unit 122 Embodiment FGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)11.020.10021.020.10031.020.10041.020.10050.9950.112560.9950.112570.9950.112580.9950.112590.9950.1125Gel Support Unit 122 Embodiment GGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9690.12520.9490.137530.9490.137540.9490.137550.9490.137560.9490.137570.9690.12580.9690.12590.9950.1125Gel Support Unit 122 Embodiment HGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9950.112520.9690.12530.9690.12540.9490.137550.9490.137560.9490.137570.9490.137580.9490.137590.9690.125Gel Support Unit 122 Embodiment IGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9690.12520.9690.12530.9950.112540.9950.112550.9950.112560.9950.112570.9950.112580.9950.112590.9950.1125Gel Support Unit 122 Embodiment JGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9950.112520.9950.112530.9950.112540.9950.112551.020.10061.020.10071.020.10081.020.10091.020.100Gel Support Unit 122 Embodiment KGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9950.112521.020.10031.020.10041.0440.09051.0440.09061.0440.09071.0440.09081.0440.09091.0440.090Gel Support Unit 122 Embodiment LGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.0440.09021.020.10030.9950.112540.9690.12550.9490.137560.9490.137570.9690.12580.9950.112591.020.100Gel Support Unit 122 Embodiment MGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.0440.09021.0440.09031.0440.09041.0440.09051.020.10060.9950.112570.9690.12580.9690.12590.9690.125Gel Support Unit 122 Embodiment NGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9490.137520.9490.137530.9490.137540.9490.137550.9490.137560.9690.12570.9950.112581.020.10091.020.100Gel Support Unit 122 Embodiment OGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.020.10021.0440.09031.0440.09041.0440.09051.0440.09061.0440.09071.0440.09081.0440.09091.0440.090Gel Support Unit 122 Embodiment PGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.0440.09021.0440.09031.0440.09041.0440.09051.0440.10061.0440.10070.9950.112580.9690.12590.9690.125Gel Support Unit 122 Embodiment OGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9690.12520.9690.12530.9490.137540.9490.137550.9490.137560.9490.137570.9490.137580.9690.12590.9950.1125Gel Support Unit 122 Embodiment RGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9690.12520.9690.12530.9690.12540.9690.12550.9690.12560.9690.12570.9690.12580.9690.12590.9690.125Example 2. Attaching Gel Support Units in an Array to Form a GridA plurality of gel support units 122 was produced as described in Example 1. Gel support units 122 were attached to one another to form an array (i.e., rows and columns) as described in the following paragraphs.A piece of scrim fabric 151 was attached to each face of each gel support unit 122 that was to be attached to another gel support unit 122. The scrim fabric 151 was attached to the support units through heat fusion, where the scrim fabric 151 was placed over the gel support unit attachment walls 127 on one face of gel support unit 122 and the gel support unit 122 was subsequently heated such that the surface of the edges of the gel support unit attachment walls 127 melted slightly but without significant deformation. Therefore, portions of the melted gel support unit 122 seeped through the scrim fabric 151 such that upon cooling of the gel, the scrim fabric 151 was attached to the gel support unit attachment walls 127.After the scrim fabric 151 was attached to each gel support unit 122 that were to be attached to one another, one or more of SIMALFA® 338 and SIMALFA® 310 was applied to the scrim fabric 151 of each of the two gel support units 122 that were to be attached to one another. Pressure was applied until the adhesive dried.This attachment process was repeated until the desired gel support units 122 were attached in a conformation so as to form a support layer 120 for a mattress assembly 100. Depending on the dimensions of the gel support units 122 and the desired dimensions of the bed, portions of some gel support units 122 were trimmed.In the following Embodiments, gel support units 122 chosen from the group consisting of Gel Support Unit 122 Embodiments A-R disclosed in Example 1 were attached to one another in an array of 5 rows by 3 columns (i.e., 15 gel support units 122 were used to form each support layer 120). In each embodiment, the bottom 4 rows of gel members 124 (i.e., gel member 124 rows 6-9) on the bottom row of gel support units (i.e., the fifth row) were trimmed away, as shown in the schematic of FIG. 6.In each of the Support Layer 120 Embodiments A-E described below, each table consists of 5 rows by 3 columns, where each cell of each table corresponds to a gel support unit 122 chosen from the group consisting of Gel Support Unit 122 Embodiments A-R disclosed in Example 1.Support Layer 120 Embodiment A: Circular GridGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RSupport Layer 120 Embodiment B: High-Load, Low Firmness ConfigurationGel Support UnitGel Support UnitGel Support UnitEmbodiment AEmbodiment AEmbodiment AGel Support UnitGel Support UnitGel Support UnitEmbodiment BEmbodiment BEmbodiment BGel Support UnitGel Support UnitGel Support UnitEmbodiment CEmbodiment CEmbodiment CGel Support UnitGel Support UnitGel Support UnitEmbodiment DEmbodiment DEmbodiment DGel Support UnitGel Support UnitGel Support UnitEmbodiment EEmbodiment EEmbodiment ESupport Layer 120 Embodiment C: High-Load, High Support ConfigurationGel Support UnitGel Support UnitGel Support UnitEmbodiment FEmbodiment FEmbodiment FGel Support UnitGel Support UnitGel Support UnitEmbodiment GEmbodiment GEmbodiment GGel Support UnitGel Support UnitGel Support UnitEmbodiment HEmbodiment HEmbodiment HGel Support UnitGel Support UnitGel Support UnitEmbodiment IEmbodiment IEmbodiment IGel Support UnitGel Support UnitGel Support UnitEmbodiment JEmbodiment JEmbodiment JSupport Layer 120 Embodiment D:Baseline Firmness, Firmer LumbarGel Support UnitGel Support UnitGel Support UnitEmbodiment KEmbodiment KEmbodiment KGel Support UnitGel Support UnitGel Support UnitEmbodiment LEmbodiment LEmbodiment LGel Support UnitGel Support UnitGel Support UnitEmbodiment MEmbodiment MEmbodiment MGel Support UnitGel Support UnitGel Support UnitEmbodiment NEmbodiment NEmbodiment NGel Support UnitGel Support UnitGel Support UnitEmbodiment OEmbodiment OEmbodiment OSupport Layer 120 Embodiment E:Baseline Firmness, Firmer LumbarGel Support UnitGel Support UnitGel Support UnitEmbodiment KEmbodiment KEmbodiment KGel Support UnitGel Support UnitGel Support UnitEmbodiment LEmbodiment LEmbodiment LGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment SEmbodiment SEmbodiment SGel Support UnitGel Support UnitGel Support UnitEmbodiment OEmbodiment OEmbodiment OExample 4. Mattress AssemblyTo form a mattress assembly 100, a support layer 120 chosen from Support Layer 120 Embodiments A-E disclosed in Example 2 was disposed over a base layer. The base layer 110 comprised memory polyurethane foam with a thickness of about 1.0 inch. The base layer 110 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.An upper layer 130 was disposed over the support layer 120. The upper layer 130 comprised memory polyurethane foam with a thickness of about 0.5 inches. The upper layer 130 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.Side panels 114 comprising polyurethane foam were added to the mattress assembly 100 to extend around the base layer 110, support layer 120, and upper layer 130. The side panels 114 were attached to the base layer 110, support layer 120, and upper layer 130 using adhesive such as SIMALFA® 338 and SIMALFA® 310.An elastomeric cushioning element 140 was disposed over the upper layer 130, where the thickness of the elastomeric cushioning element 140 was about 30.8% of the overall thickness of the mattress assembly 100. Adhesion material 150 (i.e., scrim fabric 151) was attached to the elastomeric cushioning element 140 through heat fusion. Subsequently, adhesives such as SIMALFA® 338 and SIMALFA® 310 were used to attach the elastomeric cushioning element 140 to the upper layer 130.An outer covering 112 comprising a stretchable material was disposed around the base layer 110, support layer 120, upper layer 130, and side panels 114.EQUIVALENTSWhile certain embodiments have been illustrated and described, a person with ordinary skill in the art, after reading the foregoing specification, can effect changes, substitutions of equivalents and other types of alterations to the compositions of the present technology as set forth herein. Each aspect and embodiment described above can also have included or incorporated therewith such variations or aspects as disclosed regarding any or all of the other aspects and embodiments.The present technology is also not to be limited in terms of the particular aspects described herein, which are intended as single illustrations of individual aspects of the present technology. Many modifications and variations of this present technology can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods within the scope of the present technology, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. It is to be understood that this present technology is not limited to particular methods, reagents, compounds, or compositions, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Thus, it is intended that the specification be considered as exemplary only with the breadth, scope and spirit of the present technology indicated only by the appended claims, definitions therein and any equivalents thereof.The embodiments, illustratively described herein may suitably be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms “comprising,”“including,”“containing,” etc. shall be read expansively and without limitation. Additionally, the terms and expressions employed herein have been used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the claimed technology.In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group. Each of the narrower species and subgeneric groupings falling within the generic disclosure also form part of the technology. This includes the generic description of the technology with a proviso or negative limitation removing any subject matter from the genus, regardless of whether or not the excised material is specifically recited herein.As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,”“at least,”“greater than,”“less than,” and the like, include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.All publications, patent applications, issued patents, and other documents (for example, journals, articles and / or textbooks) referred to in this specification are herein incorporated by reference as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated by reference in its entirety. Definitions that are contained in text incorporated by reference are excluded to the extent that they contradict definitions in this disclosure.The present technology may include, but is not limited to, the features and combinations of features recited in the following lettered paragraphs, it being understood that the following paragraphs should not be interpreted as limiting the scope of the claims as appended hereto or mandating that all such features must necessarily be included in such claims:A. A support layer for a mattress comprising a plurality of gel support units attached to one another in an array, wherein each of the gel support units comprises a plurality of gel members.B. The support layer of Paragraph A, wherein gel members are spaced by gel member connecting walls, wherein each gel member connecting wall extends about perpendicularly from an outer edge of a wall of a first gel member to an outer edge of a wall of a second gel member.C. The support layer of Paragraph B, wherein the gel member connecting walls have a length of about 0.1 inches to about 5 inches.D. The support layer of Paragraph B or C, wherein the gel support units further comprise one or more gel support unit attachment walls that extend about perpendicularly from an outer edge of a wall of a gel member located in an outer row or outer column of the gel support unit.E. The support layer of Paragraph D, wherein the one or more gel support unit attachment walls have lengths that are about one half of the length of the gel member connecting walls of the gel support unit.

[0099] F. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are hollow and have a wall thickness between about 0.05 inches and about 0.2 inches.

[0100] G. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are hollow and have a wall thickness between about 0.09 inches and about 0.14 inches.

[0101] H. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are either a rectangular prism or cylindrical.

[0102] I. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are cylindrical.

[0103] J. The support layer of Paragraph I, wherein one or more gel members have a diameter of between about 0.5 inches and about 1.5 inches.

[0104] K. The support layer of Paragraph I or J, wherein one or more gel members have a diameter of between about 0.90 inches and about 1.05 inches.

[0105] L. The support layer of any one of the preceding Paragraphs, wherein each of the gel support units have between about 5 gel members and about 15 gel members in width and between about 5 gel members and about 15 gel members in length.

[0106] M. The support layer of any of the preceding Paragraphs, wherein each of the gel support units have between about 8 gel members and about 11 gel members in width and between about 8 gel members and about 11 gel members in length.

[0107] N. The support layer of any of the preceding Paragraphs, wherein each of the gel support units have between about 9 gel members and about 10 gel members in width and between about 9 gel members and about 10 gel members in length.

[0108] O. The support layer of any of the preceding Paragraphs, wherein each of the gel support units are rectangular and have a length between about 10 inches and about 24 inches and a width between about 10 inches and about 24 inches.

[0109] P. The support layer of any of the preceding Paragraphs, wherein each of the gel support units has a height between about 6.0 inches and about 9.0 inches.

[0110] Q. The support layer of any of the preceding Paragraphs, wherein each of the gel support units has a height of about 7.5 inches.

[0111] R. A mattress assembly comprising:

[0112] a base layer;

[0113] a support layer of any one of Paragraphs A-Q disposed over the base layer;

[0114] an upper layer disposed over the support layer; and

[0115] an outer covering encasing the base layer, the support layer, and the upper layer.

[0116] S. The mattress assembly of Paragraph R, wherein the upper layer comprises foam.

[0117] T. The mattress assembly of Paragraph R or S, wherein the upper layer comprises a memory polyurethane foam or a latex foam rubber.

[0118] U. The mattress assembly of any one of Paragraphs R-T, wherein the upper layer has a thickness between about 0.1 inches to about 1.0 inches.

[0119] V. The mattress assembly of any one of Paragraphs R-U, wherein the upper layer has a thickness of about 0.5 inches.

[0120] W. The mattress assembly of any one of Paragraphs R-V, wherein the outer covering is a stretchable fabric.

[0121] X. The mattress assembly of any one of Paragraphs R-W, wherein the base layer has a thickness between about 0.5 inches and about 1.5 inches.

[0122] Y. The mattress assembly of any one of Paragraphs R-X, wherein the base layer has a thickness of about 1.0 inch.

[0123] Z. The mattress assembly of any one of Paragraphs R-Y, further comprising side panels.

[0124] AA. The mattress assembly of any one of Paragraphs R-Z, further comprising an adhesion material.

[0125] AB. The mattress assembly of Paragraph AA, wherein the adhesion material is scrim fabric.

[0126] AC. A method of forming a support layer for a mattress, comprising attaching a plurality of gel support units in an array.

[0127] AD. The method of Paragraph AC, wherein the gel support units are attached to one another by:

[0128] (a) attaching a first piece of scrim fabric to an outer edge of a first gel support unit;

[0129] (b) attaching a second piece of scrim fabric to an outer edge of a second gel support unit;

[0130] (c) adhering the first piece of scrim fabric and the second piece of scrim fabric; and

[0131] (d) repeating steps (a)-(c) until each of the plurality of gel support units is attached to one or more other gel support units to form an array of gel support units.

[0132] AE. The method of Paragraph AD, wherein scrim fabric is attached to an outer edge of a gel support unit using heat fusion.

[0133] AF. The method of Paragraph AD or AE, wherein the first piece of scrim fabric and the second piece of scrim fabric are attached together using an adhesive.

[0134] AG. A method of forming a mattress assembly, comprising:

[0135] (a) forming a support layer as described in any one of Paragraphs AC-AF;

[0136] (b) disposing the support layer over a base layer;

[0137] (c) disposing an upper layer over the support layer; and

[0138] (d) encasing the base layer, the support layer, and the upper layer in an outer covering.

[0139] AH. The method of Paragraph AG, wherein the upper layer is attached to the support layer using an adhesive.

[0140] AI. The method of Paragraph AG or AH, wherein the support layer is attached to the base layer using an adhesive.

[0141] AJ. The mattress assembly of claim AA, wherein the adhesion material comprises a portion of a gel member of the plurality of gel members.

[0142] AK. The method of claim AC, wherein the gel support units are attached to one another by heat fusion.

Examples

example 1

Manufacturing of Gel Support Units

[0073]Gel support units 122 were manufactured using a molding process. While gel support units 122 may be manufactured with gel members 124 of any suitable shape, the gel support units 122 of the present embodiments were manufactured to have hollow, circular gel members 124 (i.e., cylinders).

[0074]Several embodiments of gel support units 122 were manufactured. In at least one embodiment, the diameter of each gel member 124 and the thickness of each gel member wall 125 was the same across all gel members 124 within the gel support unit 122 (see Gel Support Unit 122 Embodiment R). In some embodiments, the diameter of gel members 124 and the thickness of gel member walls 125 varied across gel members 124 of the gel support unit 122 (see Gel Support Unit 122 Embodiments A-Q). Gel support units 122 were manufactured with gel member wall 125 thicknesses of about 0.090 inches, about 0.100 inches, about 0.1125 inches, about 0.125 inches, about 0.130 inches,...

example 2

Attaching Gel Support Units in an Array to Form a Grid

A plurality of gel support units 122 was produced as described in Example 1. Gel support units 122 were attached to one another to form an array (i.e., rows and columns) as described in the following paragraphs.

A piece of scrim fabric 151 was attached to each face of each gel support unit 122 that was to be attached to another gel support unit 122. The scrim fabric 151 was attached to the support units through heat fusion, where the scrim fabric 151 was placed over the gel support unit attachment walls 127 on one face of gel support unit 122 and the gel support unit 122 was subsequently heated such that the surface of the edges of the gel support unit attachment walls 127 melted slightly but without significant deformation. Therefore, portions of the melted gel support unit 122 seeped through the scrim fabric 151 such that upon cooling of the gel, the scrim fabric 151 was attached to the gel support unit attachment walls 127.

Afte...

example 4

Mattress Assembly

To form a mattress assembly 100, a support layer 120 chosen from Support Layer 120 Embodiments A-E disclosed in Example 2 was disposed over a base layer. The base layer 110 comprised memory polyurethane foam with a thickness of about 1.0 inch. The base layer 110 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.

An upper layer 130 was disposed over the support layer 120. The upper layer 130 comprised memory polyurethane foam with a thickness of about 0.5 inches. The upper layer 130 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.

Side panels 114 comprising polyurethane foam were added to the mattress assembly 100 to extend around the base layer 110, support layer 120, and upper l...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 778,197, filed Mar. 26, 2025, the contents of which are incorporated herein by reference in their entirety for any and all purposesTECHNICAL FIELD

[0002] Embodiments of the disclosure relate generally to mattresses and more specifically to supporting elements used in mattresses, and to methods of making such mattresses.BACKGROUND

[0003] Sleep is an important bodily function. Sleep allows the body to repair and supports bodily functions such as, among other things, brain development, mental function and concentration, and stress reduction. Sleep also helps lower the risk of conditions such as high blood pressure, stroke, and diabetes.

[0004] Mattresses can help improve sleep quality and therefore overall health. However, different people often have different mattress preferences and requirements. Factors such as a person's body type, preferred sleeping position, and personal comfort preferences can each affect an individual's requirements for a mattress.

[0005] Therefore, a need exists to develop technologies to provide mattresses that can be customized to fit an individual's requirements in a mattress.SUMMARY

[0006] The present disclosure is directed to mattress assemblies that use a support layer comprising a plurality of gel support units that each comprise a plurality of gel members, where individual gel support units are attached to one another in an array (e.g., rows and columns) to form a support layer. The gel support units may be manufactured with different materials and / or dimensions to provide different levels of support. Therefore, gel support units with varying levels of support can be arranged within the array to provide a support layer of a mattress that offers customizable levels of support in different locations across the mattress based on the user's needs and preferences. Therefore, the presently disclosed technology overcomes technological barriers that previously limited customization of mattresses in this way.

[0007] In one aspect, the present technology is directed towards a support layer for a mattress, where the support layer comprises a plurality of gel support units comprising a plurality of gel members, where individual gel support units are attached to one another in an array (e.g., rows and columns) to form a support layer. In some embodiments, adjacent gel members of a gel support unit are separated from one another and attached to one another using gel member connecting walls. In any embodiments, all gel member connecting walls adjoining adjacent gel members may have approximately the same length and width. In any embodiments, gel members within a gel support unit may have different gel member wall thicknesses and different widths or diameters than other gel members within the same gel support unit. In any embodiments, a piece of adhesion material such as scrim fabric may be attached to one or more outer walls of a gel support unit using a heat fusion process. In any embodiments, gel support units may be attached to one another using adhesive to adhere pieces of adhesion material such as scrim fabric that have been attached to the outer walls of gel support units.

[0008] In another aspect, the present technology is directed towards mattress assemblies comprising a base layer; support layer (as described above) disposed over the base layer; an upper layer disposed over the support layer; and an outer covering encasing the base layer, the support layer, and the upper layer. In some embodiments, the upper layer may comprise foam such as a memory polyurethane foam and / or a latex foam rubber. In any embodiments, the upper lay may have a thickness between about 0.1 inches and about 1.0 inches.

[0009] In another aspect, the present technology is directed towards methods of forming support layers for mattress assemblies. In some embodiments, the method comprises forming a support layer comprising a plurality of gel support units that comprise a plurality of gel members. In any embodiments, a plurality of gel support units may be attached to one another in an array (e.g., rows and columns) to form a grid. In any embodiments, gel support units may be attached to one another using adhesive to adhere pieces of adhesion material such as scrim fabric that have been attached to the outer walls of gel support units. In any embodiments, the adhesion material may be attached to the gel support units through heat fusion.

[0010] In another aspect, the present technology is directed towards methods of forming a mattress assembly. In any embodiments, the method of forming a mattress assembly comprises forming a support layer; disposing the support layer over a base layer; disposing an upper layer over the support layer; and encasing the base layer, support layer, and upper layer in an outer covering. In any embodiments, the upper layer may be attached to the support layer using an adhesive.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:

[0012] FIG. 1 is a perspective view of a mattress assembly according to the present disclosure.

[0013] FIGS. 2A-2B are a simplified perspective view of the mattress assembly of FIG. 1, where FIG. 2A includes gel member connecting walls 126 (see also FIGS. 3A-3B) between gel members 124 and FIG. 2B omits gel member connecting walls 126.

[0014] FIG. 3A is a schematic of a top view of a gel support unit according to one or more embodiments of the present disclosure.

[0015] FIG. 3B is a schematic of a top view of subset of a gel support unit according to one or more embodiments of the present disclosure, zoomed to show gel member walls and gel member connecting walls.

[0016] FIG. 4A is a perspective view of a gel support unit according to one or more embodiments of the present disclosure.

[0017] FIG. 4B is a perspective view of the gel support unit of FIG. 4A after adhesion material has been attached to the gel support unit.

[0018] FIG. 5A is a top view of two gel support units before adhesion.

[0019] FIG. 5B is a top view of the gel support units of FIG. 6A after adhesion, forming the support layer.

[0020] FIG. 6 is a top view of a support layer after gel support units have been attached in an array (e.g., rows and columns to form a grid) of three columns by five rows, with an inset showing a single gel support unit. The dashed line in both the entire support layer and single support unit inset depicts where one or more gel support units of the support layer may be trimmed to conform to desired support layer dimensions.

[0021] FIG. 7 is a flowchart of a method of forming a mattress assembly according to one or more embodiments of the present disclosure.DETAILED DESCRIPTION

[0022] 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 employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional manufacturing techniques and materials employed in the industry.

[0023] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice the disclosure. However, other embodiments may be utilized, and structural, procedural, and other changes may be made without departing from the scope of the disclosure. The illustrations presented herein are not meant to be actual views of any particular system, device, structure, or process, but are idealized representations that are employed to describe the embodiments of the disclosure. The drawings presented herein are not necessarily drawn to scale. Similar structures or components in the various drawings may retain the same or similar numbering for the convenience of the reader; however, the similarity in numbering does not mean that the structures or components are necessarily identical in size, composition, configuration, or other property.

[0024] The following terms are used throughout as defined below.

[0025] As used herein and in the appended claims, singular articles such as “a” and “an” and “the” and similar referents in the context of describing the elements (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

[0026] As used herein, “about” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” will mean up to plus or minus 10% of the particular term—for example, “about 10% by volume” would be understood to mean “9% by volume to 11% by volume.” It is to be understood that when “about” precedes a term, the term is to be construed as disclosing “about” the term as well as the term without modification by “about”—for example, “about 10% by volume” discloses “9% by volume to 11% by volume” as well as disclosing “10% by volume.”

[0027] The phrase “and / or” as used in the present disclosure will be understood to mean any one of the recited members individually or a combination of any two or more thereof—for example, “A, B, and / or C” would mean “A or B or C; A and B; A and C; B and C; or the combination of A, B, and C.”

[0028] Unless otherwise indicated, numeric ranges, for instance as in “from 2 to 10,” are inclusive of the numbers defining the range (e.g., 2 and 10).

[0029] As used herein, any relational term, such as “first,”“second,”“top,”“bottom,”“upper,”“base,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise. For example, these terms may refer to an orientation of elements of a mattress when oriented for sleeping in a conventional manner. Furthermore, these terms may refer to an orientation of elements of a mattress assembly as illustrated in the drawings.

[0030] As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. 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.

[0031] 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).

[0032] 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.

[0033] 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.”

[0034] Unless otherwise indicated or obvious from the context, any reference to a two-dimensional shape may also be a reference to the corresponding three-dimensional shape, and any reference to a three-dimensional shape may also be a reference to the corresponding two dimensional shape. For example, any reference to a “circle” may also be a reference to a “cylinder;” likewise, any reference to a “cylinder” may also be a reference to a “circle.” As another example, any reference to a “rectangle” may also be reference to a “rectangular prism;” likewise, any reference to a “rectangular prism” may also be a reference to a “rectangle.”

[0035] Embodiments of the present disclosure include a mattress assembly 100 comprising a base layer 110; a support layer 120 disposed over the base layer 110; an upper layer 130 disposed over the support layer 120; and an outer covering 112 encasing the base layer 110, the support layer 120, and the upper layer 130; wherein the support layer 120 comprises a plurality of gel support units 122 attached to one another in an array of rows and columns, wherein each of the gel support units 122 comprises a plurality of gel members 124.

[0036] FIG. 1 shows a mattress assembly 100 according to one or more embodiments of the present disclosure. FIGS. 2A-2B show a simplified top perspective view of the mattress assembly 100 of FIG. 1, where FIG. 2A includes gel member connecting walls 126 (see also FIGS. 3A-3B) between gel members 124 and FIG. 2B omits gel member connecting walls 126. In FIGS. 2A-2B, various portions of the mattress assembly 100 are removed to provide a cutaway view and to better show internal components of the mattress assembly 100. Referring to FIG. 1 and FIGS. 2A-2B together, in one or more embodiments, the mattress assembly may include a base layer 110, a support layer 120, an upper layer 130, an elastomeric cushioning element 140, an edge portion 118, one or more side panels 114, and an outer covering 112.Gel Support Units

[0037] The support layer 120 may include a plurality of gel support units 122. The gel support units 122 may be made of any suitable material, including, for example, gel. Gel supports are described in U.S. Pat. No. 8,434,748 to Pearce et al., the entire disclosure of which is incorporated herein by reference. Notably, gel supports such as gel springs may be designed to buckle at predetermined pressure thresholds, which can relieve pressure hot spots and redistribute pressure so that no part of the object being supported by the gel support receives pressure above a predetermined threshold.

[0038] In one or more embodiments, the gel supports units 122 may comprise an elastomeric material. Such elastomeric materials are described in U.S. Pat. No. 11,317,733, to Pearce et al., the entire disclosure of which is incorporated herein by reference. Moreover, U.S. Pat. No. 11,317,733, to Pearce et al. references U.S. Pat. Nos. 5,994,450; 7,964,664; 4,369,284; and 8,919,750; the entire disclosures of each of which are incorporated herein by 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.

[0039] Gel support units 122 may be produced by any process that results in the desired dimensional specifications and desired material. Manufacturing methods are described in U.S. Pat. No. 8,434,748 to Pearce et al., the entire disclosure of which is incorporated herein by reference. For example, the gel support units may be manufactured using injection molding, compression molding, rotational molding, extrusion, screed molding, or any other suitable manufacturing process.

[0040] The design of the gel support units 122 must factor in several variables, including but not limited to the spacing of the gel members 124, the stiffness of the gel, the width / diameter of the gel members 124, the height of the gel members 124, the thickness of the gel member walls 125, the durometer of the gel from which the gel support units 122 are made, the expected weight of the person to use the mattress, the expected surface area of the person to contact the mattress, and the degree to which other materials and / or parts in the mattress assembly affect the behavior of the gel members 124. Generally, test data and experience may dictate the dimensional variables, and the composition of the gel may be varied experimentally to optimize the desired support features.

[0041] In some embodiments, the support layer 120 may comprise multiple gel support units 122, wherein each gel support unit 122 comprises a plurality of gel members 124. The gel members 124 may be connected to each other at two or more points by gel member connecting walls 126 and arranged in an array (e.g., rows and columns) to form a grid pattern. The gel members 124 can be of any shape, and in any embodiment may be rectangular or circular (or, in three dimensions, each gel member may be a rectangular prism or a cylinder). The gel members 124 may be hollow (and therefore have gel member walls 125) or solid.

[0042] FIG. 3A and FIG. 3B demonstrate an example embodiment of a gel support unit 122. FIG. 3A shows a gel support unit 122 consisting of ninety hollow, circular gel members 124 (9 rows×10 columns) separated from and connected to one another by gel member connecting walls 126. As shown by FIG. 3A, the gel members 124 may be arranged in an array (e.g., rows and columns) to form a grid pattern, wherein the gel members 124 may be spaced by gel member connecting walls 126. As can be seen by FIG. 3A and in detail in FIG. 3B, the gel members 124 may be spaced by gel member connecting walls 126 of a uniform thickness (e.g., width), regardless of the gel member wall 125 thickness. Referring still to FIG. 3A and FIG. 3B, gel support unit attachment walls 127 may extend about perpendicularly from an outer edge of a gel member wall 125 when said gel member 124 is located in an outer row or outer column of the gel support unit 122. For example, for a gel support unit 122 with an array of gel members 124 consisting of 9 rows and 10 columns, row 1, row 9, column 1, and column 10 of the gel support unit 122 may have gel support unit attachment walls 127 extending about perpendicularly from an outer edge of each gel member wall 125. Referring again to FIG. 3A, the gel support units 122 may optionally incorporate an indicator 128 to indicate the proper orientation for the gel support units 122 when the gel support units 122 are adjoined to form the support layer 120 (see discussion below).

[0043] While the thickness of the gel member walls 125 in any single gel support unit 122 may remain constant, the thickness of gel member walls 125 may vary within a single gel support unit 122 and / or from one gel support unit 122 to another gel support unit 122 within a support layer. For example, referencing FIG. 3B, the gel member 124 in the bottom right has a thicker gel member wall 125 than the other three gel members 124 shown in the schematic. The differences in the thickness of gel member walls 125 may allow for some zones of the support layer 120 to provide more support with thicker gel member walls 125 whereas some zones of the support layer 120 with thinner gel member walls 125 may provide less support, thereby enabling customizable mattress support combinations. In some embodiments, the thickness of the gel member walls 125 may be about 0.05 inches, about 0.06 inches, about 0.07 inches, about 0.08 inches, about 0.09 inches, about 0.095 inches, about 0.1 inches, about 0.105 inches, about 0.11 inches, about 0.1125 inches, about 0.1150 inches, about 0.1175 inches, about 0.12 inches, about 0.1225 inches, about 0.1250 inches, about 0.1275 inches, about 0.13 inches, 0.1325 inches, about 0.1350 inches, about 0.1375 inches, about 0.14 inches, about 0.15 inches, about 0.16 inches, about 0.17 inches, about 0.18 inches, about 0.19 inches, about 0.20 inches, or any range including and / or in-between any two of these values.

[0044] The gel support units 122 may have any suitable dimensions. For example, in some embodiments, the gel support units 122 may have a length of about 6 inches, about 8 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, about 14 inches, about 15 inches, about 16 inches, about 17 inches, about 18 inches, about 19 inches, about 20 inches, about 21 inches, about 22 inches, about 23 inches, about 24 inches, about 26 inches, about 28 inches, about 30 inches, or any range including and / or in-between any two of these values. Additionally, in some embodiments, the gel support units 122 may have a width of about 6 inches, about 8 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, about 14 inches, about 15 inches, about 16 inches, about 17 inches, about 18 inches, about 19 inches, about 20 inches, about 21 inches, about 22 inches, about 23 inches, about 24 inches, about 26 inches, about 28 inches, about 30 inches, or any range including and / or in-between any two of these values.

[0045] Similarly, the gel members 124 of the gel support units 122 may have any suitable dimensions. For example, in some embodiments, the gel members 124 may be circular and have a diameter of about 0.90 inches, about 0.91 inches, about 0.92 inches, about 0.93 inches, about 0.94 inches, about 0.941 inches, about 0.942 inches, about 0.943 inches, about 0.944 inches, about 0.945 inches, about 0.946 inches, about 0.947 inches, about 0.948 inches, about 0.949 inches, about 9.95 inches, about 0.96 inches, about 0.961 inches, about 0.962 inches, about 0.963 inches, about 0.964 inches, about 0.965 inches, about 0.966 inches, about 0.967 inches, about 0.968 inches, about 0.969 inches, about 0.97 inches, about 0.98 inches, about 9.99 inches, about 0.991 inches, about 0.992 inches, about 0.993 inches, about 0.994 inches, about 0.995 inches, about 0.996 inches, about 0.997 inches, about 0.998 inches, about 0.999 inches, about 1.0 inches, about 1.01 inches, about 1.02 inches, about 1.03 inches, about 1.04 inches, about 1.05 inches, or any range including and / or in-between any two of these values. In some embodiments, the gel members 124 may be rectangular and have lengths and / or widths of about 0.5 inches, about 0.6 inches, about 0.7 inches, about 0.8 inches, about 0.9 inches, about 1.0 inches, about 1.1 inches, about 1.2 inches, about 1.3 inches, about 1.4 inches, about 1.5 inches, about 2.0 inches, about 2.5 inches, about 3.0 inches, about 3.5 inches, about 4.0 inches, or any range including and / or in-between any two of these values. In any embodiments, the shape and dimensions of gel members 124 may not necessarily be uniform across all gel members 124 within a single gel support unit 122.

[0046] Similarly, in embodiments that incorporate gel member connecting walls 126, the gel member connecting walls 126 spacing adjacent gel members 124 from one another and connecting adjacent gel members 124 to one another may be of any suitable length. For example, in some embodiments, the gel member connecting walls 126 may have a length of about 0.1 inches, about 0.15 inches, about 0.2 inches, about 0.25 inches, about 0.3 inches, about 0.35 inches, about 0.4 inches, about 0.45 inches, about 0.5 inches, about 0.55 inches, about 0.6 inches, about 0.65 inches, about 0.7 inches, about 0.75 inches, about 0.8 inches, about 0.85 inches, about 0.9 inches, about 0.95 inches, about 1.0 inches, about 1.05 inches, about 1.1 inches, about 1.15 inches, about 1.2 inches, about 1.25 inches, about 1.3 inches, about 1.35 inches, about 1.4 inches, about 1.55 inches, about 1.5 inches, or any range including and / or in-between any two of these values.

[0047] Similarly, the gel member connecting walls 126 may be of any suitable width.

[0048] In some embodiments, the length of the gel support unit attachment walls 127 that form the outer edges of a gel support unit 122 may be about half the length of the gel member connecting walls 126 connecting two or more gel members 124 within a single gel support unit 122. For example, FIG. 3B shows that the gel support unit attachment walls 127 extend perpendicularly from the outer edge of the circular gel members 124. Still referring to FIG. 3B, the gel support unit attachment walls 127 are about one half the length of the gel member connecting walls 126.

[0049] Therefore, in some embodiments, the width of the gel support units 122 may be about 1 gel member 124, about 2 gel members 124, about 3 gel members 124, about 4 gel members 124, about 5 gel members 124, about 6 gel members 124, about 7 gel members 124, about 8 gel members 124, about 9 gel members 124, about 10 gel members 124, about 11 gel members 124, about 12 gel members 124, about 13 gel members 124, about 14 gel members 124, about 15 gel members 124, or any range including and / or in-between any two of these values. Similarly, in some embodiments, the length of the gel support units 122 may be about 1 gel member 124, about 2 gel members 124, about 3 gel members 124, about 4 gel members 124, about 5 gel members 124, about 6 gel members 124, about 7 gel members 124, about 8 gel members 124, about 9 gel members 124, about 10 gel members 124, about 11 gel members 124, about 12 gel members 124, about 13 gel members 124, about 14 gel members 124, about 15 gel members 124, or any range including and / or in-between any two of these values. In preferred embodiments, the gel support units 122 may be about 9 gel members 124 in width by about 10 gel members 124 in length.

[0050] In some embodiments, the thickness (i.e., height) of the gel support units 122 (and therefore also of the support layer-see discussion below) may be about 6.0 inches, about 6.5 inches, about 7.0 inches, about 7.5 inches, about 8.0 inches, about 8.5 inches, about 9.0 inches, or any range including and / or in-between any two of these values.Support Layer Formation

[0051] The gel support units 122 may be connected to one another in any suitable manner. In some embodiments, an adhesion material 150 may be used. The adhesion material 150 may be, for example, a cotton spandex blend “scrim.” This scrim fabric 151 may be used to provide a surface for adhering (e.g., gluing) the gel support unit 122 to surrounding materials, such as another gel support unit 122 or a surface of the upper layer 130 disposed over the support layer. The scrim fabric 151 may be attached to the gel support unit 122 in any suitable manner. In some embodiments, the scrim fabric 151 may be attached to the gel support unit 122 using heat fusion, such as by heating the gel support unit 122 to where the surface of the gel support unit 122 begins to melt without significantly deforming, so that portions of the gel support unit 122 may seep through (i.e., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric 151. In other words, an adhesion material 150 can be fused into the gel of a gel support unit 122. Referring now to FIG. 4A and FIG. 4B together, FIG. 4A shows a gel support unit 122 with protruding gel support unit attachment walls 127 before any adhesion material 150 has been attached to the gel support unit 122, while FIG. 4B shows the same gel support unit 122 after a scrim fabric 151 has been adhered to the gel support unit attachment walls 127 through heat fusion.

[0052] After attachment of the adhesion material 150 to the gel support unit 122, the gel support unit 122 may be attached by any suitable means to another gel support unit 122 and / or a surface of the upper layer 130 disposed over the support layer 120. For example, in some embodiments, the adhesion material 150 that has been attached to a gel support unit 122 may be attached using an adhesive to a second piece of adhesion material 150 that has been attached to a second gel support unit 122. As another example, in some embodiments, the adhesion material 150 that has been attached to a gel support unit 122 may be attached using an adhesive to a surface of the upper layer 130 disposed over the support layer 120. The adhesive may comprise latex, synthetic rubber (e.g., styrene-butadiene rubbers (SBR), polyisoprene, neoprene, nitrile rubber, silicone rubber, or a combination of any two or more thereof), acrylic resin, ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, the adhesive may include a latex water-based adhesive. For example, the adhesive may include a dispersion of acrylic resin and synthetic rubber in water. For example, the adhesive may include a thermoplastic adhesive (e.g., hot melt glue or hot glue), which may include ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, in one or more embodiments, the adhesive may comprise one or more of SIMALFA® 338, SIMALFA® 310, and SIMALFA 350-R. The process of attaching gel support units 122 to one another may be repeated to form an array (e.g., rows and columns) of gel support units 122 until the desired support layer 120 dimensions (e.g., mattress dimensions) are achieved.

[0053] The gel support units 122 may be connected to one another in any suitable manner. In some embodiments, an adhesion material 150 may be used. The adhesion material 150 may be, for example, one or more portions of the gel support units 122 attached via heat fusion. The adhesion material 150 may be for example, one or more portions of gel members 124, gel member connecting walls 126, gel support unit attachment walls 127, or a combination of any two or more thereof from each gel support unit 122 at the point of connection via heat fusion, such as by heating a portion of the gel support unit 122 at a temperature where the surface of the portion of the gel support unit 122 begins to melt without significantly deforming, so that the portion of the gel support unit 122 may fuse with (i.e., be melt-fused with) another gel support unit 122. For example, one gel support unit 122 may be heated for heat fusion or both gel support units 122 may be heated for heat fusion. Heat fusion may be by any suitable manner, such as with a hot knife or hot wire cutter. Referring now to FIG. 5A and FIG. 5B together, FIG. 5A shows a top view of two gel support units 122A and 122B before adhesion, while FIG. 5B shows a top view of the gel support units after adhesion, forming a support layer 120. Gel support unit attachment walls 127A of the gel support unit 122A may adhere to a gel support unit attachment walls 127B of the gel support unit 122B via the adhesion layer 150. The adhesion layer 150 may not include a scrim layer.

[0054] The gel support unit 122 may be attached by any suitable means to another gel support unit 122 and / or a surface of the upper layer 130 disposed over the support layer 120. For example, a gel support unit 122 may be attached to one another gel support unit 122 via heat fusion without a scrim layer. As another example, a gel support unit 122 may be attached to one another gel support unit 122 via an adhesive, and the adhesion layer 150 may include the adhesive. The adhesive may include latex, synthetic rubber (e.g., styrene-butadiene rubbers (SBR), polyisoprene, neoprene, nitrile rubber, silicone rubber, or a combination of any two or more thereof), acrylic resin, ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, the adhesive may include a latex water-based adhesive. For example, the adhesive may include a dispersion of acrylic resin and synthetic rubber in water. For example, the adhesive may include a thermoplastic adhesive (e.g., hot melt glue or hot glue), which may include ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylate copolymers, polyolefin, or a combination of any two or more thereof. For example, in one or more embodiments, the adhesive may comprise one or more of SIMALFA® 338, SIMALFA® 310, and SIMALFA 350-R. The process of attaching gel support units 122 to one another may be repeated to form an array (e.g., rows and columns) of gel support units 122 until the desired support layer 120 dimensions (e.g., mattress dimensions) are achieved.

[0055] As noted above, in some embodiments of gel support units 122, the length of the gel support unit attachment walls 127 (i.e., the distance that the gel support unit attachment walls 127 extend away from the outer edge of gel member walls 125) may be about half the length of the gel member connecting walls 126. In these embodiments, a first gel support unit attachment wall 127 of a first gel support unit 122 may be attached to a second gel support unit attachment wall 127 of a second gel support unit 122, thereby creating a wall that spans the two gel support units 122 and is the same length as the gel member connecting walls 126 connecting two or more gel members 124 within a single gel support unit 122. For example, FIG. 3A, FIG. 3B, and FIG. 6 show embodiments of a gel support unit 122 with gel support unit attachment walls 127 of about half the length of gel member connecting walls 126 in the same gel support unit 122. FIG. 6 also demonstrates that once the gel support units 122 are attached to form a support layer 120, a gel support unit attachment wall 127 of a first gel support unit 122 may be attached to a gel support unit attachment wall 127 of a second gel support unit 122, thereby creating a wall that spans the two gel support units 122 and is the same length as the gel member connecting walls 126 connecting two or more gel members 124 within a single gel support unit 122.

[0056] In some embodiments, it may be desirable to trim (i.e., remove) some portion of one or more gel support units 122. The trimming may occur either before or after gel support units 122 have been attached to one another to create a support layer 120. Trimming may be desirable, for example, to conform the support layer 120 to dimensions suitable for standard mattress sizes (e.g., twin, queen, king). As an example, FIG. 6 shows a support layer 120 formed from attaching fifteen gel support units 122 in an array (i.e., grid) of 5 rows by 3 columns, with each gel support unit 122 consisting of an array (i.e., grid) of 9 rows by 10 columns of gel members 124. Still referring to FIG. 6, the dashed line indicates where the gel support units 122 may be trimmed, indicating that four rows of gel members 124 may be trimmed from each of the three gel support units 122 in the fifth row of the array of gel support units 122.Mattress Assembly

[0057] In some embodiments, a mattress assembly comprises a base layer 110; a support layer 120 disposed over the base layer 110; an upper layer 130 disposed over the support layer 120; and an outer covering 112 encasing the base layer 110, the support layer 120, and the upper layer 130; wherein the support layer 120 comprises a plurality of gel support units 122 attached to one another in an array of rows and columns, wherein each of the gel support units 122 comprises a plurality of gel members 124.

[0058] The base layer 110 may have generally planar top and bottom surfaces. The support layer 120 (described in detail above) may be disposed on the top surface of the base layer 110 and between the base layer 110 and the upper layer 130. In particular, the upper layer 130 may be disposed over and may at least substantially extend over the support layer 120. The elastomeric cushioning element 140 may be disposed over an upper surface of the upper layer 130 and may extend over at least a portion of the upper layer 130. The edge portion 118 may extend around an outer peripheral edge of the elastomeric cushioning element 140. The one or more side panels 114 may extend along outer perimeters of the base layer 110 and the upper layer 130 and may be disposed between the upper layer 130 and the base layer 110.

[0059] Furthermore, the one or more side panels 114 may extend within a plane perpendicular to a plane defined by the top surface of the base layer 110. The outer covering 112 may extend from the base layer 110 and may at least substantially encase the support layer 120, upper layer 130, and elastomeric cushioning element 140.

[0060] In some embodiments, the mattress assembly 100 may include an adhesion material 150 between the elastomeric cushioning element 140 and the upper layer 130. In some instances, the adhesion material 150 may include a relatively thin material (e.g., cotton spandex blend “scrim”) and may be used to provide a surface for attaching the elastomeric cushioning element 140 to surrounding materials, such as another elastomeric cushioning element 140 and / or an upper surface of the upper layer 130. In some embodiments, the adhesion material 150 may comprise a scrim fabric 151 (e.g., a woven or non-woven fabric material) and portions of the elastomeric cushioning element 140 may seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric 151 of the adhesion material 150. For example, when the elastomeric cushioning element 140 includes a gel material, portions of the gel material may be heat fused through the adhesion material 150. The portions of the elastomeric cushioning element 140 that extend through the scrim fabric 151 of the adhesion material 150 may create a non-slip surface or reduced slip surface on a lower surface of the adhesion material 150 (e.g., surface that would contact an upper surface of the upper layer 130). The non-slip surface or reduced slip surface created by the elastomeric cushioning element 140 may help the cushioning materials stay in place relative to one another.

[0061] Furthermore, in some embodiments, an adhesive may be disposed between the adhesion material 150 and the upper surface of the upper layer 130. However, an adhesive may not be disposed between the edge portion 118 and the upper layer 130. Furthermore, an adhesive may be disposed between the base layer 110 and the support layer 120. Moreover, an adhesive may be disposed between the support layer 120 and the upper layer 130. Additionally, an adhesive may be disposed between the one or more side panels 114 and the support layer 120. In some embodiments the adhesive(s) may include a latex water-based adhesive. For instance, in one or more embodiments, the adhesive(s) may include one or more of SIMALFA® 338 and SIMALFA® 310.

[0062] In one or more embodiments, the mattress assembly 100 may not include an adhesion material 150 between the support layer 120 and the upper layer 130 of the mattress assembly 100. However, in some instances, an adhesive may be disposed between the adhesion material 150 and the upper surface of the upper layer 130. For example, the adhesive may include any of the adhesives described above.

[0063] In some embodiments, the outer covering 112 may comprise a stretchable material that may be secured to or be integral with the elastomeric cushioning element 140. Such a stretchable material is described in U.S. Pat. No. 11,793,322 to Pearce, the entire disclosure of which is incorporated herein by reference.

[0064] In one or more embodiments, the base layer 110 and the upper layer 130 may include a polyurethane foam. In additional embodiments, the base layer 110 and the upper layer 130 may include one or more of a memory polyurethane foam, a latex foam rubber, or any other suitable foam. In some embodiments, the base layer 110 may include a polyurethane foam having a nominal density of about 2.0 lb / ft3 and an indention load deflection (ILD) of 55 (i.e., 55 ILD). Additionally, the upper layer 130 may include a polyurethane foam having a nominal density of about 2.0 lb / ft3 and 18 ILD. The one or more side panels 114 may also include a polyurethane foam or any other spacer fabric known in the art. For example, the one or more side panels 114 may include any of the side panels 114 described in U.S. Pat. No. 10,881,217 to Moon et al., the entire disclosure of which is incorporated herein by reference.

[0065] As shown in FIG. 1 and FIG. 2, in some embodiments, the upper layer 130 of the mattress assembly 100 may have a thickness (e.g., height) of about 0.20 inches, about 0.25 inches, about 0.30 inches, about 0.35 inches, about 0.40 inches, about 0.45 inches, about 0.50 inches, about 0.55 inches, about 0.60 inches, about 0.65 inches, about 0.70 inches, about 0.75 inches, about 0.8 inches, or any range including and / or in-between any two of these values.

[0066] Still referring to FIG. 2, in some embodiments, the base layer 110 of the mattress assembly 100 may have a thickness (e.g., height) of about 0.50 inches, about 0.60 inches, about 0.70 inches, about 0.80 inches, about 0.90 inches, about 1.00 inches, about 1.10 inches, about 1.20 inches, about 1.30 inches, about 1.40 inches, about 1.50 inches, or any range including and / or in-between any two of these values.

[0067] Still referring to FIG. 2, in some embodiments, the elastomeric cushioning element 140 disposed over the upper layer 130 may comprise between about 15.0%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 30.2%, about 30.4%, about 30.6%, about 30.8%, about 31.0%, about 31.2%, about 31.4%, about 31.6%, about 31.8%, about 32.0%, about 33%, about 34%, about 35%, or any range including and / or in-between any two of these values.

[0068] FIG. 7 shows a schematic flowchart of a method 1000 of forming a mattress assembly 100. In some embodiments, the method 1000 may include an act 1010 of disposing a support layer 120 over a base layer 110.

[0069] Additionally, the method 1000 may include an act 1020 of disposing an upper layer 130 over the support layer 120. In some embodiments, act 1020 may not include disposing an adhesion material 150 between the support layer 120 and the upper layer 130. However, in some embodiments, act 1020 may include disposing an adhesive between the support layer 120 and the upper layer 130. For example, act 1020 may include disposing any of the adhesives described above between the support layer 120 and the upper layer 130.

[0070] Moreover, the method 1000 may include an act 1030 of disposing an elastomeric cushioning element 140 over the upper layer 130.

[0071] Additionally, the method 1000 may include act 1040 of disposing an outer covering 112 over at least the upper layer 130. For example, act 1040 can include disposing an outer covering 112 over the mattress assembly 100 such that the outer covering 112 covers at least substantially an entirety of the upper layer 130 and side panels 114 of the mattress assembly 100. In one or more embodiments, the method 1000 can include disposing an adhesive between any of the layers of the mattress assembly 100.EXAMPLES

[0072] The examples herein are provided to illustrate advantages of the present technology and to further assist a person of ordinary skill in the art with preparing or using the compositions of the present technology. The examples herein are also presented to more fully illustrate the present technology. The examples should in no way be construed as limiting the scope of the present technology, as defined by the appended claims. The examples can include or incorporate any of the variations or aspects of the present technology described above. The variations or aspects described above may also further each include or incorporate the variations of any or all other variations or aspects of the present technology.Example 1. Manufacturing of Gel Support Units

[0073] Gel support units 122 were manufactured using a molding process. While gel support units 122 may be manufactured with gel members 124 of any suitable shape, the gel support units 122 of the present embodiments were manufactured to have hollow, circular gel members 124 (i.e., cylinders).

[0074] Several embodiments of gel support units 122 were manufactured. In at least one embodiment, the diameter of each gel member 124 and the thickness of each gel member wall 125 was the same across all gel members 124 within the gel support unit 122 (see Gel Support Unit 122 Embodiment R). In some embodiments, the diameter of gel members 124 and the thickness of gel member walls 125 varied across gel members 124 of the gel support unit 122 (see Gel Support Unit 122 Embodiments A-Q). Gel support units 122 were manufactured with gel member wall 125 thicknesses of about 0.090 inches, about 0.100 inches, about 0.1125 inches, about 0.125 inches, about 0.130 inches, and about 0.1375 inches. The gel support units 122 were manufactured with cylindrical gel members 124 with diameters of about 0.949 inches, about 0.964 inches, about 0.969 inches, about 0.995 inches, and about 1.02 inches. The gel support unit 122 embodiments described below comprised an array of gel members 124 with 9 rows and 10 columns, where all gel members 124 in a given row had about the same diameter and about the same gel member wall 125 thickness.

[0075] The following tables disclose gel member 124 diameter and gel member wall 125 thickness for exemplary gel support unit 122 embodiments.Gel Support Unit 122 Embodiment AGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9640.13020.9640.13030.9640.13040.9690.12550.9690.12560.9950.112571.020.10081.020.10091.020.100Gel Support Unit 122 Embodiment BGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)11.020.10020.9950.112530.9950.112540.9950.112550.9690.12560.9690.12570.9950.112580.9950.112591.020.100Gel Support Unit 122 Embodiment CGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)11.020.10021.020.10031.020.10041.020.10050.9950.112560.9950.112570.9950.112580.9690.12590.9690.125Gel Support Unit 122 Embodiment DGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9690.12520.9640.13030.9640.13040.9640.13050.9640.13060.9640.13070.9640.13080.9690.12590.9690.125Gel Support Unit 122 Embodiment EGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9950.112520.9950.112530.9950.112540.9950.112550.9950.112560.9950.112570.9950.112580.9950.112590.9950.1125Gel Support Unit 122 Embodiment FGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)11.020.10021.020.10031.020.10041.020.10050.9950.112560.9950.112570.9950.112580.9950.112590.9950.1125Gel Support Unit 122 Embodiment GGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9690.12520.9490.137530.9490.137540.9490.137550.9490.137560.9490.137570.9690.12580.9690.12590.9950.1125Gel Support Unit 122 Embodiment HGel MemberGel MemberRowDiameter (Inches)Wall Thickness (Inches)10.9950.112520.9690.12530.9690.12540.9490.137550.9490.137560.9490.137570.9490.137580.9490.137590.9690.125Gel Support Unit 122 Embodiment IGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9690.12520.9690.12530.9950.112540.9950.112550.9950.112560.9950.112570.9950.112580.9950.112590.9950.1125Gel Support Unit 122 Embodiment JGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9950.112520.9950.112530.9950.112540.9950.112551.020.10061.020.10071.020.10081.020.10091.020.100Gel Support Unit 122 Embodiment KGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9950.112521.020.10031.020.10041.0440.09051.0440.09061.0440.09071.0440.09081.0440.09091.0440.090Gel Support Unit 122 Embodiment LGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.0440.09021.020.10030.9950.112540.9690.12550.9490.137560.9490.137570.9690.12580.9950.112591.020.100Gel Support Unit 122 Embodiment MGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.0440.09021.0440.09031.0440.09041.0440.09051.020.10060.9950.112570.9690.12580.9690.12590.9690.125Gel Support Unit 122 Embodiment NGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9490.137520.9490.137530.9490.137540.9490.137550.9490.137560.9690.12570.9950.112581.020.10091.020.100Gel Support Unit 122 Embodiment OGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.020.10021.0440.09031.0440.09041.0440.09051.0440.09061.0440.09071.0440.09081.0440.09091.0440.090Gel Support Unit 122 Embodiment PGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)11.0440.09021.0440.09031.0440.09041.0440.09051.0440.10061.0440.10070.9950.112580.9690.12590.9690.125Gel Support Unit 122 Embodiment OGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9690.12520.9690.12530.9490.137540.9490.137550.9490.137560.9490.137570.9490.137580.9690.12590.9950.1125Gel Support Unit 122 Embodiment RGel MemberGel Member WallRowDiameter (Inches)Thickness (Inches)10.9690.12520.9690.12530.9690.12540.9690.12550.9690.12560.9690.12570.9690.12580.9690.12590.9690.125Example 2. Attaching Gel Support Units in an Array to Form a GridA plurality of gel support units 122 was produced as described in Example 1. Gel support units 122 were attached to one another to form an array (i.e., rows and columns) as described in the following paragraphs.A piece of scrim fabric 151 was attached to each face of each gel support unit 122 that was to be attached to another gel support unit 122. The scrim fabric 151 was attached to the support units through heat fusion, where the scrim fabric 151 was placed over the gel support unit attachment walls 127 on one face of gel support unit 122 and the gel support unit 122 was subsequently heated such that the surface of the edges of the gel support unit attachment walls 127 melted slightly but without significant deformation. Therefore, portions of the melted gel support unit 122 seeped through the scrim fabric 151 such that upon cooling of the gel, the scrim fabric 151 was attached to the gel support unit attachment walls 127.After the scrim fabric 151 was attached to each gel support unit 122 that were to be attached to one another, one or more of SIMALFA® 338 and SIMALFA® 310 was applied to the scrim fabric 151 of each of the two gel support units 122 that were to be attached to one another. Pressure was applied until the adhesive dried.This attachment process was repeated until the desired gel support units 122 were attached in a conformation so as to form a support layer 120 for a mattress assembly 100. Depending on the dimensions of the gel support units 122 and the desired dimensions of the bed, portions of some gel support units 122 were trimmed.In the following Embodiments, gel support units 122 chosen from the group consisting of Gel Support Unit 122 Embodiments A-R disclosed in Example 1 were attached to one another in an array of 5 rows by 3 columns (i.e., 15 gel support units 122 were used to form each support layer 120). In each embodiment, the bottom 4 rows of gel members 124 (i.e., gel member 124 rows 6-9) on the bottom row of gel support units (i.e., the fifth row) were trimmed away, as shown in the schematic of FIG. 6.In each of the Support Layer 120 Embodiments A-E described below, each table consists of 5 rows by 3 columns, where each cell of each table corresponds to a gel support unit 122 chosen from the group consisting of Gel Support Unit 122 Embodiments A-R disclosed in Example 1.Support Layer 120 Embodiment A: Circular GridGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RSupport Layer 120 Embodiment B: High-Load, Low Firmness ConfigurationGel Support UnitGel Support UnitGel Support UnitEmbodiment AEmbodiment AEmbodiment AGel Support UnitGel Support UnitGel Support UnitEmbodiment BEmbodiment BEmbodiment BGel Support UnitGel Support UnitGel Support UnitEmbodiment CEmbodiment CEmbodiment CGel Support UnitGel Support UnitGel Support UnitEmbodiment DEmbodiment DEmbodiment DGel Support UnitGel Support UnitGel Support UnitEmbodiment EEmbodiment EEmbodiment ESupport Layer 120 Embodiment C: High-Load, High Support ConfigurationGel Support UnitGel Support UnitGel Support UnitEmbodiment FEmbodiment FEmbodiment FGel Support UnitGel Support UnitGel Support UnitEmbodiment GEmbodiment GEmbodiment GGel Support UnitGel Support UnitGel Support UnitEmbodiment HEmbodiment HEmbodiment HGel Support UnitGel Support UnitGel Support UnitEmbodiment IEmbodiment IEmbodiment IGel Support UnitGel Support UnitGel Support UnitEmbodiment JEmbodiment JEmbodiment JSupport Layer 120 Embodiment D:Baseline Firmness, Firmer LumbarGel Support UnitGel Support UnitGel Support UnitEmbodiment KEmbodiment KEmbodiment KGel Support UnitGel Support UnitGel Support UnitEmbodiment LEmbodiment LEmbodiment LGel Support UnitGel Support UnitGel Support UnitEmbodiment MEmbodiment MEmbodiment MGel Support UnitGel Support UnitGel Support UnitEmbodiment NEmbodiment NEmbodiment NGel Support UnitGel Support UnitGel Support UnitEmbodiment OEmbodiment OEmbodiment OSupport Layer 120 Embodiment E:Baseline Firmness, Firmer LumbarGel Support UnitGel Support UnitGel Support UnitEmbodiment KEmbodiment KEmbodiment KGel Support UnitGel Support UnitGel Support UnitEmbodiment LEmbodiment LEmbodiment LGel Support UnitGel Support UnitGel Support UnitEmbodiment REmbodiment REmbodiment RGel Support UnitGel Support UnitGel Support UnitEmbodiment SEmbodiment SEmbodiment SGel Support UnitGel Support UnitGel Support UnitEmbodiment OEmbodiment OEmbodiment OExample 4. Mattress AssemblyTo form a mattress assembly 100, a support layer 120 chosen from Support Layer 120 Embodiments A-E disclosed in Example 2 was disposed over a base layer. The base layer 110 comprised memory polyurethane foam with a thickness of about 1.0 inch. The base layer 110 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.An upper layer 130 was disposed over the support layer 120. The upper layer 130 comprised memory polyurethane foam with a thickness of about 0.5 inches. The upper layer 130 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.Side panels 114 comprising polyurethane foam were added to the mattress assembly 100 to extend around the base layer 110, support layer 120, and upper layer 130. The side panels 114 were attached to the base layer 110, support layer 120, and upper layer 130 using adhesive such as SIMALFA® 338 and SIMALFA® 310.An elastomeric cushioning element 140 was disposed over the upper layer 130, where the thickness of the elastomeric cushioning element 140 was about 30.8% of the overall thickness of the mattress assembly 100. Adhesion material 150 (i.e., scrim fabric 151) was attached to the elastomeric cushioning element 140 through heat fusion. Subsequently, adhesives such as SIMALFA® 338 and SIMALFA® 310 were used to attach the elastomeric cushioning element 140 to the upper layer 130.An outer covering 112 comprising a stretchable material was disposed around the base layer 110, support layer 120, upper layer 130, and side panels 114.EQUIVALENTSWhile certain embodiments have been illustrated and described, a person with ordinary skill in the art, after reading the foregoing specification, can effect changes, substitutions of equivalents and other types of alterations to the compositions of the present technology as set forth herein. Each aspect and embodiment described above can also have included or incorporated therewith such variations or aspects as disclosed regarding any or all of the other aspects and embodiments.The present technology is also not to be limited in terms of the particular aspects described herein, which are intended as single illustrations of individual aspects of the present technology. Many modifications and variations of this present technology can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods within the scope of the present technology, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. It is to be understood that this present technology is not limited to particular methods, reagents, compounds, or compositions, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Thus, it is intended that the specification be considered as exemplary only with the breadth, scope and spirit of the present technology indicated only by the appended claims, definitions therein and any equivalents thereof.The embodiments, illustratively described herein may suitably be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms “comprising,”“including,”“containing,” etc. shall be read expansively and without limitation. Additionally, the terms and expressions employed herein have been used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the claimed technology.In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group. Each of the narrower species and subgeneric groupings falling within the generic disclosure also form part of the technology. This includes the generic description of the technology with a proviso or negative limitation removing any subject matter from the genus, regardless of whether or not the excised material is specifically recited herein.As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,”“at least,”“greater than,”“less than,” and the like, include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.All publications, patent applications, issued patents, and other documents (for example, journals, articles and / or textbooks) referred to in this specification are herein incorporated by reference as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated by reference in its entirety. Definitions that are contained in text incorporated by reference are excluded to the extent that they contradict definitions in this disclosure.The present technology may include, but is not limited to, the features and combinations of features recited in the following lettered paragraphs, it being understood that the following paragraphs should not be interpreted as limiting the scope of the claims as appended hereto or mandating that all such features must necessarily be included in such claims:A. A support layer for a mattress comprising a plurality of gel support units attached to one another in an array, wherein each of the gel support units comprises a plurality of gel members.B. The support layer of Paragraph A, wherein gel members are spaced by gel member connecting walls, wherein each gel member connecting wall extends about perpendicularly from an outer edge of a wall of a first gel member to an outer edge of a wall of a second gel member.C. The support layer of Paragraph B, wherein the gel member connecting walls have a length of about 0.1 inches to about 5 inches.D. The support layer of Paragraph B or C, wherein the gel support units further comprise one or more gel support unit attachment walls that extend about perpendicularly from an outer edge of a wall of a gel member located in an outer row or outer column of the gel support unit.E. The support layer of Paragraph D, wherein the one or more gel support unit attachment walls have lengths that are about one half of the length of the gel member connecting walls of the gel support unit.

[0099] F. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are hollow and have a wall thickness between about 0.05 inches and about 0.2 inches.

[0100] G. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are hollow and have a wall thickness between about 0.09 inches and about 0.14 inches.

[0101] H. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are either a rectangular prism or cylindrical.

[0102] I. The support layer of any one of the preceding Paragraphs, wherein one or more gel members are cylindrical.

[0103] J. The support layer of Paragraph I, wherein one or more gel members have a diameter of between about 0.5 inches and about 1.5 inches.

[0104] K. The support layer of Paragraph I or J, wherein one or more gel members have a diameter of between about 0.90 inches and about 1.05 inches.

[0105] L. The support layer of any one of the preceding Paragraphs, wherein each of the gel support units have between about 5 gel members and about 15 gel members in width and between about 5 gel members and about 15 gel members in length.

[0106] M. The support layer of any of the preceding Paragraphs, wherein each of the gel support units have between about 8 gel members and about 11 gel members in width and between about 8 gel members and about 11 gel members in length.

[0107] N. The support layer of any of the preceding Paragraphs, wherein each of the gel support units have between about 9 gel members and about 10 gel members in width and between about 9 gel members and about 10 gel members in length.

[0108] O. The support layer of any of the preceding Paragraphs, wherein each of the gel support units are rectangular and have a length between about 10 inches and about 24 inches and a width between about 10 inches and about 24 inches.

[0109] P. The support layer of any of the preceding Paragraphs, wherein each of the gel support units has a height between about 6.0 inches and about 9.0 inches.

[0110] Q. The support layer of any of the preceding Paragraphs, wherein each of the gel support units has a height of about 7.5 inches.

[0111] R. A mattress assembly comprising:

[0112] a base layer;

[0113] a support layer of any one of Paragraphs A-Q disposed over the base layer;

[0114] an upper layer disposed over the support layer; and

[0115] an outer covering encasing the base layer, the support layer, and the upper layer.

[0116] S. The mattress assembly of Paragraph R, wherein the upper layer comprises foam.

[0117] T. The mattress assembly of Paragraph R or S, wherein the upper layer comprises a memory polyurethane foam or a latex foam rubber.

[0118] U. The mattress assembly of any one of Paragraphs R-T, wherein the upper layer has a thickness between about 0.1 inches to about 1.0 inches.

[0119] V. The mattress assembly of any one of Paragraphs R-U, wherein the upper layer has a thickness of about 0.5 inches.

[0120] W. The mattress assembly of any one of Paragraphs R-V, wherein the outer covering is a stretchable fabric.

[0121] X. The mattress assembly of any one of Paragraphs R-W, wherein the base layer has a thickness between about 0.5 inches and about 1.5 inches.

[0122] Y. The mattress assembly of any one of Paragraphs R-X, wherein the base layer has a thickness of about 1.0 inch.

[0123] Z. The mattress assembly of any one of Paragraphs R-Y, further comprising side panels.

[0124] AA. The mattress assembly of any one of Paragraphs R-Z, further comprising an adhesion material.

[0125] AB. The mattress assembly of Paragraph AA, wherein the adhesion material is scrim fabric.

[0126] AC. A method of forming a support layer for a mattress, comprising attaching a plurality of gel support units in an array.

[0127] AD. The method of Paragraph AC, wherein the gel support units are attached to one another by:

[0128] (a) attaching a first piece of scrim fabric to an outer edge of a first gel support unit;

[0129] (b) attaching a second piece of scrim fabric to an outer edge of a second gel support unit;

[0130] (c) adhering the first piece of scrim fabric and the second piece of scrim fabric; and

[0131] (d) repeating steps (a)-(c) until each of the plurality of gel support units is attached to one or more other gel support units to form an array of gel support units.

[0132] AE. The method of Paragraph AD, wherein scrim fabric is attached to an outer edge of a gel support unit using heat fusion.

[0133] AF. The method of Paragraph AD or AE, wherein the first piece of scrim fabric and the second piece of scrim fabric are attached together using an adhesive.

[0134] AG. A method of forming a mattress assembly, comprising:

[0135] (a) forming a support layer as described in any one of Paragraphs AC-AF;

[0136] (b) disposing the support layer over a base layer;

[0137] (c) disposing an upper layer over the support layer; and

[0138] (d) encasing the base layer, the support layer, and the upper layer in an outer covering.

[0139] AH. The method of Paragraph AG, wherein the upper layer is attached to the support layer using an adhesive.

[0140] AI. The method of Paragraph AG or AH, wherein the support layer is attached to the base layer using an adhesive.

[0141] AJ. The mattress assembly of claim AA, wherein the adhesion material comprises a portion of a gel member of the plurality of gel members.

[0142] AK. The method of claim AC, wherein the gel support units are attached to one another by heat fusion.

Examples

example 1

Manufacturing of Gel Support Units

[0073]Gel support units 122 were manufactured using a molding process. While gel support units 122 may be manufactured with gel members 124 of any suitable shape, the gel support units 122 of the present embodiments were manufactured to have hollow, circular gel members 124 (i.e., cylinders).

[0074]Several embodiments of gel support units 122 were manufactured. In at least one embodiment, the diameter of each gel member 124 and the thickness of each gel member wall 125 was the same across all gel members 124 within the gel support unit 122 (see Gel Support Unit 122 Embodiment R). In some embodiments, the diameter of gel members 124 and the thickness of gel member walls 125 varied across gel members 124 of the gel support unit 122 (see Gel Support Unit 122 Embodiments A-Q). Gel support units 122 were manufactured with gel member wall 125 thicknesses of about 0.090 inches, about 0.100 inches, about 0.1125 inches, about 0.125 inches, about 0.130 inches,...

example 2

Attaching Gel Support Units in an Array to Form a Grid

A plurality of gel support units 122 was produced as described in Example 1. Gel support units 122 were attached to one another to form an array (i.e., rows and columns) as described in the following paragraphs.

A piece of scrim fabric 151 was attached to each face of each gel support unit 122 that was to be attached to another gel support unit 122. The scrim fabric 151 was attached to the support units through heat fusion, where the scrim fabric 151 was placed over the gel support unit attachment walls 127 on one face of gel support unit 122 and the gel support unit 122 was subsequently heated such that the surface of the edges of the gel support unit attachment walls 127 melted slightly but without significant deformation. Therefore, portions of the melted gel support unit 122 seeped through the scrim fabric 151 such that upon cooling of the gel, the scrim fabric 151 was attached to the gel support unit attachment walls 127.

Afte...

example 4

Mattress Assembly

To form a mattress assembly 100, a support layer 120 chosen from Support Layer 120 Embodiments A-E disclosed in Example 2 was disposed over a base layer. The base layer 110 comprised memory polyurethane foam with a thickness of about 1.0 inch. The base layer 110 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.

An upper layer 130 was disposed over the support layer 120. The upper layer 130 comprised memory polyurethane foam with a thickness of about 0.5 inches. The upper layer 130 was attached to the support layer 120 using an adhesion material 150 (i.e., scrim fabric 151) attached to the support layer 120 with heat fusion and adhesive such as SIMALFA® 338 and SIMALFA® 310.

Side panels 114 comprising polyurethane foam were added to the mattress assembly 100 to extend around the base layer 110, support layer 120, and upper l...

Claims

1. A support layer for a mattress comprising a plurality of gel support units attached to one another in an array, wherein each of the gel support units comprises a plurality of gel members.

2. The support layer of claim 1, wherein gel members are spaced by gel member connecting walls, wherein each gel member connecting wall extends about perpendicularly from an outer edge of a wall of a first gel member to an outer edge of a wall of a second gel member.

3. The support layer of claim 2, wherein the gel member connecting walls have a length of about 0.1 inches to about 5 inches.

4. The support layer of claim 2, wherein the gel support units further comprise one or more gel support unit attachment walls that extend about perpendicularly from an outer edge of a wall of a gel member located in an outer row or outer column of the gel support unit,wherein the one or more gel support unit attachment walls have lengths that are about one half of the length of the gel member connecting walls of the gel support unit.

5. The support layer of claim 1, wherein one or more gel members are hollow and have a wall thickness between about 0.09 inches and about 0.14 inches.

6. The support layer of claim 1, wherein one or more gel members are cylindrical;wherein one or more gel members have a diameter of between about 0.90 inches and about 1.05 inches.

7. The support layer of claim 1, wherein each of the gel support units have between about 8 gel members and about 11 gel members in width and between about 8 gel members and about 11 gel members in length.

8. The support layer of claim 1, wherein each of the gel support units are rectangular and have a length between about 10 inches and about 24 inches and a width between about 10 inches and about 24 inches.

9. The support layer of claim 1, wherein each of the gel support units has a height between about 6.0 inches and about 9.0 inches.

10. A mattress assembly comprising:a base layer;a support layer of claim 1 disposed over the base layer;an upper layer disposed over the support layer; andan outer covering encasing the base layer, the support layer, and the upper layer.

11. The mattress assembly of claim 10, wherein the upper layer comprises a memory polyurethane foam or a latex foam rubber.

12. The mattress assembly of claim 10, further comprising an adhesion material.

13. The mattress assembly of claim 12, wherein the adhesion material is scrim fabric.

14. The mattress assembly of claim 12, wherein the adhesion material comprises a portion of a gel member of the plurality of gel members.

15. A method of forming a support layer for a mattress, comprising attaching a plurality of gel support units in an array.

16. The method of claim 15, wherein the gel support units are attached to one another by:(a) attaching a first piece of scrim fabric to an outer edge of a first gel support unit;(b) attaching a second piece of scrim fabric to an outer edge of a second gel support unit;(c) adhering the first piece of scrim fabric and the second piece of scrim fabric; and(d) repeating steps (a)-(c) until each of the plurality of gel support units is attached to one or more other gel support units to form an array of gel support units.

17. The method of claim 16, wherein scrim fabric is attached to an outer edge of a gel support unit using heat fusion.

18. The method of claim 16, wherein the first piece of scrim fabric and the second piece of scrim fabric are attached together using an adhesive.

19. The method of claim 15, wherein the gel support units are attached to one another by heat fusion.

20. A method of forming a mattress assembly, comprising:(a) forming a support layer as described in claim 15;(b) disposing the support layer over a base layer;(c) disposing an upper layer over the support layer; and(d) encasing the base layer, the support layer, and the upper layer in an outer covering.

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