Mattress assembly
View Patent ↗A mattress assembly includes a first layer of viscoelastic foam defining an upper surface, and a second layer of non-viscoelasiic foam supporting the first layer. The mattress assembly also includes a plurality of static spring elements positioned beneath the upper surface for enhancing a firmness of the combined first and second layers.
1. A mattress assembly comprising:
a first layer of viscoelastic foam defining an upper surface;
a second layer of non-viscoelastic foam supporting the first layer; and
a plurality of independent static spring elements positioned beneath the upper surface, the second layer of non-viscoelastic foam molded around and through each of the plurality of static spring elements, and the second layer having a thickness greater than a height of each of the plurality of static spring elements,
wherein the plurality of independent static spring elements are embedded and entirely encased within the second layer of non-viscoelastic foam to thereby substantially increase a firmness of the combined first and second layers, and
wherein an upper portion of the second layer extends continuously above each of the plurality of static spring elements, and a lower portion of the second layer extends continuously below each of the plurality of static spring elements.
2. The mattress assembly of claim 1 , wherein the viscoelastic foam includes a hardness of at least about 20 N and no greater than about 80 N.
3. The mattress assembly of claim 1 , wherein the viscoelastic foam includes a density of no less than about 30 kg/m 3 and no, greater than about 150 kg/m 3 .
4. The mattress assembly of claim 1 , wherein the second layer of non-viscoelastic foam is one of a latex foam and a high-resilience polyurethane foam.
5. The mattress assembly of claim 4 , wherein the latex foam includes a hardness of at least about 30 N and no greater than about 130 N, or wherein the high-resilience polyurethane foam includes a hardness of at least about 80 N and no greater than about 200 N.
6. The mattress assembly of claim 4 , wherein the latex foam includes a density of no less than about 40 kg/m 3 and no greater than about 100 kg/m 3 , or wherein the high-resilience polyurethane foam includes a density of no less than about 10 kg/m 3 and no greater than about 80 kg/m 3 .
7. The mattress assembly of claim 1 , wherein the plurality of static spring elements are made of a polymeric material.
8. The mattress assembly of claim 7 , wherein the plurality of static spring elements are made of a thermoplastic material.
9. The mattress assembly of claim 1 , wherein the plurality of static spring elements are aligned with a thickness of the mattress assembly.
10. The mattress assembly of claim 1 , wherein first and second spring elements of the plurality of static spring elements include different spring rates.
11. The mattress assembly of claim 1 , wherein at least one of the plurality of static spring elements includes a constant spring rate.
12. The mattress assembly of claim 1 , wherein at least one of the plurality of static spring elements includes a variable spring rate.
13. The mattress assembly of claim 1 , wherein the plurality of static spring elements are configured as coil springs.
14. The mattress assembly of claim 1 , wherein the plurality of static spring elements are arranged in an array having a plurality of rows and a plurality of columns.