Patent Application
20240251958
Embodiments of the disclosure relate generally to cushions, such as mattresses, including a pocketed coil layer and to methods of making such mattresses. More specifically, this disclosure relates to cushions that include an elastomeric cushioning element over a layer of pocketed coils that include a coil and a coil topper formed from a compressible, resilient material over the coil, as well as to methods for manufacturing such cushions.
Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and/or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well suited to different applications. Cushioning materials may be used in combination with one another to achieve selected properties. For example, mattresses may include pocketed coils in combination with layers of foam, elastomer gels, etc. in order to achieve desired results in the cushioning materials.
In mattresses, springs (e.g., coil springs, etc.) may be preferable to foam for their durability and ability to withstand compression. Springs may also impart a feel that may be more desirable to users than that of foam.
In various embodiments, a mattress assembly may include a base layer, a coil layer over the base layer, and an elastomeric cushioning element over the coil layer. Optionally, the mattress assembly may include an intermediate layer over the coil layer and beneath the elastomeric cushioning element, or between the coil layer and the elastomeric cushioning element.
The coil layer may comprise a plurality of coils. The coils may comprise pocketed coils. A pocketed coil of the coil layer may include a casing that contains a coil spring and at least one coil topper superimposed with the coil.
The optional intermediate layer may comprise a layer of a cushioning foam. The optional intermediate layer may extend over substantially over the coil layer. Alternatively, the intermediate layer may include a plurality of intermediate cushioning elements positioned over individual coils (i.e., each intermediate cushioning element is positioned over a single coil) or that extend over groups of coils (e.g., over groups of two, three, four, five, six, or seven coils).
The elastomeric cushioning element extends over a plurality of pocketed coils and optional coil toppers. The elastomeric cushioning element may have a thickness within a range of about 1.5 inches (about 3.8 cm) to about 4.5 inches (about 11.4 cm) (e.g., one and a half inches (about 3.8 cm), two inches (about 5.1 cm), two and a half inches (about 6.35 cm), three inches (about 7.6 cm), three and a half inches (about 8.9 cm), four inches (about 10.2 cm), four and a half inches (about 11.4 cm), etc.).
A mattress assembly may include a base layer, a coil layer over the base layer, and a plurality of elastomeric cushioning elements over the coil layer. Optionally, the mattress assembly may include an intermediate layer, which may be positioned between the coil layer and the at least one elastomeric cushioning element, or over the coil layer and beneath the at least one elastomeric cushioning element.
The coil layer may include a plurality of coils. The coils may comprise pocketed coils. A pocketed coil may include at least one coil topper superimposed over a corresponding coil spring, with the coil spring and each coil topper superimposed thereover packaged in a casing. An individual coil topper or a plurality of individual coils may be positioned over each coil of the coil layer.
The optional intermediate layer may comprise a layer of a cushioning foam. The optional intermediate layer may extend over substantially over the coil layer. Alternatively, the intermediate layer may include a plurality of intermediate cushioning elements positioned over individual coils or that extend over groups of coils (e.g., over groups of two, three, four, five, six, or seven coils).
The plurality of elastomeric cushioning elements may extend over a plurality of coils. Each elastomeric cushioning element may be positioned over a group of coils (e.g., two, three, four, five, six, or seven coils) of the coil layer. Each elastomeric cushioning element may have a thickness within a range of about 1.5 inches (about 3.8 cm) to about 4.5 inches (about 11.4 cm) (e.g., one and a half inches (about 3.8 cm), two inches (about 5.1 cm), two and a half inches (about 6.35 cm), three inches (about 7.6 cm), three and a half inches (about 8.9 cm), four inches (about 10.2 cm), four and a half inches (about 11.4 cm), etc.). In embodiments where the mattress assembly includes an intermediate layer with a plurality of intermediate cushioning elements, each elastomeric cushioning element may be substantially superimposed with a corresponding intermediate cushioning element having substantially the same footprint as the elastomeric cushioning element. In other embodiments, an elastomeric cushioning element may be positioned at least partially over a plurality of intermediate cushioning elements, for example, in a staggered relationship.
In other embodiments, a mattress assembly may include a base layer, a coil layer over the base layer, an optional intermediate layer over the coil layer, and at least one elastomeric cushioning element over the coil layer and the optional intermediate layer.
The coil layer may include a plurality of pocketed coils. Each pocketed coil of the plurality of pocketed coils may include a casing, a coil within the casing, and an optional coil topper over the coil, within the casing.
The optional intermediate layer may comprise a layer of a cushioning foam. The optional intermediate layer may extend over substantially over the coil layer. Alternatively, the intermediate layer may include a plurality of intermediate cushioning elements positioned over an individual coil or that extend over groups of coils (e.g., over groups of two, three, four, five, six, or seven coils).
The at least one elastomeric cushioning element may be positioned over an array of coils. In some embodiments, such as embodiments where the mattress assembly comprises a twin, extra-long (XL) twin, full, or queen size mattress, the at least one elastomeric cushioning element may extend over substantially all of the coil layer. In other embodiments, such as embodiments where the mattress assembly comprises a king size mattress, the mattress assembly may include two one elastomeric cushioning elements, with one elastomeric cushioning element being positioned over each side of the coil layer (e.g., over at least 30% of the coil layer, over about 35% or more of the coil layer, over about 40% or more of the coil layer, over about 45% or more of the coil layer, over about half of the coil layer, etc.). Each elastomeric cushioning element may have a height or thickness within a range of about 1.75 inches (about 4.5 cm) to about 5.5 inches (about 14 cm) (e.g., one and three quarter inches (about 4.5 cm), two inches (about 5.1 cm), two and a half inches (about 6.35 cm), three inches (about 7.6 cm), three and a half inches (about 8.9 cm), four inches (about 10.2 cm), four and a half inches (about 11.4 cm), five inches (about 12.7 cm), five and a quarter inches (about 13.3 cm), five and a half inches (about 14 cm), etc.). In further embodiments, a method of forming a mattress assembly may include placing a coil layer over a base layer and placing at least one elastomeric cushioning element over the coil layer. Optionally, an intermediate layer may be placed over the coil layer; thus, disposing the at least one elastomeric cushioning element over the coil layer may comprise disposing the at least one elastomeric cushioning element over the intermediate layer.
The coil layer includes a plurality of coils. Each coil may comprise a pocketed coil, which may or may not be packaged with one or more coil toppers. The coils may be individually placed over the base layer, placed over the base layer in groups or subassemblies, or placed over the base layer as a preassembled unit.
The intermediate layer, if any, may comprise a layer of a cushioning foam. The optional intermediate layer may be placed over the coil layer such that the intermediate layer extends substantially over the coil layer. Alternatively, the intermediate layer may include a plurality of intermediate cushioning elements, each of which may be placed over an individual coil or over a group of coils (e.g., over a group of two, three, four, five, six, or seven coils), depending upon the size and shape of the intermediate cushioning element.
The elastomeric cushioning element may be disposed in such a way that it extends substantially over the coil layer and any intermediate layer over the coil layer. In embodiment where a plurality of elastomeric cushioning elements are to be included in the mattress assembly, each elastomeric cushioning element may be placed over a coil or group of coils corresponding to the shape and size of the elastomeric cushioning element.
In addition, the method may include disposing an outer covering over the mattress assembly.
Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, should be apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.
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:
This description provides specific details, such as material types, manufacturing processes, uses, and structures in order to provide a thorough description of embodiments of the disclosed subject matter. However, a person of ordinary skill in the art will understand that the embodiments of the disclosed subject matter may be practiced without employing these specific details. Indeed, the embodiments of the disclosed subject matter may be practiced in conjunction with manufacturing techniques and materials employed in the industry.
In the detailed description, reference is made to the accompanying drawings, which form a part of the disclosure, and in which are shown, by way of illustration, specific embodiments in which the disclosed subject matter 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 in the drawings are not meant to be actual views of any particular system, device, structure, or process, but are representations that are employed to describe some embodiments of the disclosed subject matter. The drawings 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 any other property.
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 mattress assembly as illustrated in the drawings.
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.
As used herein, the term “elastomeric polymer” means and includes a polymer that may substantially recover 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.” Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).
As used herein, the term “elastomeric block copolymer” means and includes an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B).
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.
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., substantially recover their size and shape after deformation). Elastomeric materials include, without limitation, materials referred to in the art as “elastomer gels,” “gelatinous elastomers,” or simply “gels.”
Embodiments of the disclosed subject matter include mattress assemblies having an elastomeric cushioning element that comprises between about 10.0% and about 40.0% of an overall thickness of the mattress assembly. For example, the elastomeric cushioning element may comprise about 30% of the overall thickness of the mattress assembly. Examples of elastomeric materials to be used in constructing the elastomeric cushioning element are disclosed by U.S. Pat. No. 7,076,822, issued on Jul. 18, 2006 and titled, “Stacked Cushions,” the entire contents of which are herein incorporated by reference.
The base layer 102 may have generally planar top and bottom surfaces. The coil layer 104 may be disposed on the top surface of the base layer 102. The stabilization material 116, if any, may be disposed over and may extend substantially or completely over the coil layer 104. The elastomeric cushioning element 108 may be disposed over the stabilization material 116, if any, and over the coil layer 104. In some embodiments, the stabilization material 116 may be provided on a bottom surface of the elastomeric cushioning element 108 and comprise part of the elastomeric cushioning element 108 (e.g., an elastomeric material of the elastomeric cushioning element 108 may seep through or impregnate the stabilization material 116, etc.); thus, the elastomeric cushioning element 108 may be placed on and contact an upper surface of the coil layer 104. Optionally, another stabilization material 116 may be provided over the elastomeric cushioning element 108. Each layer of stabilization material 116, if any, and the elastomeric cushioning element 108 may extend over at least a portion of the coil layer 104. The one or more side panels 114, 119 may be oriented perpendicularly to the base layer 102. Each side panel 114 may be positioned an upper surface of the base layer 102 or be positioned adjacent to an outer perimeter of the base layer 102. The one or more side panels 114 may also extend along and around an outer perimeter of the coil layer 104. In addition, the one or more side panels 119 may extend along and around outer perimeters of the stabilization material 116, if any, and the elastomeric cushioning element 108. The outer covering 112 may extend from the base layer 102 and may at least substantially encase or enclose the coil layer 104, each layer of stabilization material 116, if any, the elastomeric cushioning element 108, and the side panels 114, 119.
The base layer 102 may have generally planar top and bottom surfaces. The coil layer 104 may be disposed on the top surface of the base layer 102. The intermediate layer 106 may be disposed over and may extend substantially or completely over the coil layer 104. The stabilization material 116, if any, and the elastomeric cushioning element 108 may be disposed over the intermediate layer 106 and may extend over at least a portion of the intermediate layer 106. In some embodiments, another stabilization material 116 may be provided over the elastomeric cushioning element 108. The one or more side panels 114, 119 may be oriented perpendicularly to the base layer 102. One or more side panels 114 may be positioned on an upper surface of the base layer 102, adjacent to an outer periphery of the base layer 102. One or more side panels 114 may be provided adjacent to the outer periphery of the base layer 102 and extend along at least a portion of an outer perimeter of the base layer 102 and at least partially around the outer perimeter of the base layer 102. In addition, the one or more side panels 114 may extend along and around outer perimeters of the coil layer 104 and the intermediate layer 106. The one or more side panels 119 may extend along and around outer perimeters of each layer of stabilization material 116, if any, and the elastomeric cushioning element 108. The outer covering 112 may extend from the base layer 102 and may at least substantially encase or enclose the coil layer 104, the intermediate layer 106, each layer of stabilization material 116, if any, the elastomeric cushioning element 108, and the side panels 114, 119.
In one or more embodiments, the base layer 102 may comprise a foam. For example, the base layer 102 may include one or more of a memory polyurethane foam, a latex foamed rubber, or any other suitable foam. In some embodiments, the base layer 102 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).
The coil layer 104 may have generally planar top and bottom surfaces. The coil layer 104 may include a plurality of coils 118. Each coil 118 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of the base layer 102. The coils 118 may positioned next to each other in an array (e.g., a grid array with rows and columns, a staggered array that minimizes spacing between adjacent coils 118, etc.) to form the coil layer 104. Each coil 118 may comprise a pocketed coil of the type described by U.S. Pat. No. 11,229,299, the entire disclosure of which is hereby incorporated herein. Various embodiments of such coils 118, in which a casing holds a coil spring and one or more cylindrical cushioning elements superimposed over the coil spring, are described in further detail hereafter, in reference to
In embodiments where the mattress assembly 100′ includes an intermediate layer 106, such as the embodiment depicted by
The buckling walls 122 may extend in two directions, interconnected or intersecting at right angles, and defining square voids 124 and, thus, square hollow columns 126. However, in some embodiments, the buckling walls 122 may be interconnected or intersect at other angles and define voids 124 and hollow columns 126 of other shapes, such as triangles, parallelograms, hexagons, etc. The elastomeric cushioning element 108 may comprise additional structures and configurations, such as those structures and configurations described in, for example, U.S. Pat. No. 8,434,748, titled “Cushions Comprising Gel Springs,” issued May 7, 2013; U.S. Pat. No. 8,628,067, titled “Cushions Comprising Core Structures and Related Methods,” issued Jan. 14, 2014; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014; and U.S. Pat. No. 8,932,692, titled “Cushions Comprising Deformable Members and Related Methods,” issued Jan. 13, 2015, the entire disclosure of each of which is hereby incorporated herein.
The buckling walls 122 may be formed of an elastomeric material. Elastomeric materials are described in, for example, U.S. Pat. No. 5,994,450, titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom,” issued Nov. 30, 1999 (hereinafter “the '450 Patent”); U.S. Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW in Mid-Block” issued Jun. 21, 2011; U.S. Pat. No. 4,369,284, titled “Thermoplastic Elastomer Gelatinous Compositions” issued Jan. 18, 1983; U.S. Pat. No. 8,919,750, titled “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014 (hereinafter “the '750 Patent”); the disclosures of each of which are incorporated herein in their entirety by this reference. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc.
The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). For example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc., of Houston, TX, under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, TX, under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651. In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene/propylene or ethylene/butylene or ethylene/ethylene/propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers.
The elastomeric material may include one or more plasticizers, such as hydrocarbon fluids. For example, elastomeric materials may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, NJ, under the trade names BLANDOL® and CARNATION®.
In some embodiments, the elastomeric material may have a plasticizer-to-polymer ratio from about 0.1:1 to about 50:1 by weight. For example, elastomeric materials may have plasticizer-to-polymer ratios from about 1:1 to about 30:1 by weight, or even from about 1.5:1 to about 10:1 by weight. In further embodiments, elastomeric materials may have plasticizer-to-polymer ratios of about 4:1 by weight.
The elastomeric material may have one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. For example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer. As another example, metal particles (e.g., aluminum, copper, etc.) may increase the thermal conductivity of the resulting elastomeric material because such particles may have greater thermal conductivity than the plasticizer or polymer. Microspheres filled with wax or another phase-change material (i.e., a material formulated to undergo a phase change near a temperature at which a cushioning element may be used) may provide temperature stability at or near the phase-change temperature of the wax or other phase-change material within the microspheres (i.e., due to the heat of fusion of the phase change). The phase-change material may have a melting point from about 20° C. to about 45° C.
The elastomeric material may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate), commercially available as IRGANOX® 1010, from BASF Corp., of Iselin, NJ or as EVERNOX®-10, from Everspring Corp. USA, of Los Angeles, CA; octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, commercially available as IRGANOX® 1076, from BASF Corp. or as EVERNOX® 76, from Everspring Chemical; and tris(2,4-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® 168, from BASF Corp. or as EVERFOS® 168, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of elastomeric material. The use of antioxidants in mixtures of plasticizers and polymers is described in columns 25 and 26 of the '450 Patent. The elastomeric material may include up to about 5 wt % antioxidants. For instance, the elastomeric material may include from about 0.10 wt % to about 1.0 wt % antioxidants.
In some embodiments, the elastomeric material may include a resin. The resin may be selected to modify the elastomeric material to slow a rebound of the elastomeric cushioning element 108 after deformation. The resin, if present, may include a hydrogenated pure monomer hydrocarbon resin, such as those commercially available from Eastman Chemical Company, of Kingsport, TN, under the trade name REGALREZ®. The resin, if present, may function as a tackifier, increasing the stickiness of a surface of the elastomeric material.
In some embodiments, the elastomeric material may include a pigment or a combination of pigments. Pigments may be aesthetic and/or functional. That is, pigments may provide the elastomeric cushioning element 108 with an appearance appealing to consumers. In addition, an elastomeric cushioning element 108 having a dark color may absorb radiation differently than an elastomeric cushioning element 108 having a light color.
The elastomeric material may include any type of gelatinous elastomer. For example, the elastomeric material may include a melt-blend of one part by weight of a styrene-ethylene-ethylene-propylene-styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® 4055) with four parts by weight of a 70-weight straight-cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and/or other additives.
The elastomeric material may include a material that may substantially return to its original shape after deformation and that may be elastically stretched. The elastomeric material may be rubbery in feel, but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials, and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5.
In embodiments where the mattress assembly 100, 100′ includes a stabilization material 116, a layer of the stabilization material 116 may be carried by a bottom portion (e.g., on a bottom surface, etc.) of the elastomeric cushioning element 108, by a top portion (e.g., on an upper surface, etc.) of the elastomeric cushioning element 108, or each of the bottom portion and the top portion of the elastomeric cushioning element 108 may carry a layer of the stabilization material 116. The stabilization material 116 may include a relatively thin material (e.g., a cotton spandex blend “scrim”) and may be used to provide a surface for adhering (e.g., gluing) the elastomeric cushioning element 108 to surrounding materials, such as an upper surface of another elastomeric cushioning element 108, an upper surface of the coil layer 104 (see
The one or more side panels 114, 119 may also comprise a foam, a spacer fabric, or the like. In embodiments where the one or more side panels 114, 119 comprise a foam, the foam may be a polyurethane foam.
Optionally, an adhesive material may be disposed between various components of the mattress assembly 100, 100′. For example, an adhesive material may be disposed between the stabilization material 116 and the upper surface of the coil layer 104 (see
The outer covering 112 may comprise a stretchable material that may be secured to the elastomeric cushioning element 108. Such a stretchable material is described in U.S. Patent Application Publication US 2017/0251825 A1, published Sep. 7, 2017, the entire disclosure of which is hereby incorporated herein.
Referring again to
Referring to
As illustrated in
In some embodiments, such as that illustrated in
In some embodiments, such as that illustrated in
The first coil topper 133″ may comprise a compressible, resilient material. In various embodiments, the first coil topper 133″ can comprise one or more of a polyurethane foam (e.g., a high density foam, a lux foam, a high resiliency foam, etc.), a memory foam (i.e., a viscoelastic polyurethane foam, or low-resistance polyurethane (LRPu) foam), a latex rubber foam, or any other suitable foam. In some embodiments, the first coil topper 133″ may comprise 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 first coil topper 133″ may include a polyurethane foam having a nominal density of about 2.0 lb/ft3 and 18 ILD.
The second coil topper 134″ may comprise an elastomeric material, for example, a gelatinous elastomer, such as the plasticized block copolymers described previously herein, and define a plurality of interconnected walls that in turn define an array of voids, as previously described herein in reference to
In some embodiments, the second coil topper 134″ is simply placed on top of the first coil topper 133″. As shown in
In addition or alternatively, the second coil topper 134″ can be adhered to the first coil topper 133″. In some embodiments, the second coil topper 134″ is adhered to the first coil topper 133″ with a suitable adhesive material. Some nonlimiting examples of suitable adhesive materials include fabric glues and latex water based adhesive materials (e.g., SIMALFA® 338 water based adhesive, SIMALFA® 310 water based adhesive, etc.).
As another option, as shown in
Each coil topper 132, 132″, 132′″ may have any suitable shape. Without limitation, each coil topper 132, 132′, 132″ can be generally cylindrical in shape, or puck-shaped, such as the embodiment illustrated in
In some embodiments where the coil topper 132″, 132′″ includes a first coil topper 133″, 133′″ and a second coil topper 134″, 134″, the first coil topper 133″, 133′″ and the second coil topper 134″, 134″ may have the same height. In other embodiments where the coil topper 132″, 132′″ includes a first coil topper 133″, 133′ and a second coil topper 134″, 134″, the first coil topper 133″, 133″ may have a height or thickness that differs from a height or thickness of the second coil topper 134″, 134″. For example, the second coil topper 134″, 134′″ may be taller or thicker than the second coil topper 133″, 133″. As a more specific example, the first topper 132 may have a height of approximately 1.5 to 3.5 inches. The second topper 134 may have a corresponding height of approximately 0.5 to 1.5 inches. In some embodiments, the second topper 134 has a height that is approximately 50-90% taller than a height of the first topper 132. For example, the second topper 134 may have a height of approximately 1.5 to 3.5 inches. The first topper 132 may have a corresponding height of approximately 0.5 to 1.5 inches. In some embodiments, the height or thickness of the first and/or second topper 132, 134 is correlated to a height of the coil 118 included in the pocketed coil 118. In some embodiments, the first and/or second toppers 132, 134 have a diameter or profile that corresponds to a diameter of the coil 118.
In some embodiments, the elastomeric cushioning element 108 may be superimposed over only over a center portion of the coil layer 104 of the mattress assembly 100. For example, the elastomeric cushioning element 108 may not be superimposed over a peripheral portion of the coil layer 104. In such embodiments, the segments of foam 128 may be superimposed over portions of the coil layer 104 not superimposed by the elastomeric cushioning element 108 (e.g., the peripheral portion of the coil layer 104, etc.). The foregoing configuration may be utilized with mattress sizes where only one sleeper is expected (i.e., twin and full sized mattress).
In additional embodiments, the elastomeric cushioning element 108 may be disposed only in areas anticipated as predominant sleeping areas of sleepers. For example, the elastomeric cushioning element 108 may include two separate sections centered on opposing longitudinal halves of the mattress assembly 100. The foregoing configuration may be utilized with mattress sizes where two sleepers are expected (i.e., king, queen, and full sized mattresses). Furthermore, the foregoing embodiment is described in further detail with reference to
As shown in
Referring still to
As shown in
Optionally, the method 1000 may include an act 1020 of disposing an intermediate layer 106 over the coil layer 104. In some embodiments, act 1020 may not include disposing a stabilization material between the coil layer 104 and the intermediate layer 106. However, in some embodiments, act 1020 may include disposing an adhesive between the coil layer 104 and the intermediate layer 106. For example, act 1020 may include disposing any of the adhesives described above between the coil layer 104 and the intermediate layer 106. Furthermore, act 1020 may include disposing an intermediate layer 106 over the coil layer 104 according to any of the configurations described above in regard to
The method 1000 may include an act 1030 of disposing an elastomeric cushioning element 108 over the coil layer 104. In some embodiments, the elastomeric cushioning element 108, a stabilization material 116 on a bottom surface of the elastomeric cushioning element 108, or an elastomeric material of the elastomeric cushioning element 108 that seeps through a stabilization material 116 may be placed directly over the coil layer 104 and, thus, contact an upper surface of the coil layer (e.g., the tops of the coils 118, etc.). In other embodiments, the elastomeric cushioning element 108 may be placed on an intermediate layer 106 that has been placed on the coil layer 104. In such embodiments, act 1030 can include disposing an elastomeric cushioning element 108 that comprises about 15.0% to about 32.0% of an overall thickness of the mattress assembly 100 over the coil layer 104. For instance, a thickness of the elastomeric cushioning element 108 comprises about 20.0% to about 32.0% of an overall thickness of the mattress assembly 100. In additional embodiments, act 1030 can include disposing an elastomeric cushioning element 108 that comprises about 25.0% to about 32.0% of an overall thickness of the mattress assembly 100 over the coil layer 104. In further embodiments, act 1030 can include disposing an elastomeric cushioning element 108 that comprises about 30.0% to about 32.0% of an overall thickness of the mattress assembly 100 over the coil layer 104. For instance, act 1030 can include disposing an elastomeric cushioning element 108 that comprises about 30.8% of an overall thickness of the mattress assembly 100 over the coil layer 104.
In some embodiments, act 1030 can include disposing a plurality of elastomeric cushioning element 108 segments over the coil layer 104. Moreover, act 1030 can include disposing an elastomeric cushioning element 108 according to any of the configurations described above and including any of the materials described in regard to
In one or more embodiments, the method 1000 can include disposing an adhesive between any components of the mattress assembly 100.
Additionally, the method 1000 may include act 1040 of disposing an outer covering 112 over at least a portion of the mattress assembly 100 such that the outer covering 112 covers at least substantially an entirety of the side panels 114 of the mattress assembly 100 and the coil layer 104 surrounded by the side panels 114. The outer covering 112 may also be disposed over the elastomeric cushioning element(s) 108 over the coil layer 104.
The configuration of the coil layer 104 and/or the elastomeric cushioning element 108 can contribute to a hardness or softness profile for the overall mattress assemblies 100. In some embodiments, a hardness or softness profile can be based on a variety of factors, such as a number of coils included in the coil layer 104 (e.g., an edge-to-edge coil count); an overall height of the coil layer 104; a combination of coil types; inclusion of one or more toppers in the coil layer 104; a height of the elastomeric cushioning element 108; a material of the border 110; and/or other appropriate factors. For example, a coil layer 104 can have an edge-to-edge coil count of approximately 650 to 795 coils, such as 675, 700, 725, 750, 775, 780, 789, 790 coils or a number of coils within a range defined by any two of the foregoing values. Each coil can have a height ranging from 6 to 10 inches, such as each coil having an approximately 7.5 or 8 inch height. In some embodiments, the coils are quiet, or ultra-quiet, coils. In some embodiments, the coil layer 104 includes a combination of coils and toppers. For example, the coil layer 104 for a hard or firm mattress may include 7 inch soft coils combined with 3 inch toppers, resulting in an overall height for the coil layer 104 of 10 inches. The elastomeric cushioning element 108 (with its border 110) disposed on top of the 10 inch coil layer can have a height of approximately 1.5 to 4 inches, such as 2 inches, 3 inches, 3.5 inches, or a height within a range defined by any two of the foregoing values.
The mattress assemblies 100 of
While this disclosure is made with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that the disclosure is not limited to the illustrated embodiments. Additions, deletions, modifications to the illustrated embodiments may be made without departing from the scope of the disclosure. In addition, features from one embodiment may be combined with features of another embodiment. Further, embodiments of the disclosure have utility with different and various types of mattresses and other cushions.
