IP Library Granted Patent US 12660940
Granted Patent B2
US 12660940 · App. 17/735,795 · Granted Jun 23, 2026

Mattresses including a coil layer and an elastomeric cushioning element

Inventors: Tony M. Pearce (Alpine, UT); Lars Christen Hamilton (Alpine, UT); Tanner Rick Wheadon (Lehi, UT)
Assignee: Purple Innovation, LLC
A47C27/20A47C27/001A47C27/056A47C27/06A47C27/064A47C27/146A47C27/148A47C27/15
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Quick Facts
Patent No.
US 12660940
App. No.
17/735,795
Granted
Jun 23, 2026
Kind
B2
Abstract

A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

Claims (43)

1 . A mattress assembly, comprising:

a pocketed coil layer comprising a plurality of coils;

a stabilization layer comprising a scrim fabric;

an elastomeric cushioning element on the stabilization layer, an elastomeric material of the elastomeric cushioning element seeping through the stabilization layer to secure an upper surface of the stabilization layer to the elastomeric cushioning element, the elastomeric material exposed and defining a reduced slip surface or a non-slip surface on a lower surface of the stabilization layer;

a plurality of foam segments adjacent to the elastomeric cushioning element, the elastomeric cushioning element and the plurality of foam segments forming a substantially planar upper surface;

an upper layer disposed over the coil layer, wherein the reduced slip surface or the non-slip surface is positioned against an upper surface of the upper layer, the plurality of foam segments positioned above the upper layer and the coil layer; and

an outer covering encasing the coil layer, the stabilization layer, the upper layer, the elastomeric cushioning element, and the plurality of foam segments.

2 . The mattress assembly of claim 1 , further comprising: a base layer beneath the pocketed coil layer.

3 . The mattress assembly of claim 2 , wherein the base layer comprises a compressible, resilient foam.

4 . The mattress assembly of claim 1 , wherein the upper layer comprises a compressible, resilient foam.

5 . The mattress assembly of claim 1 , wherein the pocketed coil layer comprises a plurality of individually pocketed coils.

6 . The mattress assembly of claim 1 , wherein the pocketed coil layer has a thickness of about 6.00 inches to about 8.00 inches.

7 . The mattress assembly of claim 1 , wherein the elastomeric cushioning element has a thickness of about 2.0 inches to about 4.5 inches.

8 . The mattress assembly of claim 1 , further comprising:

an adhesive disposed between the stabilization layer and the upper layer.

9 . The mattress assembly of claim 8 , wherein adhesive is not disposed over at least a portion of the upper layer.

10 . A mattress assembly, comprising:

a coil layer comprising a plurality of pocketed coils;

an upper layer over the coil layer;

a stabilization layer comprising a scrim fabric; and

at least one elastomeric cushioning element on the stabilization layer, an elastomeric material of the at least one elastomeric cushioning element seeping through the scrim fabric of the stabilization layer to secure an upper surface of the stabilization layer to the at least one elastomeric cushioning element and to provide a non-slip surface or a reduced slip surface on a lower surface of the scrim fabric, the non-slip surface or the reduced slip surface positioned against an upper surface of the upper layer;

a plurality of foam segments adjacent the elastomeric cushioning element, the elastomeric cushioning element and the plurality of foam segments forming a substantially planar upper surface, and the plurality of foam segments positioned above the upper layer and the coil layer; and

an outer covering encasing the coil layer, the upper layer, the stabilization layer, the at least one elastomeric cushioning element, and the plurality of foam segments,

wherein the at least one elastomeric cushioning element covers a portion of an upper surface of the upper layer.

11 . The mattress assembly of claim 10 , wherein each pocketed coil of the pocketed coils comprises:

a plurality of nested casings; and

a single coil disposed within an innermost casting of the plurality of nested casings.

12 . The mattress assembly of claim 10 , wherein the at least one elastomeric cushioning element comprises a plurality of distinct elastomeric cushioning elements disposed at different locations over the upper layer.

13 . The mattress assembly of claim 10 , wherein the at least one elastomeric cushioning element comprises a grid of interconnected walls defining hollow buckling columns.

14 . The mattress assembly of claim 10 , further comprising:

an adhesive disposed between the stabilization layer and the upper layer.

15 . A method of forming a mattress assembly, comprising:

providing a pocketed coil layer;

disposing an elastomeric cushioning element including a stabilization layer and a non-slip surface or a reduced slip surface formed by elastomeric material on a lower surface of the stabilization layer over the coil layer, the stabilization layer being located on a bottom surface of the elastomeric cushioning element, the elastomeric material of the elastomeric cushioning element securing the elastomeric cushioning element to an upper surface of the stabilization layer;

disposing a plurality of foam segments adjacent to the elastomeric cushioning element, the elastomeric cushioning element and the plurality of foam segments forming a substantially planar upper surface;

disposing an upper layer over the coil layer such that the elastomeric cushioning element is disposed over the upper layer, wherein the non-slip surface or reduced slip surface is positioned against an upper surface of the upper layer, the plurality of foam segments positioned above the upper layer and the coil layer; and

encasing the coil layer, the upper layer, the elastomeric cushioning element, and plurality of foam segments in an outer casing.

16 . The method of claim 15 , wherein providing the pocketed coil layer comprises providing a pocketed coil layer in which each coil of the pocketed coil layer is individually disposed within a first casing and each first casing is individually disposed within a second casing.

17 . The method of claim 15 , wherein disposing the elastomeric cushioning element comprises disposing the elastomeric material on the lower surface of the stabilization layer against the upper layer.

18 . The method of claim 15 , further comprising:

securing the stabilization layer to the upper layer.

19 . The method of claim 15 , further comprising:

disposing an adhesive between the stabilization layer and the upper layer.