Hybrid mattress assemblies
View Patent ↗Mattress assemblies that provide increased user comfort and increased airflow. The mattress assemblies generally include a multilayered mattress core including at least one coil spring layer disposed on and in direct contact with a viscoelastic foam layer.
1. An elongated mattress core for a one sided mattress structure, the mattress core comprising:
an upper most layer comprising a microgel infused phase change material comprising a planar surface and a convoluted surface, wherein the convoluted surface faces downwards toward the at least one coiled spring layer;
at least one coiled spring layer;
an underlying support layer comprising a viscoelastic foam consisting of planar top and bottom surfaces free of channels therein and a sidewall extending from the bottom surface to the top surface, wherein the sidewalls define a thickness of the underlying support layer ranging from ½ inch to 2 inches, wherein the coiled spring layer is in direct contact with the viscoelastic foam; and
a base core foam layer comprising a non-viscoelastic polyurethane foam, wherein the underlying support layer comprising the viscoelastic foam overlays the base core foam layer.
2. The mattress core of claim 1 , wherein the coiled spring layer is of a multi-strand configuration.
3. The mattress core of claim 1 , further comprising a second viscoelastic foam layer disposed on and in direct contact the coiled spring layer.
4. The mattress core of claim 1 , further comprising at least one additional foam layer.
5. The mattress core of claim 4 , wherein the at least one additional layer comprises a latex foam layer.
6. The mattress core of claim 4 , wherein the at least one additional layer comprises a pre-stressed foam layer having a firmness that is different from the firmness of the same foam that was not pre-stressed.
7. The mattress core of claim 4 , wherein the at least one additional layer comprises a polyurethane foam layer.
8. The mattress core of claim 1 , wherein the at least one coiled spring layer comprises a plurality of pocketed coil springs.
9. The mattress core of claim 1 , wherein the coiled spring layer comprises open coils.
10. The mattress assembly of claim 1 , wherein the at least one coiled spring layer of the mattress core comprises a plurality of pocketed coil springs.
11. The mattress assembly of claim 1 , wherein the at least one coiled spring layer comprises 3.5 inch coils.
12. A one sided mattress assembly comprising:
a mattress core comprising an uppermost layer comprising a microgel infused phase change material comprising a planar surface and a convoluted surface, wherein the convoluted surface faces downwards toward the at least one coiled spring layer; at least one coiled spring layer, an underlying support layer comprising a viscoelastic foam consisting of planar top and bottom surfaces free of channels therein and a sidewall extending from the bottom surface to the top surface, wherein the sidewalls define a thickness of the underlying support layer ranging from ½ inch to 2 inches, wherein a bottom surface of the coiled spring layer is in direct contact with the viscoelastic foam, and a base core foam layer comprising a non-viscoelastic polyurethane foam, wherein the underlying support layer comprising the viscoelastic foam overlays the base core foam layer; and
a side rail assembly circumscribing a perimeter of the mattress core, the side rail assembly comprising a layer of a polyurethane foam comprising an open cellular structure, wherein the open cellular structure comprises about 10 to about 40 cells per inch, a hardness of about 35 pounds-force to about 100 pounds-force, and a density of about 1.2 pounds per cubic foot to about 2.0 pounds per cubic foot, wherein the layer is configured to be disposed about a perimeter of an inner core of the mattress and is configured to permit the flow of fluid from and to the mattress core through the layer.
13. The mattress assembly of claim 12 , wherein the viscoelastic foam is a viscoelastic polyurethane foam.
14. The mattress assembly of claim 12 , wherein the mattress core further comprises one or more additional layers.
15. The mattress assembly of claim 14 , wherein the one or more additional layers comprise non-viscoelastic foam, visco elastic foam, pre-stressed foam, gel-infused foam, spring coils, polyurethane foam, encased spring coils, latex, or a combination thereof.
16. The mattress assembly of claim 12 , wherein the open cellular structure of the polyurethane foam layer in the side rail assembly comprises a percentage of intact windows between adjacent cells that is less than about 50 percent.
17. The mattress assembly of claim 12 , wherein the side rail assembly comprises multiple layers.
18. The mattress assembly of claim 12 , wherein the coiled spring layer is of a multi-strand configuration.
19. The mattress assembly of claim 12 , wherein the mattress core further comprises a second viscoelastic foam layer disposed on and in direct contact the coiled spring layer.
20. The mattress assembly of claim 12 , wherein the coiled spring layer comprises open coils.
21. An elongated mattress core for a one sided mattress structure, the mattress core comprising:
at least one coiled spring layer;
an underlying support layer comprising a viscoelastic foam consisting of planar top and bottom surfaces free of channels therein and a sidewall extending from the bottom surface to the top surface, wherein the sidewalls define a thickness of the underlying support layer ranging from ½ inch to 2 inches, wherein the coiled spring layer is in direct contact with the viscoelastic foam; and
a base core foam layer comprising a non-viscoelastic polyurethane foam, wherein the underlying support layer comprising the viscoelastic foam overlays the base core foam layer.