ELASTOMERIC GRID INCLUDING DISCRETE CUSHIONING ELEMENTS

Abstract

The present application relates to a thermoplastic elastomer grid for use in a mattress assembly. The thermoplastic elastomeric grid can be designed to provide lateral stability utilizing a simple structure. The thermoplastic elastomer grid may include a first zone with first and second cushion elements, a second zone with third and fourth cushion elements, and a third zone with fifth and sixth cushion elements. In certain examples, the first, second, and third zones may be configured to respectively support a head/should region, a hip region, and a leg region of a human body.

Description

PRIORITY CLAIM

This patent application is a continuation-in-part of co-pending International Patent Application No. PCT/CN2023/073510, filed Jan. 28, 2023, the disclosure of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to mattress assemblies. More specifically, the present disclosure relates to an elastomeric grid layer used in mattress assemblies.

BACKGROUND

A mattress' construction is one of the factors that will impact its unique feel. There are various types of mattresses. One type of mattress includes a pillow top mattress that has a “floating” layer of upholstery that feels similar to having a giant pillow on top of the mattress. Pillow top mattresses may range from medium to very soft in feel. Another type of mattress includes an all-foam mattress, which can be made using some combination of polyurethane foam, memory foam, and/or latex foam. The memory foam will typically be positioned close to the sleeping surface to yield the best benefit. A further type of mattress includes a hybrid mattress that use an innerspring as a support core and added layers of specialty foam (memory foam or latex foam) on top. Hybrid mattresses provide the active support of an innerspring with the unique feel of specialty foam materials.

It is well known that one of the challenges in the mattress industry is to create a mattress that provides comfortable support to all portions of a human body. It is desirable to achieve a level of comfort that reduces localized pressure points in areas of the human body, such as shoulders, hips, back, and legs. In recent years, the mattress industry has developed mattresses pads that incorporate a combination of gel, pillow top padding, and foam layers that can conform to contours of a human body to provide support. Typically, the gel layer extends over the entire width and length of the mattress. However, the disadvantage of incorporating pillow-top padding, gel, and/or foam layers is that there exists a greater propensity for sagging mattresses and mattresses developing depressions. Also, the gel layer can increase the overall weight of the mattress.

Accordingly, there is a need in the art for an improved mattress that provides a comfortable mattress having a long useful life with increased stability. The present disclosure addresses this and other related and unrelated issues.

SUMMARY

The present application relates to a thermoplastic elastomer grid designed to overcome drawbacks of the prior art and provide a mattress that has stability and a simple structure.

The thermoplastic elastomer grid is designed to be used in mattress assemblies, but may also be utilized in seat cushions, pet beds, etc. The thermoplastic elastomer grid includes a plurality of cushion elements that have buckling walls (e.g., cell walls, collapsible walls) that define hollow or void cells. The buckling walls may be oriented in varying shapes (e.g., a square, a rectangle, a diamond, a triangle, an oval, a hexagon, a pentagon, circles, etc.) to create multiple patterns.

The thermoplastic elastomer grid may include a first zone with first and second cushion elements, a second zone with third and fourth cushion elements, and a third zone with fifth and sixth cushion elements. In certain examples, the cushion elements in the first, second, and third zones may each be constructed with a different hardness on the Shore A scale.

One aspect of the present disclosure relates to a mattress assembly that includes a base layer that has a base surface and a support layer that has a first support surface and a second support surface. The support layer may extend across the base surface such that the first support surface of the support layer interfaces with the base surface of the base layer.

The mattress assembly includes an elastomeric layer that includes a flex foam panel that defines a plurality of cut out portions and a plurality of individual cushion elements that can each be disposed respectively within the plurality of cut out portions of the flex foam panel. The second support surface of the support layer interfaces with the elastomeric layer. The elastomeric layer may have a composition that includes graphene.

The mattress assembly also includes a memory foam layer that may have a first surface and a second surface. The memory foam layer may extend across the elastomeric layer such that the first surface of the memory foam layer interfaces with the elastomeric layer.

The mattress assembly may include a cover that may have a cover surface. The cover may extend across the memory foam layer such that the cover surface interfaces with the second surface of the memory foam layer.

The mattress assembly may also include a spring layer between two support layers. The spring layer may include a plurality of coils each individually pocketed in casings made of non-woven bags.

Another aspect of the present disclosure relates to a mattress assembly that includes a tri-fold mattress. The mattress assembly may include a first segment, a second segment, and a third segment. The first, second, and third segments may each include an elastomeric layer having a flex foam panel that defines a plurality of cut out portions and a plurality of individual cushion elements disposed respectively within the plurality of cut out portions of the flex foam panel. The cut out portions and the plurality of individual cushion elements may have the same shape.

The first, second, and third segments of the mattress assembly each include a support layer, a first mattress cover, and a second mattress cover. The elastomeric layer, the support layer, and the first and second mattress covers are respectively concealed within the first, second, and third segments by a zip-fastener. The first, second, and third segments being connected together by a fabric cover. The first, second, and third segments may be pivotable and foldable along seams provided in the fabric cover of the mattress assembly.

A further aspect of the present disclosure relates to a mattress assembly that includes a base layer that has a base surface and a support layer that has a first support surface and a second support surface. The support layer may extend across the base surface such that the first support surface of the support layer interfaces with the base surface of the base layer.

The mattress assembly also includes a gel layer that has a first gel surface and a second gel surface. The gel layer may extend across the support layer such that the first gel surface of the gel layer interfaces with the second support surface of the support layer.

The mattress assembly also includes an adaptive foam layer that has a first foam surface and a second foam surface. The adaptive foam layer may extend across the gel layer such that the first foam surface of the adaptive foam layer interfaces with the second gel surface of the gel layer.

The mattress assembly further includes an elastomeric layer. The elastomeric layer may include a flex foam encasement; a first thermoplastic elastomer grid zone that includes a first cushion element and a second cushion element; a second thermoplastic elastomer grid zone that includes a third cushion element and a fourth cushion element, and a third thermoplastic elastomer grid zone that includes a fifth cushion element and a sixth cushion element. The flex foam encasement may provide a perimeter around the first, second and third thermoplastic elastomer grid zones. The first, second, and third thermoplastic elastomer grid zones of the elastomeric layer may have a composition that includes graphene.

The elastomeric layer may have a first elastomeric surface and a second elastomeric surface. The elastomeric layer may extend across the adaptive foam layer such that the first elastomeric surface of the elastomeric layer interfaces with the second foam surface of the adaptive foam layer.

Another aspect of the present disclosure relates to a graphite thermoplastic elastomer grid. The graphite thermoplastic elastomer grid includes a first zone with first and second cushion elements, a second zone with third and fourth cushion elements, and a third zone with fifth and sixth cushion elements.

The first, second, third, fourth, fifth, and sixth cushion elements each include two major sides extending parallel to one another. The two major sides of the respective first, second, third, fourth, fifth, and sixth cushion elements may be interconnected by two minor sides, extending parallel to one another.

The first and second cushion elements in the first zone may be attached together at a respective one of the two minor sides thereof. The third and fourth cushion elements in the second zone may be attached together at a respective one of the two minor sides thereof. The fifth and sixth cushion elements in the third zone may be attached together at a respective one of the two minor sides thereof.

These and other features and advantages will be apparent from a reading of the following detailed description and a review of the associated drawings. A variety of additional aspects will be set forth in the description that follows. These aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:

FIG. 1 illustrates an exploded schematic view of an example mattress assembly including a base, a support layer, a gel layer, an adaptive foam layer, an elastomeric layer, and a cover in accordance with principles of the present disclosure.

FIG. 2 illustrates the mattress assembly of FIG. 1 with the base and the cover removed.

FIG. 3 illustrates an exploded view of a portion of the mattress assembly of FIG. 1.

FIGS. 4-5 illustrate perspective views of the elastomeric layer of FIG. 1 including two dividers in accordance with the principles of the present disclosure.

FIGS. 6-7 illustrate perspective views of the elastomeric layer without the dividers.

FIG. 8 illustrates a perspective view of the elastomeric layer including a single divider in accordance with the principles of the present disclosure.

FIG. 9 illustrates a perspective view of the elastomeric layer including a single divider of a different width in accordance with the principles of the present disclosure.

FIG. 10 illustrates a top plan view of the elastomeric layer including a plurality of cushion elements in accordance with the principles of the present disclosure.

FIG. 11 illustrates an exploded view of FIG. 3 showing a stabilization material.

FIG. 12 illustrates a plan view of the stabilization material of FIG. 11.

FIGS. 13-15 illustrate multiple views of patterns and shapes of the cushion element in accordance with the principles of the present disclosure.

FIGS. 16-17 illustrate another example mattress assembly including a memory foam layer and a spring layer in accordance with the principles of the present disclosure.

FIG. 18 illustrates another example mattress assembly including a memory foam layer, a support layer, and an elastomeric layer including a flex foam panel and a plurality of individual cushion elements in accordance with the principles of the present disclosure.

FIG. 19 illustrates a perspective view of the elastomeric layer of FIG. 18.

FIG. 20 illustrates a perspective view of the flex foam layer of FIG. 18 with the plurality of individual cushion elements exploded therefrom.

FIG. 21 illustrates a top plan view of the elastomeric layer of FIG. 18.

FIG. 22 illustrates another example mattress assembly including an elastomeric layer with an increased number of individual cushion elements in the flex foam panel in accordance with the principles of the present disclosure.

FIG. 22A illustrates a perspective view of the elastomeric layer of FIG. 22.

FIG. 22B illustrates another example mattress assembly in accordance with the principles of the present disclosure.

FIG. 23 illustrates a top view of the elastomeric layer of FIG. 22B.

FIG. 24 is an enlarged view of the individual cushion elements of FIG. 20.

FIGS. 25-28 illustrate another example mattress assembly including a memory foam layer, a support layer, and an elastomeric layer including a flex foam panel and a plurality of individual cushion elements in accordance with the principles of the present disclosure.

FIGS. 29-30 illustrate another example elastomeric layer with an increased number of individual cushion elements in the flex foam panel in accordance with the principles of the present disclosure.

FIGS. 31-32 illustrate another example mattress assembly in accordance with the principles of the present disclosure.

FIG. 33 illustrates an example tri-fold mattress in accordance with the principles of the present disclosure.

FIG. 34 illustrates mattress components of the tri-fold mattress of FIG. 33, the mattress components include an elastomeric layer, a support layer, a top mattress cover and a bottom mattress cover in accordance with the principles of the present disclosure.

FIG. 35 illustrates the elastomeric layer of FIG. 34 which includes a flex foam panel and a plurality of individual cushion elements in accordance with the principles of the present disclosure.

DETAILED DESCRIPTION

The present application is directed to a thermoplastic elastomer grid for use in mattresses, seats, pet beds etc. The thermoplastic elastomer grid is configured to provide lateral stability by being formed by independent cushion elements. That is, the cushion elements are separate pieces that can be arranged discretely in a mattress assembly as part of the thermoplastic elastomer grid.

The individual cushion elements may be arranged to provide different elastic properties in zones of the thermoplastic elastomer grid. That is, a first zone may include cushion elements in a shoulder region that as a desired firmness, a second zone may include cushion elements in a hip region that has a desired firmness, and a third zone may include cushion elements in a leg region that has a desired firmness. In certain examples, the elastic support of the cushion elements in the hip region may be stronger than the elastic support of the cushion elements in the shoulder region and/or the leg region.

FIG. 1 illustrates an exploded view of an example mattress assembly 100 in accordance with the principles of the present disclosure. The mattress assembly 100 includes a multilayered construction. The mattress assembly 100 may include a base 102 (e.g., a box spring, a bed frame, or a floor), a support layer 104, a gel layer 106, an adaptive foam layer 108, an elastomeric layer 110, and a cover 112. It would be appreciated that one or more additional layers may be included as desired.

The base 102, support layer 104, gel layer 106, adaptive foam layer 108, elastomeric layer 110, and cover 112 of the mattress assembly 100 may vary in size to provide a twin bed (which generally refers to a length of about 75 inches and a width of about 38 inches), a full or double bed (which generally refers to a length of about 75 inches and a width of about 53 inches), a queen bed (which generally refers to a length of about 80 inches and a width of about 60 inches) or a king bed (which generally refers to a length of about 80 inches and a width of about 76 inches), etc.

The base 102 is typically the first layer in a mattress assembly. The base 102 is disposed on a bottom of the mattress assembly 100 and provides a foundation upon which the support layer 104, the gel layer 106, the foam layer 108, the elastomeric layer 110, and the cover 112 are arranged. In certain examples, the base 102 may comprise a foam material. The foam material may include a polyurethane foam, a latex foam, a polyethylene foam, a polypropylene foam, a polystyrene, and the like. The base 102 has a first end 114 (e.g., a top end) and a second end 116 (e.g., a bottom end). The base 102 includes a base surface 118 that extends across the base 102 between the first and second ends 114, 116. The first end 114 is associated with a header portion of a mattress and the second end 116 is associated with a footer portion of the mattress.

The base 102 may have a height or thickness T1 that may vary as desired.

In certain examples, the thickness T1 of the base 102 may be about 12 inches. In certain examples, the thickness T1 of the base 102 may be no greater than 14 inches. In other examples, the thickness T1 of the base 102 may be between about 1 inch and about 18 inches, although alternatives are possible.

In the example depicted, the base 102 has a slope part 120 (e.g., incline portion, taper portion) that tapers from the thickness T1 to a height or thickness T2. The thickness T2 of the base 102 may also vary as desired. In certain examples, the thickness T2 may be between about 1 inch and about 9 inches, although alternatives are possible.

Referring to FIG. 2, the mattress assembly 100 is depicted with the base 102 and the cover 112 removed. The support layer 104 may be designed to impart additional support and structural conformation to the mattress assembly 100. The support layer 104 may comprise a foam material that provides flexibility. The foam material may include a polyurethane foam, a latex foam, a polyethylene foam, a polypropylene foam, and/or combinations thereof. The support layer 104 may also include flat foams or convoluted foams.

In certain examples, the support layer 104 may have a density of between about 1.5 lb/ft3 and about 5 lb/ft3. The support layer 104 may also comprise an indentation load deflection (ILD) between about 10 lbs. and about 25 lbs. In certain examples, the indentation load deflection may be between 20 lbs. and about 60 lbs. The support layer 104 may have a height or thickness T3. The thickness T3 of the support layer 104 may also vary. In certain examples, the thickness T3 may be between 1 inch and 10 inches, although alternatives are possible. In certain examples, the thickness T3 may be 7 inches.

The support layer 104 has a first support surface 122 (e.g., lower surface, bottom surface) and an opposite, second support surface 124 (e.g., upper surface, top surface). During assembly, the support layer 104 may be placed on the base 102 and extend across the entirety of the base surface 118. As such, the first support surface 122 of the support layer 104 may interface (e.g., engage, bond) with the base surface 118 of the base 102. In certain examples, a water based adhesive may be used between the support layer 104 and the base 102 to form a bond.

The gel layer 106 may be formed from a liquid or solid gel, a foam gel, or a combination of a liquid, solid, and/or foam gel. In the example depicted, the gel layer 106 includes a liquid gel flexible foam layer. Example gels may include silicone gels, PVC gels, polyorganosiloxane gels, polyol gels, polyurethane gels, and polyisocyanate gels. Preferably, the gel is dimensionally stable.

In certain examples, the gel layer 106 may have a density of between 1.5 lb/ft3 and about 5 lb/ft3. The gel layer 106 may also comprise an indentation load deflection (ILD) between about 10 lbs. and about 25 lbs. In certain examples, the indentation load deflection may be between 15 lbs. and about 60 lbs. The gel layer 106 may have a height or thickness T4. The thickness T4 of the gel layer 106 may also vary. In certain examples, the thickness T4 may be between 1 inches and 3 inches, although alternatives are possible. In certain examples, the thickness T4 may be about 1 inch. In certain examples, the thickness T4 may be about 2 inches.

The gel layer 106 has a first gel surface 126 (e.g., lower surface, bottom surface) and an opposite, second gel surface 128 (e.g., upper surface, top surface). During assembly, the gel layer 106 may be placed on the support layer 104 and extend across the entirety of the support layer 104. As such, the first gel surface 126 of the gel layer 106 may interface with the second support surface 124 of the support layer 104. A water based adhesive may be used between the support layer 104 and the gel layer 106 to form a bond.

The adaptive foam layer 108 may provide bounce-back support. That is, the adaptive foam layer 108 may be designed to contour to a human body to relieve pressure points without trapping heat. The adaptive foam layer 108 may include a polyfoam open-cell design that circulates air to help the mattress breathe. An example adaptive foam may include a polyurethane foam, a memory foam, a latex foam, and a gel memory foam, although alternatives are possible.

In certain examples, the adaptive foam layer 108 may have a density of between about 1.5 lb/ft3 and about 5 lb/ft3. The adaptive foam layer 108 may also comprise an indentation load deflection (ILD). The indentation load deflection may be between about 5 lbs. and about 20 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 10 lbs. and about 30 lbs. The adaptive foam layer 108 may have a height or thickness T5. The thickness T5 of the adaptive foam layer 108 may also vary. In certain examples, the thickness T5 may be between 1 inches and 5 inches, although alternatives are possible. In certain examples, the thickness T5 may be about 1.5 inches.

The adaptive foam layer 108 has a first foam surface 130 (e.g., lower surface, bottom surface) and an opposite, second foam surface 132 (e.g., upper surface, top surface). During assembly, the adaptive foam layer 108 may be placed on the gel layer 106 and extend across the entirety of the gel layer 106. As such, the first foam surface 130 of the adaptive foam layer 108 may interface with the second gel surface 128 of the gel layer 106. A water based adhesive may be used between the adaptive foam layer 108 and the gel layer 106 to form a bond.

Turning to FIG. 3, a portion of the mattress assembly 100 is depicted showing the elastomeric layer 110 and the gel layer 106. The elastomeric layer 110 may include a flex foam encasement 134 and a plurality of cushion elements. The plurality of cushion elements may include a first cushion element 136, a second cushion element 138, a third cushion element 140, a fourth cushion element 142, a fifth cushion element 144, and a sixth cushion element 146.

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

In certain examples, multiple pieces together form the flex foam encasement 134 to define the center opening 148. That is, the flex foam encasement 134 may not be made of a single unitary construction. For example, the flex foam encasement 134 may be constructed of four pieces 134a, 134b, 134c, and 134d that together define the center opening 148. The four pieces 134a, 134b, 134c, and 134d may be fixedly coupled to one another by fastener, adhesive, frictional engagement of the pieces 134a, 134b, 134c, and 134d themselves, or combinations thereof. In other examples, the flex foam encasement 134 may be formed by more or less pieces.

During assembly, the flex foam encasement 134 may surround the first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 to provide a perimeter thereabout. That is, the first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 may be received within the center opening 148 of the flex foam encasement 134 during assembly.

The flex foam encasement 134 and the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may have the same height or thickness T6 (see FIG. 2), although alternatives are possible. The thickness T6 may also vary. In certain examples, the thickness T6 may be between 1 inch and 3 inches, although alternatives are possible. In certain examples, the thickness T6 may be between 1 inch and 2 inches. The flex foam encasement 134 may have a width W (see FIG. 4) of about 120 mm (millimeters), although alternatives are possible. In certain examples, the flex foam encasement 134 may have a density of between about 1.5 lb/ft3 and about 5 lb/ft3. The flex foam encasement 134 may also comprise an indentation load deflection (ILD). The indentation load deflection may be between about 10 lbs. and about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 20 lbs. and about 40 lbs.

Still referring to FIG. 3, the first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 respectively make up zones inside the center opening 148 of the flex foam encasement 134. For example, the first and second cushion elements 136, 138 together define a first thermoplastic elastomer grid zone 150, the third and fourth cushion elements 140, 142 together define a second thermoplastic elastomer grid zone 152, and the fifth and sixth cushion elements 144, 146 together define a third thermoplastic elastomer grid zone 154.

The first, second, and third thermoplastic elastomer grid zones 150, 152, 154 are separated within the center opening 148 of the flex foam encasement 134 by dividers 156 (e.g., partitions, walls, or barriers). The dividers 156 may have a different material composition than that of the flex foam encasement 134. The dividers 156 may be mounted within the center opening 148 in perpendicular relation to major sides 158 of the flex foam encasement 134 and parallel to minor sides 160 of the flex foam encasement 134, although alternatives are possible. As such, the dividers 156 may be oriented perpendicular to a longitudinal axis X of the flex foam encasement 134 and attach to the major sides 158 of the flex foam encasement 134, although alternatives are possible.

Referring to FIGS. 4-5, two dividers 156 are shown to separate the first, second, third thermoplastic elastomer grid zones 150, 152, 154. The width W1 of the dividers 156 may vary, for example, based on the bed size. In certain examples, the width W1 of the dividers may be between about 120 mm to about 160 mm, although alternatives are possible. In other examples, a divider may not be used to separate the first, second, third thermoplastic elastomer grid zones 150, 152, 154 (see FIGS. 6-7).

In still other examples, a single divider 156a may be provided to separate the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146, respectively along the longitudinal axis X (see FIGS. 8-9). The divider 156a may have a width W2 (see FIG. 9) that also varies based on the bed size. In certain examples, the divider 156a may have a width W2 of about 50 mm for a queen size bed, although alternatives are possible. In certain examples, the divider 156a may have a width W2 of about 185 mm for a king size bed, although alternatives are possible. The divider 156a may be attached to the respective first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 by adhesive.

The first, second, third thermoplastic elastomer grid zones 150, 152, 154 may be positioned along the longitudinal axis X of the flex foam encasement 134 so as to provide the amount of lateral support desired. The first, second, third thermoplastic elastomer grid zones 150, 152, 154 may be disposed in a generally parallel array with respect to each other. The first, second, third thermoplastic elastomer grid zones 150, 152, 154 may extend laterally across the center opening 148 of the flex foam encasement 134.

Referring to FIG. 10, a plan, top view of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 is depicted. When assembled in the mattress assembly 100, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 are configured to be respectively separated by the two dividers 156.

The first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 each includes a first major side 162 and a second major side 164 that extend parallel to one another. The first and second major sides 162, 164 of the respective first, second, third, fourth, fifth, and sixth cushion elements 136, 138, 140, 142, 144, 146 are interconnected by a first minor side 166 and a second minor side 168 that extend parallel to one another.

In the example depicted in FIG. 10, the second minor side 168 of the first cushion element 136 is attached to the first minor side 166 of the second cushion element 138 along the longitudinal axis X, although alternatives are possible. Also, the second minor side 168 of the third cushion element 140 is attached to the first minor side 166 of the fourth cushion element 142 along the longitudinal axis X, although alternatives are possible. Further, the second minor side 168 of the fifth cushion element 144 is attached to the first minor side 166 of the sixth cushion element 146 along the longitudinal axis X, although alternatives are possible.

When there is no divider 156 in the elastomeric layer 110 as shown in FIGS. 6-7, the second major side 164 of the first cushion element 136 may also be attached to the first major side 162 of the third cushion element 140. Also, the second major side 164 of the third cushion element 140 may also be attached to the first major side 162 of the fifth cushion element 144. The second major side 164 of the second cushion element 138 may also be attached to the first major side 162 of the fourth cushion element 142. The second major side 164 of the fourth cushion element 142 may also be attached to the first major side 162 of the sixth cushion element 146.

When a single divider 156a is provided in the elastomeric layer 110 as depicted in FIGS. 8-9, the first, third, and fifth cushion elements 136, 140, 144 can be attached at their respective first and second major sides 162, 164. Also, the second, fourth, and sixth cushion elements 138, 142, 146 can be attached at their respective first and second major sides 162, 164.

The size of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may vary based on the bed size and what, if any, a divider is used. For example, if the mattress assembly 100 has dividers 156 for a queen size bed, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 500 mm×642 mm. If the mattress assembly 100 has dividers 156 for a king size bed, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 500 mm×845 mm.

Referring back to FIGS. 6-7, when there is no divider in the construction, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 are attached together at the respective major and minor sides 162, 164, 166, 168. For a queen size bed with no dividers, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 600 mm×642 mm. For a king size bed with no dividers, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 600 mm×845 mm.

Referring back to FIGS. 8-9, when the mattress assembly 100 includes the divider 156a, the divider 156a can be attached to the respective first and second minor sides 166, 168 of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146. For both a queen size bed and a king size bed that includes the divider 156a, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be sized at about 645 mm×690 mm.

In certain examples, the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may each comprise A-B diblock copolymers and A-B-A riblock copolymers having a ratio between 15%-85%; plasticizer (e.g., mineral oils) having a ratio between 30%-85%; polyethylene having a ratio of between 0.01%-20%; antioxidant having a ratio of between 0.1%-4%; erucylamide having a ratio between 0.01%-2%; and graphene having a ratio between 0.1%-10%, although alternatives are possible. It will be appreciated that the composition of each of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may differ in the respective first, second, third thermoplastic elastomer grid zones 150, 152, 154 to achieve a desired comfort and lateral stability. For example, the first and second cushion elements 136, 138 in the first thermoplastic elastomer grid zone 150 may have a composition to achieve a desired firmness at the neck and shoulder region. The third and fourth cushion elements 140, 142 in the second thermoplastic elastomer grid zone 152 may have a composition to achieve a desired firmness at the hip region that may be different or the same relative to the first thermoplastic elastomer grid zone 150. The fifth and sixth cushion elements 144, 146 in the third thermoplastic elastomer grid zone 154 may have a composition to achieve a desired firmness at the leg region that may be different or the same relative to the first and second thermoplastic elastomer grid zones 150, 152, respectively.

Turning to FIGS. 11-12, the mattress assembly 100 may also include a stabilization material 170 (e.g., a scrim, a fabric). During assembly, the stabilization material 170 can be attached to an underside 172 of each one of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 using an adhesive. As such, the stabilization material 170 and the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 may be coupled to the adaptive foam layer 108. The underside 172 of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 including the stabilization material 170 interfaces with the second foam surface 132 of the adaptive foam layer 108. In certain examples, the stabilization material 170 may be used to provide structural conformation of the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146 to the adaptive foam layer 108.

The stabilization material 170 defines cutouts 174 (e.g., openings, voids) that are configured to be arranged between the first, second, third thermoplastic elastomer grid zones 150, 152, 154, respectively, during assembly. The cutouts 174 may have a width W3 of about 66 mm, although alternatives are possible. When the dividers 156 are assembled into the center opening 148 of the flex foam encasement 134, the dividers 156 may extend across the cutouts 174. The dividers 156 may adhere to the stabilization material 170 and the adaptive foam layer 108 to enhance the stability of the elastomeric layer 110.

The stabilization material 170 does not extend to the flex foam encasement 134. The flex foam encasement 134 provides a strong boarder around the first, second, third, fourth, fifth, sixth cushion elements 136, 138, 140, 142, 144, 146.

FIGS. 13-15 depict example cushion elements 136, 136a, 136b that have different patterns and shapes in accordance with the principles of the present disclosure. The cushion elements 136, 136a, 136b can be configured in various shapes and sizes. In certain examples, the cushion elements may have a different pattern or shape, such as a square pattern or shape, a circular pattern or shape, a diamond pattern or shape, a triangle pattern or shape, a hexagon pattern or shape, a rectangular pattern or shape, a pentagon pattern or shape, and/or any combinations thereof.

The cushion elements 136, 136a, 136b include walls 176 that form the various patterns and shapes depicted in FIGS. 13-15. The walls 176 are designed to be interconnected to one another to define voids 178 (e.g., holes, spaces, cavities). In certain examples, the walls 176 of the cushion elements 136, 136a, 136b may have a uniform height, although alternatives are possible. The walls 176 define the grid structure of the patterns and shapes of the cushion elements 136, 136a, 136b. The voids 178 help to create air flow in the mattress assembly 100 by removing hot air under the human body. The walls 176 are made to buckle and return to its original shape after deformation. The amount of deformation may vary depending on the desired stiffness based on a hardness on the Shore A scale. The desired cushioning can be greater or lesser for each cushion element arranged in the mattress assembly 100. In certain examples, the height or thickness of the walls 176 is no greater than 3 inches, which allows the walls 176 to support the pattern or shape of the cushion elements 136, 136a, 136b.

The cover 112 of the mattress assembly 100 includes a fabric that also provides a cooling feature. The cover can comprise various materials or fabrics, including cotton, polyester, polymeric, water resistant materials, synthetics and any combination thereof. In certain examples, the cover 112 may be flexible or elastic to stretch and return to its original shape and/or size. The cover 112 can be disposed at least partially around the entirety of the construction of the multilayered construction. The cover 112 has a mating slope part 180 (see FIG. 1) to that of the slope part 120 of the base 102 such that the slope parts 120, 180 engage when attached together.

Referring to FIGS. 16-17, another example mattress assembly 200 is depicted. The mattress assembly 200 is similar to the mattress assembly 100 previously described except the mattress assembly 200 includes a spring layer 212 between a gel layer 206 and a support layer 204 and has a memory foam layer 214 between an adaptive foam layer 208 and an elastomeric layer 210. As such, only the spring layer 212 and the memory foam layer 214 will be described in detail. It will be appreciated that the features described herein with reference to the mattress assembly 100 will also apply to the mattress assembly 200. Similar reference numbers to the mattress assembly 100 will be used to reference the layers in the mattress assembly 200, but in the 200s.

The spring layer 212 may provide additional support or rigidity in the mattress assembly 100. The spring layer 212 includes a plurality of coils 216 each individually pocketed in casings 218. In certain examples, the coils 216 may be barrel-shaped. The casings 218 may include non-woven bags. The spring layer 212 may comprise an indentation load deflection (ILD). The indentation load deflection may be between about 10 lbs. and about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 20 lbs. and about 40 lbs. The spring layer 212 may have a height or thickness T7 that ranges between about 5 inches to 10 about inches, although alternatives are possible. The coils 216 make up a coil unit that may be encased by an edge foam support 220, which may be similar in composition to the flex foam encasement 134. In certain examples, the spring layer 212 has a 15 gauge coil unit.

The memory foam layer 214 may comprise polyurethane visco-elastic foam material. The memory foam layer 214 is constructed to contour to the human body during use of the mattress assembly 100. In certain examples, the memory foam layer 214 may have a density of between about 1.5 lb/ft3 and about 5 lb/ft3. The memory foam layer 214 may have a height or thickness T8 that may be between 1 inch and 2 inches, although alternatives are possible. The memory foam layer 214 may comprise an indentation load deflection (ILD). The indentation load deflection may be between about 10 lbs. and about 20 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 5 lbs. and about 15 lbs.

Referring to FIGS. 18-21, another example mattress assembly 300 is depicted without a top mattress cover 301 (e.g., upper cover) and a bottom mattress cover 303 (e.g., lower cover). The mattress assembly 300 is similar to the mattress assemblies 100 and 200 previously described except the mattress assembly 300 has a different elastomeric layer 302 positioned between a memory foam layer 304 and a support layer 306. As such, only the elastomeric layer 302 will be described in detail. It will be appreciated that the features described herein with reference to the mattress assemblies 100 and 200 will also apply to the mattress assembly 300.

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

The individual cushion elements 310 may comprise a material that differs from that of the flex foam panel 308. The individual cushion elements 310 may comprise a thermoplastic material (e.g., a thermoplastic elastomers). The individual cushion elements 310 may each comprise A-B diblock copolymers and A-B-A riblock copolymers having a ratio between 15%-85%; plasticizer (e.g., mineral oils) having a ratio between 30%-85%; polyethylene having a ratio of between 0.01%-20%; antioxidant having a ratio of between 0.1%-4%; erucylamide having a ratio between 0.01%-2%; and graphene having a ratio between 0.1%-10%, although alternatives are possible. In certain examples, the individual cushion elements 310 may comprise a gel and one or more non-gel materials.

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

In certain examples, the flex foam panel 308 may have a density of between about 1.5 lb/ft3 and about 5 lb/ft3. The flex foam panel 308 may also comprise an indentation load deflection (ILD). The indentation load deflection may be between about 10 lbs. and about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 20 lbs. and about 40 lbs.

Turning to FIG. 20, the flex foam panel 308 defines a plurality of cut out portions 312 that each provide a recess or opening for receiving a respective one of the individual cushion elements 310. Any suitable pattern may be used for cutting the cut out portions 312. The cut out portions 312 may be created by punching, cutting-out, stamping-out or by any other process or suitable tool.

The cut out portions 312 may pass all the way through the flex foam panel 308. In other examples, the cut out portions 312 may be present to a predefined depth within the flex foam panel 308. The spacing and size of the cutout portions 312 may be uniform, as illustrated in FIGS. 19, 21, 23, although alternatives are possible.

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

In certain examples, the number of cut out portions 312 defined in the flex foam panel 308 may increase, as illustrated in FIGS. 22-23, although the spacing and size of the cut out portions 312 may remain the same. For example, FIG. 21 shows the cut out portions 312 defined in the flex foam panel 308 arranged in five vertical columns and seven horizontal rows, although alternatives are possible. In another mattress assembly 300a shown in FIGS. 22, the cut out portions 312 defined in the flex foam panel 308a (see FIGS. 22A, 23) are arranged in six vertical columns and nine horizontal rows, although alternatives are possible. As depicted, increasing the number of cut out portions 312 in the flex foam panel 308a of the mattress assembly 300a also increases the number of individual cushion elements 310a in the flex foam panel 308a. As such, the overall density may increase.

The cut out portions 312 can be sized and shaped to receive an individual cushion element 310. The cut out portions 312 can be in a variety of shapes such as, but not limited to circular, square, rectangular, triangular, star-shaped, hexagonal, octagonal, pentagonal, oval, etc. In the example shown in FIGS. 19 and 22, the cutouts 312 are circular in shape. In other examples, the cut out portions 312 defined in the same flex foam panel 308 may be different from each other in shape, size, spacing, etc. Accordingly, the individual cushion elements 310 in the flex foam panel 308 may be different from each other in shape, size, spacing, etc.

The individual cushion elements 310 are inserted into a respective one of the cut out portions 312. No adhesive or glue is used to secure the individual cushion elements 310 within the cut out portions 312. The individual cushion elements 310 may have the same size and shape as the cut out portions 312 so that each individual cushion elements 310 may be firmly, but releasably, retained in the appropriate cut out portions 312 through frictional forces. The individual cushion elements 310 may each be positioned into a respective cut out portion 312 without creating uncomfortable ridges or creases that might be felt by the user. The symmetrical and uniform design of the elastomeric layer 302 allows for the desired comfort, stability and balance in the mattress assembly 300. For example, a desired comfort can be achieved at the head region, hip region, and leg region of the mattress assembly 300.

Turning to FIG. 24, the individual cushion elements 310 each include a circular outer periphery to complement the circular shape of the cut out portions 312. The individual cushion elements 310 are shown isolated from one another in the flex foam panel 308. That is, the individual cushion elements 310 are not interconnected with one another in an adjacent column or row in the flex foam panel 308.

The individual cushion elements 310 each include a unique pattern. The individual cushion elements 310 may each include a cylindrical, rod-shaped element 314 at its center and a plurality of interconnected side wall segments 316 extending from the cylindrical, rod-shaped element 314 about its axis. The plurality of interconnected side wall segments 316 also extend at various angles to an outer circumferential wall 318 of the individual cushion element 310.

In certain examples, the plurality of interconnected side wall segments 316 can be angled with respect to each other to provide a plurality of polygon shaped members. In certain examples, the plurality of interconnected side wall segments 316 can be angled with respect to each other to provide a plurality of pentagon-shaped members in addition to other polygon shapes. It will be appreciated that the interconnected side wall segments 316 of the individual cushion elements 310 may be arranged to form other shapes such as quadrilateral, hexagon, heptagon, octagon, etc.

The pentagon-shaped members and other shapes formed by the interconnected side wall segments 316 of the individual cushion elements 310 may be void of material such that they are essentially empty cells or voids. That is, the interconnected side wall segments 316 create a number of open cavities 320 that allow the individual cushion elements 310 to be flexible. Furthermore, the open cavities 320 of the individual cushion elements 310 may provide ventilation in the mattress assembly 300.

Turning again to FIG. 18, the elastomeric layer 302 can be connected to the memory foam layer 304 and the support layer 306 by an adhesive or glue. In certain examples, a water based adhesive may be between the memory foam layer 304 and the elastomeric layer 302 to form a bond. A water based adhesive may also be between the support layer 306 and the elastomeric layer 302 to form a bond. No other fabric or connecting layer is between the elastomeric layer 302 and the memory foam layer 304 or between the elastomeric layer 302 and the support layer 306.

In the example depicted, the memory foam layer 304 is positioned on top of the elastomeric layer 302 and the support layer 306 is positioned below the elastomeric layer 302. The memory foam layer 304 and the support layer 306 may each extend across the entirety of the elastomeric layer 302.

The memory foam layer 304 may be similar to the memory foam layer 214 described above. The memory foam layer 304 is constructed to contour to the human body during use of the mattress assembly 300. In certain examples, the memory foam layer 304 may have a density of between about 1.5 lb/ft3 and about 5 lb/ft3. The memory foam layer 304 may have a height or thickness T10 that may be between 1 inch and 2 inches, although alternatives are possible. The memory foam layer 304 may comprise an indentation load deflection (ILD). The indentation load deflection may be between about 10 lbs. and about 20 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 5 lbs. and about 15 lbs.

The support layer 306 has similar features to the support layers 104, 204 described above. The support layer 306 may be designed to impart additional support and structural conformation to the mattress assembly 300. The support layer 306 may comprise a foam material that provides flexibility. The foam material may include a polyurethane foam, a latex foam, a polyethylene foam, a polypropylene foam, and/or combinations thereof. The support layer 306 may also include flat foams or convoluted foams.

The support layer 306 may have a height or thickness T11. The thickness T11 of the support layer 306 may be similar to the thickness T10 of the memory foam layer 304, but may vary. In certain examples, the thickness T11 may be between 1 inch and 10 inches, although alternatives are possible.

The support layer 306a of the mattress assembly 300a may have a greater height or thickness T11 than the support layer 306 of the mattress assembly 300. In certain examples, the thickness T11a of the support layer 306a may be 5 inches, although alternatives are possible. In certain examples, the thickness T11a of the support layer 306a may be between 5 inches and 10 inches, although alternatives are possible.

FIG. 22B shows another mattress assembly 300b in accordance with the principles of the present disclosure. The support layer 306b of the mattress assembly 300b may have a height or thickness T11b similar to the support layer 306 of the mattress assembly 300. In certain examples, the thickness T11b of the support layer 306b may between 1 inch and 2 inches, although alternatives are possible. In other examples, the support layer 306b of the mattress assembly 300b may be about 1.2 inches to about 1.5 inches, although alternatives are possible. The mattress assembly 300b includes an elastomeric layer 302b that is similar to the elastomeric layer 302a of the mattress assembly 300a and a memory foam layer 304b similar to the memory foam layers 304, 304a.

Referring to FIGS. 25-28, another example mattress assembly 400 is depicted with a top mattress cover 401 (e.g., upper cover) and a bottom mattress cover 403. The mattress assembly 400 is similar to the mattress assembly 300 described except the mattress assembly 400 has a different elastomeric layer 402 positioned between a memory foam layer 404 and a support layer 406. The memory foam layer 404 is identical to the memory foam layer 304 described above and the support layer 406 is identical to the support layer 306 described above. As such, only the elastomeric layer 402 will be described in detail. It will be appreciated that the features described herein with reference to the mattress assembly 300 will also apply to the mattress assembly 400.

The elastomeric layer 402 includes a flex foam panel 408 and a plurality of individual cushion elements 410. The individual cushion elements 410 may each comprise A-B diblock copolymers and A-B-A riblock copolymers having a ratio between 15%-85%; plasticizer (e.g., mineral oils) having a ratio between 30%-85%; polyethylene having a ratio of between 0.01%-20%; antioxidant having a ratio of between 0.1%-4%; erucylamide having a ratio between 0.01%-2%; and graphene having a ratio between 0.1%-10%, although alternatives are possible.

The flex foam panel 408 is similar to the flex foam panel 308, although it has a greater height or thickness T12. In certain examples, the height or thickness T12 may be between 1 inch and 10 inches, although alternatives are possible. In certain examples, the height or thickness T12 may be about 2 inches. In certain examples, the height or thickness T12 may be about 3 inches. In certain examples, the height or thickness T12 may be about 4 inches. In certain examples, the height or thickness T12 may be about 6 inches.

The flex foam panel 408 include cut out portions 412 that each have a shape that matches the shape of the individual cushion elements 410. In the example depicted, the individual cushion elements 410 each include a plurality of interconnected side wall segments 416 that intersect to form a grid of pentagons. The outer periphery of the cut out portions 412 defined in the flex foam panel 408 generally form a star shaped geometry that corresponds with the outer periphery of the individual cushion elements 410. As such, the individual cushion elements 410 can be inserted into the cut out portions 412 of the flex foam panel 408 such that there are no gaps therein. That is, the contours of the individual cushion elements 410 are perfectly matched within the cut out portions 412. It will be appreciated that the individual cushion elements 410 may vary in shape and pattern in other embodiments. Accordingly, the cut out portions 412 may also vary in shape and pattern to correspond with the individual cushion elements 410. It will be appreciated that the any change in the shape and pattern of the individual cushion elements 310, 410 or cut out portions 312, 412 do not alter or change the desired performance of the mattress assemblies 300, 400.

The cut out portions 410 in the flex foam panel 408 can be sized about 150 mm wide. The cut out portions 410 in the flex foam panel 408 can be spaced about 100 mm to about 106 mm apart from each other in the vertical and horizontal directions, respectively.

As depicted in FIGS. 29-30, there may be an increased number of cut out portions 412a in the flex foam panel 408a. The cut out portions 412a in the flex foam panel 408a can each be about 150 mm wide. The cut out portions 412a in the flex foam panel 408a can be spaced about 50 mm to about 56 mm apart from each other in the vertical and horizontal directions, respectively.

Referring to FIGS. 31-32, another example mattress assembly 500 is depicted. The mattress assembly 500 is similar to the mattress assemblies 300, 400 previously described except the mattress assembly 500 includes a spring layer 512 between first and second support layers 506a. 506b. The support layers 506a, 506b may be similar to the support layers 306, 306, 306b described above, although alternatives are possible. The spring layer 512 may be similar to the spring layer 212 in the mattress assembly 200, although alternatives are possible.

The mattress assembly 500 also includes a memory foam layer 504 between a top mattress cover 501 (e.g., upper cover) and an elastomeric layer 502. The elastomeric layer 502 including flex foam panel 508 and plurality of individual cushion elements 510. The memory foam layer 504 is connected directly to the flex foam panel 508 by adhesive. The mattress assembly 500 further includes a bottom mattress cover 503 (e.g., lower cover) positioned below the second support layer 506b. It will be appreciated that the features described herein with reference to the mattress assemblies, 100, 200, 300, 400 may also apply to the mattress assembly 500. Similar reference numbers to the mattress assembly 300 may be used to reference the layers in the mattress assembly 500, but in the 500s.

The spring layer 512 may provide additional support or rigidity in the mattress assembly 500. The spring layer 512 includes a plurality of coils 516. In certain examples, the coils 516 may be barrel-shaped. The plurality of coils 516 can each be individually pocketed in casings 518. The casings 518 may include non-woven bags. The spring layer 512 may comprise an indentation load deflection (ILD). The indentation load deflection may be between about 10 lbs. and about 60 lbs, although alternatives are possible. In certain examples, the indentation load deflection may be between 20 lbs. and about 40 lbs.

The spring layer 512 may have a height or thickness T13 that ranges between about 5 inches to 10 about inches, although alternatives are possible. The coils 516 make up a coil unit that may be encased by an edge foam support 520, which may be similar in composition to the flex foam panel 508. In certain examples, the spring layer 512 has a 15 gauge coil unit. The first support layer 506a is connected directly to the edge foam support 520 of the spring layer 512.

FIG. 33 is another example mattress assembly 600 in accordance with the principles of the present disclosure. The mattress assembly 600 is a tri-fold mattress that includes separate, individual components. For example, the tri-fold mattress includes a first segment 602, a second segment 604, and a third segments 606 that are connected together by a fabric covering 608. The first, second, and third segments 602, 604, 606 each include mattress components that are respectively concealed therein by a respective zip-fastener 603 or any other alternative fastener may be utilized. The zip-fastener may extend along one side, along two sides, or along three sides of the respective first, second, and third segments 602, 604, 606. The mattress components within the first, second, and third segments 602, 604, 606 may remain attached together even when the zip-fastener is undone or they may be detachable from each other when the zip-fastener is undone.

A fabric division, seam, or stitching 605 can be provided in the fabric covering 608 to divide the mattress assembly 600 into the first, second, and third segments 602, 604, 606. The fabric division, seam, or stitching 605 provides a pivotal connection between the first, second, and third segments 602, 604, 606 to allow for pivotal movement for folding. The mattress assembly 600 is shown divided into three equally sized squares. It will be appreciated that the mattress assembly 600 may be divided into a different number of equally sized segments, into a plurality of differently sized segments and/or into differently shaped segments.

FIG. 34 depicts the mattress components designed to be positioned within each of the first, second, and third segments 602, 604, 606 of the mattress assembly 600. The mattress components comprise an elastomeric layer 610 that includes a flex foam panel 612 and a plurality of individual cushion elements 614; a support layer 616; a top mattress cover 618 (e.g., upper cover); and a bottom mattress cover 620 (e.g., lower cover). The features of the elastomeric layer 610, the support layer 616, the top mattress cover 618, and the bottom mattress cover 620 are similar to those described above. The plurality of individual cushion elements 614 within the flex foam panel 612 are arranged in two vertical columns and four horizontal rows, although alternatives are possible.

Turning again to FIG. 33, the mattress assembly 600 also includes a handle 622 provided on the first and third segments 602, 606 which are suitably secured thereon for carrying the mattress assembly 600.

Referring to FIG. 35, the elastomeric layer 610 within each of the first, second, and third segments 602, 604, 606 has a length L and width W. The length L of the elastomeric layer 610 can be about 900 mm, although alternatives are possible. The width W can be about 660 mm, although alternatives are possible. The total width W1 of the mattress assembly 600 may be about 1980 mm, although alternatives are possible.

The spacing S between each of the individual cushion elements 614 from edge to edge (e.g., outer periphery) in a respective row can be about 100 mm, although alternatives are possible. Spacing S1 between the individual cushion elements 614 to a respective fabric division, seam, or stitching 605 can be about 140 mm, although alternatives are possible. Spacing S2 between the individual cushion elements 614 to either a top end 624 or a bottom end 626 may be about 75 mm, although alternatives are possible. The top and bottom ends 624, 626 being generally perpendicular to the fabric division, seam or stitching 605.

It will be appreciated that the measurements mentioned herein are entirely for purposes of illustration and not in limitation.

From the forgoing detailed description, it will be evident that modifications and variations can be made without departing from the spirit and scope of the disclosure.

Claims

1. A mattress assembly, comprising:

a base having a base surface;

a support layer having a first support surface and a second support surface, the support layer extending across the base surface such that the first support surface of the support layer interfaces with the base surface of the base;

an elastomeric layer, including: a flex foam panel defining a plurality of cut out portions; and a plurality of individual cushion elements each being disposed respectively within a cut out portion of the plurality of cut out portions of the flex foam panel, wherein the second support surface of the support layer interfaces with the elastomeric layer, wherein the elastomeric layer comprises a composition that includes graphene;

a memory foam layer having a first surface and a second surface, the memory foam layer extending across the elastomeric layer such that the first surface of the memory foam layer interfaces with the elastomeric layer; and

a cover having a cover surface that interfaces with the second surface of the memory foam layer, wherein the cover attaches to the base.

2. The mattress assembly of claim 1, wherein the memory foam layer is connected to the elastomeric layer by adhesive.

3. The mattress assembly of claim 1, wherein the support layer is connected directly to the elastomeric layer by adhesive.

4. The mattress assembly of claim 1, wherein the plurality of individual cushion elements are isolated from each other in the flex foam panel.

5. The mattress assembly of claim 1, wherein the plurality of cut out portions are formed to match a size and shape of the plurality of individual cushion elements.

6. The mattress assembly of claim 1, wherein the mattress does not include a fabric layer.

7. A graphite thermoplastic elastomer grid, comprising:

a first zone including first and second cushion elements;

a second zone including third and fourth cushion elements; and

a third zone including fifth and sixth cushion elements;

wherein the first, second, third, fourth, fifth, and sixth cushion elements each includes two major sides extending parallel to one another, wherein the two major sides of the respective first, second, third, fourth, fifth, and sixth cushion elements are interconnected by two minor sides, extending parallel to one another.

8. The graphite thermoplastic elastomer grid of claim 7, further comprising a fabric that extends across the graphite thermoplastic elastomer grid.

9. The graphite thermoplastic elastomer grid of claim 8, wherein the fabric is attached to the graphite thermoplastic elastomer grid by an adhesive.

10. The graphite thermoplastic elastomer grid of claim 7, wherein the graphite thermoplastic elastomer grid has a hardness on the Shore A scale of less than 35.

11. The graphite thermoplastic elastomer grid of claim 10, wherein the first, second, and third zones of the graphite thermoplastic elastomer grid each includes a different hardness on the Shore A scale.

12. The graphite thermoplastic elastomer grid of claim 7, wherein the first and second cushion elements in the first zone are attached together at a respective one of the two minor sides thereof, the third and fourth cushion elements in the second zone are attached together at a respective one of the two minor sides thereof, and the fifth and sixth cushion elements in the third zone are attached together at a respective one of the two minor sides thereof.

13. The graphite thermoplastic elastomer grid of claim 7, wherein the first and third cushion elements are attached together at a respective one of the two major sides thereof, the third and fifth cushion elements are attached together at a respective one of the two major sides thereof, the second and fourth cushion elements are attached together at a respective one of the two major sides thereof, and the fourth and sixth cushion elements are attached together at a respective one of the two major sides thereof.

14. A mattress assembly, comprising:

a base layer having a base surface;

a support layer having a first support surface and a second support surface, the support layer extending across the base surface such that the first support surface of the support layer interfaces with the base surface of the base layer;

a gel layer having a first gel surface and a second gel surface, the gel layer extending across the support layer such that the first gel surface of the gel layer interfaces with the second support surface of the support layer;

an adaptive foam layer having a first foam surface and a second foam surface, the adaptive foam layer extending across the gel layer such that the first foam surface of the adaptive foam layer interfaces with the second gel surface of the gel layer; and

an elastomeric layer, including: a flex foam encasement; a first thermoplastic elastomer grid zone including first and second cushion elements configured to attach together; a second thermoplastic elastomer grid zone including third and fourth cushion elements configured to attach together; and a third thermoplastic elastomer grid zone including fifth and sixth cushion elements configured to attach together, wherein the flex foam encasement provides a perimeter around the first, second and third thermoplastic elastomer grid zones; wherein the elastomeric layer extends across the adaptive foam layer such that a first surface of the elastomeric layer interfaces with the second foam surface of the adaptive foam layer; and wherein the first, second and third thermoplastic elastomer grid zones of the elastomeric layer comprises a composition that includes graphene.

15. The mattress assembly of claim 14, wherein the flex foam encasement is formed by a plurality of flex foam encasement parts.

16. The mattress assembly of claim 14, wherein the flex foam encasement and the first, second, third, fourth, fifth, and sixth cushion elements each have the same height.

17. The mattress assembly of claim 14, wherein the first, second, third thermoplastic elastomer grid zones extend laterally across the center opening of the flex foam encasement.

18. The mattress assembly of claim 14, wherein the first, second, and third thermoplastic elastomer grid zones of the elastomeric layer each includes different material compositions.

19. The mattress assembly of claim 14, further comprising a spring layer between the gel layer and the support layer, wherein the spring layer includes a plurality of coils each individually pocketed in casings made of non-woven bags.

20. The mattress assembly of claim 14, further comprising a first divider separating the first and second thermoplastic elastomer grid zones of the elastomeric layer and a second divider separating the second and third thermoplastic elastomer grid zones of the elastomeric layer, wherein the first and second dividers are separate parts from the flex foam encasement.

21. A mattress assembly, comprising:

a first mattress cover having a cover surface;

a first support layer having a first support surface and a second support surface, the support layer extending across the cover surface such that the first support surface of the support layer interfaces with the cover surface of the base;

a spring layer including a plurality of coils each individually pocketed in casings made of non-woven bags, wherein the second support surface of the support layer interfaces with the spring layer;

a second support layer having a support surface that interfaces with the spring layer, wherein the support surface of the second support layer is connected directly to the spring layer by adhesive;

an elastomeric layer, including: a flex foam panel defining a plurality of cut out portions; and a plurality of individual cushion elements each being disposed respectively within one of the plurality of cut out portions of the flex foam panel, wherein the second support layer is positioned between the elastomeric layer and the spring layer, wherein the elastomeric layer comprises a composition that includes graphene;

a memory foam layer having a first surface and a second surface, the memory foam layer extending across the elastomeric layer such that the first surface of the memory foam layer interfaces with the elastomeric layer; and

a second mattress cover having a cover surface that interfaces with the second surface of the memory foam layer, wherein the first mattress cover attaches to the second mattress cover.

22. A mattress assembly including a tri-fold mattress, the mattress assembly comprising:

a first segment, a second segment, and a third segment, the first, second, and third segments each including: an elastomeric layer that includes a flex foam panel defining a plurality of cut out portions and a plurality of individual cushion elements disposed respectively within a cut out portion of the plurality of cut out portions of the flex foam panel, the cut out portions and the plurality of individual cushion elements having the same shape; a support layer; a first mattress cover; and a second mattress cover;

wherein the elastomeric layer, the support layer, and the first and second mattress covers are respectively concealed within the first, second, and third segments by a zip-fastener;

wherein the first, second, and third segments are connected together by a fabric cover; and

wherein the first, second, and third segments are pivotable and foldable along seams provided in the fabric cover of the mattress assembly.