MATTRESSES INCLUDING AN ELASTOMERIC CUSHIONING ELEMENT AND A POCKETED COIL LAYER AND RELATED METHODS
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.
1 . A mattress, comprising:
a first layer comprising a plurality of coils;
a second layer over at least a portion of the first layer, the second layer comprising a foam;
an elastomeric cushioning element over at least a portion of the second layer and adhered to the second layer.
2 . The mattress of claim 1 , wherein:
the plurality of coils comprises a plurality of individually wrapped coils.
3 . The mattress of claim 1 , further comprising:
an outer covering encasing the first layer, the second layer, and the elastomeric cushioning element.
4 . The mattress of claim 1 , further comprising:
one or more side panels extending around outer perimeters of the first layer and the second layer.
5 . The mattress of claim 4 , further comprising:
an outer covering encasing the first layer, the one or more side panels, the second layer, and the elastomeric cushioning element.
6 . The mattress of claim 1 , wherein the second layer comprises a polyurethane foam.
7 . The mattress of claim 1 , wherein the elastomeric cushioning element comprises a grid of interconnected walls defining hollow buckling columns.
8 . A mattress, comprising:
a coil layer comprising an array of coils;
a foam layer over the coil layer, the foam layer including a lower surface oriented toward the coil layer and an upper surface oriented away from the coil layer;
an elastomer layer over the upper layer, the elastomer layer including a lower surface oriented toward the foam layer and an upper surface oriented away from the foam layer, the lower surface of the elastomer layer adhered to the foam layer.
9 . The mattress of claim 8 , wherein the array of coils comprises individually wrapped coils.
10 . The mattress of claim 9 , wherein each coil of the array of coils is disposed within a first polypropylene bag and the first polypropylene bag is disposed within a second polypropylene bag.
11 . The mattress of claim 10 , further comprising:
a base layer beneath the coil layer.
12 . The mattress of claim 11 , further comprising:
at least one side panel surrounding an outer periphery of the coil layer.
13 . The mattress of claim 12 , wherein the base layer, the at least one side panel, and the foam layer encase the coil layer, dampening sound from the coil layer.
14 . The mattress of claim 13 , further comprising:
a cover over the base layer, the coil layer, the foam layer, the at least one side panel, and the elastomer layer.
15 . The mattress of claim 14 , having a maximum sound level of about 45 decibels.
16 . The mattress of claim 14 , having a maximum sound level of about 40 decibels.
17 . The mattress of claim 8 , wherein the foam layer has a thickness of about 0.5 inch to about 1 inch.
18 . The mattress of claim 8 , wherein the upper surface of the foam layer is porous to enable the elastomer layer to adhere to the upper surface of the foam layer.
19 . The mattress of claim 18 , wherein the elastomer layer includes a scrim fabric at lower surface.
20 . The mattress of claim 19 , wherein an elastomeric material of the elastomer layer secures the scrim fabric in place at the lower surface.
21 . The mattress of claim 20 , wherein the scrim fabric enables the elastomer layer to adhere to the upper surface of the foam layer.
22 . The mattress of claim 18 , wherein the lower surface of the foam layer is porous to enable the foam layer to adhere to the coil layer.
23 . The mattress of claim 8 , wherein the elastomer layer is superimposed with a central location of the foam layer but not with peripheral portions of the foam layer.