Patent Description:
Embodiments of the disclosure relate generally to cushioning elements such as mattresses including a pocketed coil layer, and to methods of making such mattresses.

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) 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. Despite these advantages, springs may not provide a positive aesthetic and/or tactile experience if they are seen or felt through side panels of the mattress, prompting manufacturers to conceal the feel of springs on the sides of mattresses. One solution includes a wire frame around the edge of the mattress to provide structure to a cover of the mattress. However, the metal of the wire frame may be felt through the cover of the mattress. In addition, such a wire frame may not be particularly suited to handle compression during use and to packing mattresses for shipping and/or storage, such as direct-to-consumer mattresses that are shipped in logs, boxes, etc..

<CIT> describes a pillowtop mattress which comprises a base mattress and a renewable pillowtop removably attached to the base mattress portion.

The present invention provides a mattress assembly according to claim <NUM>.

The present invention further provides a method of forming a mattress assembly according to claim <NUM>.

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.

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.

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.

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 <NUM>% met, at least about <NUM>% met, or even at least about <NUM>% met.

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).

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., 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.

Embodiments of the present disclosure include a mattress assembly having an elastomeric cushioning element that comprises between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly. For example, the elastomeric cushioning element may comprise about <NUM>% of the overall thickness of the mattress assembly.

The mattress assembly according to the invention has a coil layer that includes a plurality of coils with each coil of the plurality of coils being disposed in multiple casings (e.g., bags). For example, each coil may be disposed within two or more polypropylene bags.

Further embodiments of the present disclosure include a mattress assembly having a latex water based adhesive disposed between one or more layers of the mattress assembly.

<FIG> shows a mattress assembly <NUM> according to one or more embodiments of the present disclosure. <FIG> shows a simplified top perspective view of the mattress assembly <NUM> of <FIG>. In <FIG>, various portions of the mattress assembly <NUM> are removed to provide a cutaway view and to better show internal components of the mattress assembly <NUM>. Referring to <FIG> and <FIG> together, in one or more embodiments, the mattress assembly <NUM> includes a base layer <NUM>, a coil layer <NUM>, an upper layer <NUM>, an elastomeric cushioning element <NUM>, and an outer covering <NUM>, and may include an edge portion <NUM>, and one or more side panels <NUM>.

The base layer <NUM> may have generally planar top and bottom surfaces. The coil layer <NUM> is disposed on the top surface of the base layer <NUM> and between the base layer <NUM> and the upper layer <NUM>. In particular, the upper layer <NUM> is disposed over and may at least substantially extend over the coil layer <NUM>. The elastomeric cushioning element <NUM> is disposed over an upper surface of the upper layer <NUM> and may extend over at least a portion of the upper layer <NUM>. The edge portion <NUM> may extend around an outer peripheral edge of the elastomeric cushioning element <NUM>. The one or more side panels <NUM> may extend along outer perimeters of the base layer <NUM> and the upper layer <NUM> and may be disposed between the upper layer <NUM> and the base layer <NUM>. Furthermore, the one or more side panels <NUM> may extend within a plane perpendicular to a plane defined by the top surface of the base layer <NUM>. The outer covering <NUM> may extend from the base layer <NUM> and encases the coil layer <NUM>, upper layer <NUM>, and elastomeric cushioning element <NUM>.

The mattress assembly <NUM> includes a stabilization material <NUM> between the elastomeric cushioning element <NUM> and the upper layer <NUM>. The stabilization material <NUM> includes a relatively thin material (e.g., cotton spandex blend "scrim") and may be used to provide a surface for adhering (e.g., gluing) the elastomeric cushioning element <NUM> to surrounding materials, such as another elastomeric cushioning element <NUM> and/or an upper surface of the upper layer <NUM>. The stabilization material <NUM> comprises the relatively thin material or a scrim fabric (e.g., a woven or non-woven fabric material) and portions of the elastomeric cushioning element <NUM> seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the stabilization material <NUM>. For example, when the elastomeric cushioning element <NUM> includes a gel material (as described below), portions of the gel material may be heat fused through the stabilization material <NUM>. The portions of the elastomeric cushioning element <NUM> that extend through the scrim fabric of the stabilization material <NUM> create a non-slip surface or reduced slip surface on a lower surface of the stabilization material <NUM> (e.g., surface that would contact an upper surface of the upper layer <NUM>). The non-slip surface or reduced slip surface created by the elastomeric cushioning element <NUM> may help the cushioning materials stay in place relative to one another.

Furthermore, in some embodiments, an adhesive may be disposed between the stabilization material <NUM> and the upper surface of the upper layer <NUM>. However, an adhesive may not be disposed between the edge portion <NUM> and the upper layer <NUM>. Furthermore, an adhesive may be disposed between the base layer <NUM> and the coil layer <NUM>. Moreover, an adhesive may be disposed between the coil layer <NUM> and the upper layer <NUM>. Additionally, an adhesive may be disposed between the one or more side panels <NUM> and the coil layer <NUM>. 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® <NUM> and SIMALFA® <NUM>.

In some instances, an adhesive may be disposed between the stabilization material <NUM> and the upper surface of the upper layer <NUM>. For example, the adhesive may include any of the adhesives described above.

In some embodiments, the outer covering <NUM> may comprise a stretchable material that may be secured to or be integral with the elastomeric cushioning element <NUM>. Such a stretchable material is described in <CIT>.

The upper layer <NUM> comprises a foam and is disposed over the coil layer <NUM>. In one or more embodiments, the base layer <NUM> and the upper layer <NUM> may include a polyurethane foam. In additional embodiments, the base layer <NUM> and the upper layer <NUM> 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 <NUM> may include a polyurethane foam having a nominal density of about <NUM> lb/ft<NUM> (about <NUM>/m<NUM>) and an indention load deflection (ILD) of <NUM> (i.e., <NUM> ILD). Additionally, the upper layer <NUM> may include a polyurethane foam having a nominal density of about <NUM> lb/ft<NUM> (about <NUM>/m<NUM>) and <NUM> ILD. The one or more side panels <NUM> may also include a polyurethane foam or any other spacer fabric known in the art. For example, the one or more side panels <NUM> may include any of the side panels described in <CIT>.

The coil layer <NUM> includes a plurality of coils <NUM> (e.g., steel coils), and each coil <NUM> of the plurality of coils <NUM> is encased in at least one respective casing <NUM> (e.g., polypropylene socks or bags). Each casing <NUM> forms a pocket for a respective coil <NUM>. In other words, the plurality of coils <NUM> includes a plurality of pocketed coils <NUM>. In some embodiments, each coil <NUM> may include a relatively thin-gauge, barrel-shaped (e.g., helical-shaped), knotless coil. Furthermore, in one or more embodiments, each coil <NUM> may be encased in multiple casings <NUM>. For instance, each coil <NUM> may be double bagged or triple bagged. In one or more embodiments, the casings <NUM> may include a polypropylene material.

The casings <NUM> may include a two-ply polypropylene non-woven material. In one or more embodiments, the polypropylene non-woven material may include one or more of BERRY® products <NUM>, <NUM>, and <NUM>. In some embodiments, each ply of the casings <NUM> may have a thickness within a range of about <NUM> and about <NUM>. As a non-limiting example, each ply of the casings <NUM> may have a thickness within a range of about <NUM> and about <NUM>. However, any suitable material may be used. The casings <NUM> may provide sound dampening effects.

For example, the mattress assembly <NUM> was tested according to a test method of utilizing the application SOUND METER by Abc Apps from the Google Play Store on a Galaxy S6 Active phone to measure sound levels from the mattress assembly <NUM>. During the test method, a 3x3 coil structure having each coil <NUM> covered by the above-described casings <NUM> was compressed multiple times for the duration of <NUM> seconds, and the 3x3 coil structure exhibited an average sound level within a range of about <NUM> decibels and about <NUM> decibels. For example, the 3x3 coil structure exhibited an average sound level of about <NUM> decibels. In comparison, conventional mattresses, when tested according to the above test method, exhibited an average sound level of about <NUM> decibels. Accordingly, by encasing each coil <NUM> with multiple casings <NUM> (e.g., a first casing <NUM> and a second casing <NUM>), the mattress assembly <NUM> of the present disclosure may be advantageous over conventional mattress assemblies. For example, the mattress assembly <NUM> may be quieter than conventional mattresses (e.g., may exhibit about <NUM>% less sound than conventional mattresses).

In some embodiments, each casing <NUM> of each coil <NUM> of the plurality of coils <NUM> may be individual and discrete. In additional embodiments, the casings <NUM> of the plurality of coils <NUM> may be connected (i.e., joined) and may form a single body. Furthermore, each coil <NUM> of the plurality of coils <NUM> may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of the base layer <NUM>. Furthermore, the plurality of coils <NUM> may be oriented next to each other in an array (e.g., rows and columns or a grid pattern) to form the coil layer <NUM>.

<FIG> is a simplified perspective view of the elastomeric cushioning element <NUM>. The elastomeric cushioning element <NUM> may include a singly-molded elastomeric cushioning element <NUM>. For example, the entirety of the elastomeric cushioning element <NUM> may be formed via a single molding process. The elastomeric cushioning element <NUM> includes buckling walls <NUM>. The buckling walls <NUM> of the elastomeric cushioning element <NUM> are interconnected to one another and define hollow columns <NUM> or voids in an expanded form. As used herein, the term "expanded form" means and includes a state in which an elastomeric cushioning element <NUM> has its original size and shape and wherein the buckling walls <NUM> are separated and define hollow columns <NUM>.

The buckling walls <NUM> may extend in two directions, intersecting at right angles, and defining square voids <NUM>. However, in some embodiments, the buckling walls <NUM> may intersect at other angles and define voids <NUM> of other shapes, such as triangles, parallelograms, hexagons, etc. The elastomeric cushioning element <NUM> may comprise additional structures and configurations such as those structures and configurations described in, for example, <CIT>; <CIT>; <CIT>; and <CIT>.

The buckling walls <NUM> may be formed of an elastomeric material. Elastomeric materials are described in, for example, <CIT> (hereinafter "the '<NUM> Patent"); <CIT>; <CIT>; <CIT> (hereinafter "the '<NUM> Patent"). 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® <NUM>, 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 <NUM>:<NUM> to about <NUM>:<NUM> by weight. For example, elastomeric materials may have plasticizer-to-polymer ratios from about <NUM>:<NUM> to about <NUM>:<NUM> by weight, or even from about <NUM>:<NUM> to about <NUM>:<NUM> by weight. In further embodiments, elastomeric materials may have plasticizer-to-polymer ratios of about <NUM>:<NUM> 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 <NUM> to about <NUM>.

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(<NUM>-(<NUM>,<NUM>-di-tert-butyl-<NUM>-hydroxyphenyl) propionate), commercially available as IRGANOX® <NUM>, from BASF Corp. , of Iselin, NJ or as EVERNOX®-<NUM>, from Everspring Corp. USA, of Los Angeles, CA; octadecyl-<NUM>-(<NUM>,<NUM>-di-tert-butyl-<NUM>-hydroxyphenyl) propionate, commercially available as IRGANOX® <NUM>, from BASF Corp. or as EVERNOX® <NUM>, from Everspring Chemical; and tris(<NUM>,<NUM>-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® <NUM>, from BASF Corp. or as EVERFOS® <NUM>, 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 <NUM> and <NUM> of the '<NUM> Patent. The elastomeric material may include up to about <NUM> wt% antioxidants. For instance, the elastomeric material may include from about <NUM> wt% to about <NUM> 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 <NUM> 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 <NUM> with an appearance appealing to consumers. In addition, an elastomeric cushioning element <NUM> having a dark color may absorb radiation differently than an elastomeric cushioning element <NUM> 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® <NUM>) with four parts by weight of a <NUM>-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 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 <NUM>, from about <NUM> to about <NUM>, or less than about <NUM>.

Referring again to <FIG> again, a configuration of having the coil layer <NUM> with the upper layer <NUM> on top of the coil layer <NUM> and the elastomeric cushioning element <NUM> on top of the upper layer <NUM> may provide advantages over conventional mattress assemblies. For example, in comparison to conventional mattress assemblies, the plurality of coils <NUM> of the coil layer <NUM> may better conform to an upper surface of the mattress assembly <NUM>. For instance, when subjected to a weight (e.g., a person on the mattress assembly <NUM>) and a resulting deformation, the plurality of coils <NUM> of the coil layer <NUM> may better conform to the deformation. Furthermore, the configuration may provide an increase in lateral stability in comparison to conventional mattress assemblies. Additionally, the foregoing configuration may make methods of manufacturing the mattress assembly <NUM> easier in comparison to conventional methods of manufacturing mattresses because it removes a need to laminate/glue the coil layer <NUM> to the elastomeric cushioning element <NUM>. Having the upper layer <NUM> between the coil layer <NUM> and the elastomeric cushioning element <NUM> provides a porous surface to adhere to both of the coil layer <NUM> and the elastomeric cushioning element <NUM>. Furthermore, the upper layer <NUM> dampens sound from the coil layer <NUM>.

<FIG> show schematic side cross-sectional views of mattress assemblies according to embodiments of the present disclosure. As shown in <FIG>, in some embodiments, the elastomeric cushioning element <NUM> may not cover an entirety of an upper surface of the upper layer <NUM> of the mattress assembly <NUM>. In such embodiments, the mattress assembly <NUM> may further include one or more segments <NUM> of foam (e.g., a polyurethane foam) in place of the elastomeric cushioning element <NUM> to provide an at least substantially planar upper surface of the mattress assembly <NUM>. For instance, the one or more segments <NUM> of foam may be disposed adjacent to the elastomeric cushioning element <NUM> on the upper layer <NUM> of the mattress assembly <NUM>.

In some embodiments, the elastomeric cushioning element <NUM> may be disposed only over a center portion of the upper layer <NUM> of the mattress assembly <NUM>. For example, the elastomeric cushioning element <NUM> may not cover a portion of the upper layer <NUM> extending around a perimeter of the upper layer <NUM> of the mattress assembly <NUM>. In such embodiments, the segments of foam <NUM> may be disposed over the portion of the upper layer <NUM> extending around a perimeter of the upper layer <NUM>. 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 <NUM> may be disposed only in areas anticipated as predominant sleeping areas of sleepers. For example, the elastomeric cushioning element <NUM> may include two separate sections centered on opposing longitudinal halves of the mattress assembly <NUM>. 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 <FIG>.

As show in <FIG>, a thickness of the elastomeric cushioning element <NUM> may vary. According to the invention, the elastomeric cushioning element <NUM> has a thickness T of within a range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). Furthermore, in some instances, the thickness T of the elastomeric cushioning element <NUM> may comprise between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly <NUM>. For instance, the elastomeric cushioning element <NUM> may have a thickness T of about <NUM> inches (<NUM>) and a thickness T that comprises about <NUM>% of the overall thickness of the mattress assembly <NUM>. In additional embodiments, the elastomeric cushioning element <NUM> may have a thickness T of within a range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). Moreover, in some embodiments, the thickness T of the elastomeric cushioning element <NUM> may comprise between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly <NUM>. For example, the elastomeric cushioning element <NUM> may have a thickness T of about <NUM> inches (<NUM>) and a thickness T that comprises about <NUM>% of the overall thickness of the mattress assembly <NUM>. In further embodiments, the elastomeric cushioning element <NUM> may have a thickness T of within a range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). Additionally, in one or more embodiments, the thickness T of the elastomeric cushioning element <NUM> may comprise between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly <NUM>. As a non-limiting example, the elastomeric cushioning element <NUM> may have a thickness T of about <NUM> inches (<NUM>) and a thickness T that comprises about <NUM>% of the overall thickness of the mattress assembly <NUM>.

Referring still to <FIG>, in some embodiments, the upper layer <NUM> of the mattress assembly <NUM> may have a thickness within a range of about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>). For instance, the upper layer <NUM> of the mattress assembly <NUM> may have a thickness of about <NUM> inch (<NUM>). Additionally, the coil layer <NUM> of the mattress assembly <NUM> may have a thickness (e.g., height) within range of about <NUM> inches (<NUM>) and about <NUM> inches (<NUM>). For example, the coil layer <NUM> of the mattress assembly <NUM> may have a thickness of about <NUM> inches (<NUM>). Moreover, the base layer <NUM> of the mattress assembly <NUM> may a thickness within a range of about <NUM> inch (<NUM>) and about <NUM> inches (<NUM>). As a non-limiting example, the base layer <NUM> may have a thickness of about <NUM> inch (<NUM>).

<FIG> show top views of mattress assemblies according to embodiments of the present disclosure. As shown in <FIG>, in some embodiments, the mattress assembly <NUM> may include one or more elastomeric cushioning element sections <NUM>, <NUM> (e.g., a plurality of distinct elastomeric cushioning elements). Furthermore, the one or more elastomeric cushioning element sections <NUM>, <NUM> may be disposed (e.g., located) in anticipated sleeping areas of one or more sleepers. For example, for a mattress size where two sleepers are anticipated (e.g., a queen and/or king size bed), the mattress assembly <NUM> may include a first elastomeric cushioning element section <NUM> and a second elastomeric cushioning element section <NUM>. The first elastomeric cushioning element section <NUM> may be centered longitudinally within a first half <NUM> of the overall mattress assembly <NUM> (divided longitudinally), and the second elastomeric cushioning element section <NUM> may be centered longitudinally within a second half <NUM> of the overall mattress assembly <NUM>. In some embodiments, each of the first elastomeric cushioning element section <NUM> and the second elastomeric cushioning element section <NUM> may have a width within a range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). For instance, each of the first and second elastomeric cushioning element sections <NUM>, <NUM> may have a width of about <NUM> inches (<NUM>). Furthermore, each of the first and second elastomeric cushioning element sections <NUM>, <NUM> may have a length (e.g., longitudinal length) within a range of about <NUM> inches (<NUM>) to about <NUM> inches (<NUM>). For example, the first and second elastomeric cushioning element sections <NUM>, <NUM> may have a length of about <NUM> inches (<NUM>). Furthermore, a polyurethane foam <NUM> may be disposed where coverage is not provided by the first and second elastomeric cushioning element sections <NUM>, <NUM>. In some instances, the polyurethane foam <NUM> may include a polyurethane foam having a nominal density of about <NUM> lb/ft<NUM> (about <NUM>/m<NUM>) and <NUM> ILD.

As shown in <FIG>, in some embodiments, the elastomeric cushioning element <NUM> may provide complete coverage over a mattress assembly <NUM>. For example, the elastomeric cushioning element <NUM> may cover at least substantially an entire upper surface of the upper layer <NUM> (<FIG>) of the mattress assembly <NUM>.

<FIG> shows a schematic flowchart of a method <NUM> of forming a mattress assembly <NUM>. According to the invention, the method <NUM> includes an act <NUM> of disposing a coil layer <NUM> over a base layer <NUM>. For example, act <NUM> may include disposing a plurality of coils <NUM> within a plurality of casings <NUM>, wherein each coil <NUM> of the plurality of coils <NUM> is disposed within at least two respective casings <NUM>, and disposing the plurality of coils <NUM> over the base layer <NUM>. Additionally, act <NUM> can include disposing the plurality of coils <NUM> within polypropylene bags. Furthermore, act <NUM> may include orienting the plurality of coils <NUM> within an array (e.g., rows and columns) over the base layer <NUM>. Moreover, act <NUM> may include disposing the coil layer <NUM> over the base layer <NUM> according to any of the configurations described above in regard to <FIG>, <FIG>, and <FIG>.

Additionally, the method <NUM> includes an act <NUM> of disposing an upper layer <NUM> over the coil layer <NUM>. In some embodiments, act <NUM> may not include disposing a stabilization material between the coil layer <NUM> and the upper layer <NUM>. However, in some embodiments, act <NUM> may include disposing an adhesive between the coil layer <NUM> and the upper layer <NUM>. For example, act <NUM> may include disposing any of the adhesives described above between the coil layer <NUM> and the upper layer <NUM>. Furthermore, act <NUM> may include disposing an upper layer <NUM> over the coil layer <NUM> according to any of the configurations described above in regard to <FIG>, <FIG>, and <FIG>.

Moreover, the method <NUM> includes an act <NUM> of disposing an elastomeric cushioning element <NUM> over the upper layer <NUM>. Act <NUM> includes disposing an elastomeric cushioning element <NUM> over the upper layer <NUM> that comprises between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly <NUM>. For instance, a thickness of the elastomeric cushioning element <NUM> comprises between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly <NUM>. In additional embodiments, act <NUM> can include disposing an elastomeric cushioning element <NUM> over the upper layer <NUM> that comprises between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly <NUM>. In further embodiments, act <NUM> can include disposing an elastomeric cushioning element <NUM> over the upper layer <NUM> that comprises between about <NUM>% and about <NUM>% of an overall thickness of the mattress assembly <NUM>. For instance, act <NUM> can include disposing an elastomeric cushioning element <NUM> over the upper layer <NUM> that comprises about <NUM>% of an overall thickness of the mattress assembly <NUM>.

In some embodiments, act <NUM> can include disposing a plurality of elastomeric cushioning element <NUM> segments over the upper layer <NUM>. Moreover, act <NUM> can include disposing an elastomeric cushioning element <NUM> over the upper layer <NUM> according to any of the configurations described above and including any of the materials described in regard to <FIG>.

Claim 1:
A mattress assembly (<NUM>), comprising:
a base layer (<NUM>);
a coil layer (<NUM>) disposed over the base layer (<NUM>), the coil layer (<NUM>) comprising a plurality of pocketed coils (<NUM>);
an upper layer (<NUM>) comprising a foam disposed over the coil layer (<NUM>);
an elastomeric cushioning element (<NUM>) disposed over an upper surface of the upper layer (<NUM>); and
an outer covering (<NUM>) encasing at least the elastomeric cushioning element (<NUM>), the upper layer (<NUM>), and the coil layer (<NUM>);
the mattress assembly (<NUM>) characterized by:
a stabilization material (<NUM>) comprising a relatively thin material or a scrim fabric between the elastomeric cushioning element (<NUM>) and the upper layer (<NUM>) with portions of the elastomeric cushioning element (<NUM>) seeping through the stabilization material (<NUM>) and creating a non-slip or reduced slip surface on a lower surface of the stabilization material (<NUM>) and contacting the upper surface of the upper layer (<NUM>); and
the elastomeric cushioning element (<NUM>) comprising buckling walls (<NUM>) interconnected to one another and defining voids (<NUM>), the elastomeric cushioning element (<NUM>) having a thickness of about <NUM> (<NUM> inches) to about <NUM> (<NUM> inches).