IP Library Granted Patent US 11,730,277
Granted Patent B2
US 11,730,277 · App. 17/568,478 · Granted Aug 22, 2023

Composite mattresses with air chambers

Inventors: Brock Keith Harris (Draper, UT); James T. Grutta (Draper, UT); Brett Pearson (Taylorsville, UT); Michael Allen Pierce (American Fork, UT)
Assignee: Purple Innovation, LLC
A47C27/083A47C27/06A47C27/10A47C27/18A47C31/105
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Quick Facts
Patent No.
US 11,730,277
App. No.
17/568,478
Granted
Aug 22, 2023
Kind
B2
Abstract

A composite mattress includes a pressurizable layer and a top layer. A coiled spring layer may also be included in the composite mattress. The composite mattress may also include a base layer and/or an intermediate layer. A foundation, or rail, may laterally surround the pressurizable layer and the top layer. The composite mattress may include a cover, including a base panel, a periphery, and a top panel. The cover may encase the other components of the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples to customize a mattress by selecting one or more tops from a plurality of available tops for use with one or more bases from a plurality of available bases.

Claims (37)

1. A mattress, comprising:

a coiled spring layer;

a pressurizable layer; and

a top layer over the coiled spring layer and the pressurizable layer and comprising a plurality of compressible walls defining an array of buckling columns.

2. The mattress of claim 1 , further comprising:

a foundation including at least one peripheral foundation member defining a foundation receptacle.

3. The mattress of claim 2 , wherein the coiled spring layer is located within the foundation receptacle.

4. The mattress of claim 3 , wherein the pressurizable layer is located within the foundation receptacle.

5. The mattress of claim 1 , further comprising:

an intermediate layer on the pressurizable layer, the top layer being located on the intermediate layer.

6. The mattress of claim 1 , further comprising:

a bottom cover including a cover base with a peripheral edge;

a cover periphery extending from the peripheral edge of the bottom cover, with a cover receptacle being defined by the cover periphery and the cover base, the cover receptacle receiving the coiled spring layer; and

a top cover over the top layer.

7. The mattress of claim 6 , wherein at least a portion of the cover periphery is continuous with the cover base and further comprising:

a coupler at or adjacent to a top edge of the cover periphery, the coupler coupling the top cover to the cover periphery.

8. The mattress of claim 1 , wherein the pressurizable layer is located over the coiled spring layer.

9. The mattress of claim 1 , wherein the pressurizable layer comprises a plurality of air chambers.

10. The mattress of claim 9 , wherein the plurality of air chambers are independently pressurizable.

11. The mattress of claim 9 , further comprising:

a pressure sensor associated with the top layer.

12. The mattress of claim 9 , further comprising:

a web of elastomeric material defining a structured grid defining a plurality of polygonal openings superimposed with the top layer.

13. A cushion, comprising:

a pressurizable layer; and

a cushioning layer over the pressurizable layer and comprising a plurality of compressible walls defining an array of buckling columns to support at least part of an individual's body, a contour of the cushioning layer definable by pressurization of the pressurizable layer.

14. The cushion of claim 13 , wherein the pressurizable layer comprises a plurality of air chambers.

15. The cushion of claim 14 , wherein the plurality of air chambers comprises a plurality of independently pressurizable air chambers.

16. The mattress of claim 13 , further comprising:

a pressure sensor associated with the cushioning layer.

17. A cushioning method, comprising:

positioning at least part of an individual's body on a cushioning layer comprising a plurality of compressible walls defining an array of buckling columns to support at least the part of the individual's body; and

pressurizing at least one air chamber to define a contour of the cushioning layer.

18. The cushioning method of claim 17 , wherein pressurizing at least one air chamber comprises individually pressurizing at least one air chamber of a plurality of air chambers.

19. The cushioning method of claim 17 , further comprising:

adjusting pressure within the at least one air chamber after positioning at least part of the individual's body on the cushioning layer.

20. The cushioning method of claim 19 , wherein adjusting pressure comprises adjusting pressure in accordance with a program.

Assignments (10)
SECURITY INTEREST Recorded Jan 25, 2024
From: BANK OF MONTREAL
To: DELAWARE TRUST COMPANY
Reel/Frame 066369/0365 →
SECURITY INTEREST Recorded Jan 25, 2024
From: PURPLE INNOVATION, INC.; PURPLE INNOVATION, LLC; INTELLIBED, LLC
To: DELAWARE TRUST COMPANY
Reel/Frame 066369/0610 →
RELEASE OF SECURITY INTEREST Recorded Jan 25, 2024
From: DELAWARE TRUST COMPANY
To: PURPLE INNOVATION, LLC
Reel/Frame 066369/0487 →
SECURITY INTEREST Recorded Jan 25, 2024
From: CALLODINE COMMERCIAL FINANCE, LLC
To: DELAWARE TRUST COMPANY
Reel/Frame 066369/0431 →
CORRECTIVE ASSIGNMENT TO CORRECT THE SIGNATORIES OF THE GRANTORS AND GRANTOR COLUMN ADDED TO SCHEDULE PREVIOUSLY RECORDED ON REEL 064522 FRAME 0839. ASSIGNOR(S) HEREBY CONFIRMS THE GRANT OF SECURITY INTEREST - PATENTS. Recorded Aug 18, 2023
From: PURPLE INNOVATION, LLC; PURPLE INNOVATION, INC.; INTELLIBED, LLC
To: CALLODINE COMMERCIAL FINANCE, LLC, AS ADMINISTRATIVE AGENT
Reel/Frame 064640/0737 →
SECURITY INTEREST Recorded Aug 8, 2023
From: PURPLE INNOVATION, LLC
To: BANK OF MONTREAL
Reel/Frame 064530/0181 →
RELEASE OF SECURITY INTEREST Recorded Aug 8, 2023
From: KEYBANK NATIONAL ASSOCIATION
To: PURPLE INNOVATION, LLC
Reel/Frame 064519/0978 →
SECURITY INTEREST Recorded Aug 7, 2023
From: PURPLE INNOVATION, LLC; PURPLE INNOVATION, INC.; INTELLIBED, LLC
To: CALLODINE COMMERCIAL FINANCE, LLC, AS ADMINISTRATIVE AGENT
Reel/Frame 064522/0839 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 8, 2022
From: HARRIS, BROCK KEITH; GRUTTA, JAMES T.; PEARSON, BRETT; PIERCE, MICHAEL ALLEN
To: PURPLE INNOVATION, LLC
Reel/Frame 059550/0437 →
COLLATERAL ASSIGNMENT OF PATENTS Recorded Mar 1, 2022
From: PURPLE INNOVATION, LLC
To: KEYBANK NATIONAL ASSOCIATION
Reel/Frame 059267/0215 →