IP Library Granted Patent US 11,583,101
Granted Patent B2
US 11,583,101 · App. 13/354,571 · Granted Feb 21, 2023

Mattress or mattress pad with gel section

Inventors: Richard F. Gladney (Fairburn, GA); Corey Westerman (Newnan, GA); Michael S. DeFranks (Decatur, GA)
Assignee: DREAMWELL, LTD.
A47C27/148A47C27/15A47C27/20Y10T156/1039
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Quick Facts
Patent No.
US 11,583,101
App. No.
13/354,571
Granted
Feb 21, 2023
Kind
B2
Abstract

A mattress or a mattress pad with one or more gel sections. The gel section may provide improved support and comfort at a localized area of a mattress or a mattress pad.

Claims (10)

1. A foam mattress assembly, comprising:

a mattress pad positioned atop a mattress and a foundation, the mattress pad being removably attached to the mattress comprising:

at least one foam support layer comprising a first zone having a convoluted foam surface positioned to support an end user's neck and shoulders, a second zone including a recess positioned to support an end user's lumbar region, wherein the recess is defined by perimeter foam walls extending about the recess in its entirety and a foam bottom surface and at least one additional zone positioned to support an end user's lower legs having a convoluted and/or a smooth foam surface, and wherein top surfaces of the smooth surfaces and the convoluted surfaces are substantially flush relative to one another;

an unpackaged gel section filling the recess in the at least one foam support layer, wherein the gel section is integrally formed within the recess and self-adhered to the perimeter foam walls and the bottom foam surface of the recess in the at least one foam support layer, wherein the gel section comprises a dimensionally stable gel and a plastic film over the dimensionally stable gel, wherein the dimensionally stable gel is a single gel selected from the group consisting of a silicone gel, a PVC gel, a polyorganosiloxane gel, a polyol gel, a polyisocyanate gel, and a gel including a pyrogenically produced oxide; and

a cover encapsulating the at least one foam support layer and the gel section.

2. A two-sided mattress assembly, the two-sided mattress assembly comprising:

at least one foam support layer above a mattress core abutting a first sleeping surface on a first side of the mattress assembly, the at least one foam support layer above the mattress core comprising a first zone having a convoluted foam surface, a second zone including a first aperture, wherein the first aperture is defined by perimeter foam walls extending about the first aperture in its entirety, and at least one additional zone having a convoluted and/or a smooth foam surface, and wherein top surfaces of the smooth surfaces and the convoluted surfaces are substantially flush relative to one another;

a gel section in the aperture of the at least one foam support layer above the mattress core, the gel section is integrally formed within the aperture and self-adhered to the perimeter foam walls of the at least one foam support layer, wherein the gel section comprises a dimensionally stable gel and a plastic film over the dimensionally stable gel, wherein the dimensionally stable gel is a single gel selected from the group consisting of a silicone gel, a PVC gel, a polyorganosiloxane gel, a polyol gel, a polyisocyanate gel, and a gel including a pyrogenically produced oxide; and

at least one foam support layer below the mattress core abutting a second sleeping surface on a second side of the mattress assembly, the at least one foam support layer below the mattress core comprising a first zone having a convoluted foam surface, a second zone including a second aperture, wherein the second aperture is defined by perimeter foam walls extending about the second aperture in its entirety and at least one additional zone having a convoluted and/or a smooth foam surface, and wherein top surfaces of the smooth surfaces and the convoluted surfaces are substantially flush relative to one another; a gel section in the aperture and self-adhered to the perimeter foam walls of the at least one foam support layer below the mattress core, wherein the gel section is a dimensionally stable gel intermixed with a foam body, wherein the dimensionally stable gel is a single gel selected from the group consisting of a silicone gel, a PVC gel, a polyorganosiloxane gel, a polyol gel, a polyisocyanate gel, and a gel including a pyrogenically produced oxide,

wherein the mattress core is intermediate the at least one foam support layer above and the at least one foam support layer below the mattress core.

Assignments (19)
SECURITY INTEREST Recorded Aug 2, 2024
From: WELLS FARGO BANK, NATIONAL ASSOCIATION; NATIONAL BEDDING COMPANY, L.L.C.; SERTA SIMMONS BEDDING, LLC; SSB MANUFACTURING COMPANY; TOMORROW SLEEP LLC; TUFT & NEEDLE, LLC; DREAMWELL, LTD.
To: ECLIPSE BUSINESS CAPITAL LLC, AS ADMINISTRATIVE AGENT
Reel/Frame 068325/0886 →
TERM LOAN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded May 10, 2024
From: DREAMWELL, LTD.; NATIONAL BEDDING COMPANY, L.L.C.; SERTA SIMMONS BEDDING, LLC; SSB MANUFACTURING COMPANY; TOMORROW SLEEP LLC; TUFT & NEEDLE, LLC
To: WILMINGTON SAVINGS FUND SOCIETY, FSB
Reel/Frame 067379/0782 →
SECURITY AGREEMENT Recorded Jul 3, 2023
From: DREAMWELL, LTD.; TUFT & NEEDLE, LLC; SERTA SIMMONS BEDDING, LLC; NATIONAL BEDDING COMPANY, L.L.C.; TOMORROW SLEEP LLC
To: WELLS FARGO BANK, NATIONAL ASSOCIATION
Reel/Frame 064193/0668 →
TERM LOAN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Jun 30, 2023
From: DREAMWELL, LTD.; TUFT & NEEDLE, LLC; SERTA SIMMONS BEDDING, LLC; NATIONAL BEDDING COMPANY, L.L.C.; TOMORROW SLEEP LLC; SSB MANUFACTURING COMPANY
To: WILMINGTON SAVINGS FUND SOCIETY, FSB, AS ADMINISTRATIVE AGENT
Reel/Frame 064185/0583 →
RELEASE OF FIRST LIEN SECURITY INTEREST IN INTELLECTUAL PROPERTY Recorded Jun 30, 2023
From: ECLIPSE BUSINESS CAPITAL LLC, AS ADMINISTRATIVE AGENT
To: DREAMWELL, LTD.; SSB MANUFACTURING COMPANY; NATIONAL BEDDING COMPANY L.L.C.; SERTA SIMMONS BEDDING, LLC; TUFT & NEEDLE, LLC; TOMORROW SLEEP LLC
Reel/Frame 064185/0236 →
RELEASE OF FIRST LIEN SECURITY INTEREST IN INTELLECTUAL PROPERTY Recorded Jun 30, 2023
From: UBS AG, STAMFORD BRANCH, AS ADMINISTRATIVE AGENT
To: DREAMWELL, LTD.; SSB MANUFACTURING COMPANY; NATIONAL BEDDING COMPANY, L.L.C.
Reel/Frame 064185/0293 →
RELEASE OF SUPER-PRIORITY SECURITY INTEREST IN INTELLECTUAL PROPERTY Recorded Jun 30, 2023
From: WILMINGTON SAVINGS FUND SOCIETY, FSB, AS ADMINISTRATIVE AGENT
To: DREAMWELL, LTD.; SSB MANUFACTURING COMPANY; NATIONAL BEDDING COMPANY, L.L.C.; SERTA SIMMONS BEDDING, LLC; TUFT & NEEDLE, LLC; TOMORROW SLEEP LLC
Reel/Frame 064185/0479 →
NOTICE OF AGENCY RESIGNATION AND ASSIGNMENT OF SUPER-PRIORITY TERM LOAN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Feb 6, 2023
From: UBS AG, STAMFORD BRANCH, AS THE RESIGNING ADMINISTRATIVE AGENT
To: WILMINGTON SAVINGS FUND SOCIETY, FSB, AS SUCCESSOR ADMINISTRATIVE AGENT
Reel/Frame 063272/0391 →
SECURITY INTEREST Recorded Jan 31, 2023
From: DREAMWELL, LTD.; SSB MANUFACTURING; NATIONAL BEDDING; SERTA SIMMONS BEDDING, LLC; TUFT & NEEDLE, LLC; TOMORROW SLEEP LLC
To: ECLIPSE BUSINESS CAPITAL LLC
Reel/Frame 062571/0391 →
SECURITY INTEREST Recorded Jan 27, 2023
From: DREAMWELL, LTD.; SSB MANUFACTURING; NATIONAL BEDDING; SERTA SIMMONS BEDDING, LLC; TUFT & NEEDLE, LLC; TOMORROW SLEEP LLC
To: ECLIPSE BUSINESS CAPITAL LLC
Reel/Frame 062525/0458 →
RELEASE OF SECOND LIEN SECURITY INTEREST IN INTELLECTUAL PROPERTY RECORDED AT R/F 040813/1075 Recorded May 10, 2022
From: GOLDMAN SACHS BANK USA, AS ADMINISTRATIVE AGENT
To: DREAMWELL, LTD.
Reel/Frame 059925/0322 →
SUPER-PRIORITY TERM LOAN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Jun 24, 2020
From: DREAMWELL, LTD.
To: UBS AG, STAMFORD BRANCH, AS ADMINISTRATIVE AGENT
Reel/Frame 053022/0029 →
ABL INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Dec 5, 2016
From: DREAMWELL, LTD.
To: UBS AG, STAMFORD BRANCH, AS ADMINISTRATIVE AGENT
Reel/Frame 040813/0213 →
FIRST LIEN TERM LOAN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Dec 5, 2016
From: DREAMWELL, LTD.
To: UBS AG, STAMFORD BRANCH, AS ADMINISTRATIVE AGENT
Reel/Frame 040813/0136 →
SECOND LIEN TERM LOAN INTELLECTUAL PROPERTY SECURITY AGREEMENT Recorded Dec 5, 2016
From: DREAMWELL, LTD.
To: GOLDMAN SACHS BANK USA, AS ADMINISTRATIVE AGENT
Reel/Frame 040813/0175 →
RELEASE OF SECURITY INTEREST Recorded Nov 18, 2016
From: MORGAN STANLEY SENIOR FUNDING, INC., AS AGENT
To: DREAMWELL, LTD.; SIMMONS BEDDING COMPANY; NATIONAL BEDDING COMPANY L.L.C.
Reel/Frame 040647/0639 →
CORRECTIVE ASSIGNMENT TO CORRECT THE RECEIVING PARTY DATA INFORMATION FROM UBS AG, STAMFORD BRANCH, AS AGENT TO MORGAN STANLEY SENIOR FUNDING, INC. PREVIOUSLY RECORDED ON REEL 029128 FRAME 0126. ASSIGNOR(S) HEREBY CONFIRMS THE RECEIVING PARTY DATA INFORMATION. Recorded May 1, 2014
From: SIMMONS BEDDING COMPANY; DREAMWELL, LTD.; NATIONAL BEDDING COMPANY L.L.C.
To: MORGAN STANLEY SENIOR FUNDING, INC., AS AGENT
Reel/Frame 032810/0697 →
SECURITY AGREEMENT Recorded Oct 15, 2012
From: SIMMONS BEDDING COMPANY; DREAMWELL, LTD.; NATIONAL BEDDING COMPANY L.L.C.
To: UBS AG, STAMFORD BRANCH, AS AGENT
Reel/Frame 029128/0091 →
SECURITY AGREEMENT Recorded Oct 15, 2012
From: SIMMONS BEDDING COMPANY; DREAMWELL, LTD.; NATIONAL BEDDING COMPANY L.L.C.
To: UBS AG, STAMFORD BRANCH, AS AGENT
Reel/Frame 029128/0126 →