IP Library Granted Patent US 12,342,941
Granted Patent B2
US 12,342,941 · App. 18/236,776 · Granted Jul 1, 2025

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 12,342,941
App. No.
18/236,776
Granted
Jul 1, 2025
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 customize a mattress by selecting one or more tops from a plurality of available for use with one or more bases from a plurality of available bases.

Claims (44)

1. A mattress, comprising:

a foundation defining a receptacle;

a base layer positioned within the receptacle;

a pressurizable layer positioned over the base layer and contacting at least a portion of the base layer within the receptacle; and

a top layer positioned within the receptacle and over at least a portion of the pressurizable layer, the top layer comprising an elastomer gel.

2. The mattress of claim 1 , wherein the elastomer gel comprises a block copolymer.

3. The mattress of claim 2 , wherein the block copolymer comprises an A-B-A triblock copolymer.

4. The mattress of claim 2 , wherein the elastomer gel further comprises a plasticizer.

5. The mattress of claim 4 , wherein the plasticizer comprises an oil.

6. The mattress of claim 1 , wherein the elastomer gel defines a plurality of interconnected walls defining an arrangement of buckling columns.

7. The mattress of claim 1 , wherein the elastomer gel defines a structured grid with a plurality of openings.

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

9. The mattress of claim 8 , wherein the plurality of pressurizable chambers are independently pressurizable.

10. The mattress of claim 1 , further comprising:

a coiled spring layer.

11. The mattress of claim 1 , further comprising:

at least one sensor associated with the top layer positioned within the receptacle.

12. A cushion, comprising:

a foundation defining a receptacle;

a base layer positioned within the receptacle;

a pressurizable layer positioned over the base layer and contacting at least a portion of the base layer within the receptacle; and

a top layer positioned within the receptacle and over at least a portion of the pressurizable layer, the top layer comprising an elastomer gel.

13. The cushion of claim 12 , wherein the elastomer gel comprises a block copolymer.

14. The cushion of claim 12 , wherein the elastomer gel defines a plurality of compressible walls defining an array of buckling columns.

15. The cushion of claim 12 , wherein the elastomer gel defines a structured grid with a plurality of openings.

16. The cushion of claim 12 , wherein the pressurizable layer comprises a plurality of pressurizable chambers.

17. A cushion, comprising:

a foundation defining a receptacle;

a base layer positioned within the receptacle;

a pressurizable layer positioned over the base layer and contacting at least a portion of the base layer within the receptacle; and

a top layer positioned within the receptacle and over at least a portion of the pressurizable layer and comprising a plurality of compressible walls defining an array of buckling columns.

18. The cushion of claim 17 , wherein the pressurizable layer comprises a plurality of pressurizable bladders.

19. The cushion of claim 18 , wherein the plurality of pressurizable bladders are independently pressurizable.

20. The cushion of claim 17 , further comprising:

a coiled spring layer.

21. The cushion of claim 17 , further comprising:

at least one sensor associated with the top layer positioned within the receptacle.

22. A cushioning method, comprising:

positioning at least part of an individual's body on a top layer disposed at least partially within a receptacle defined by a foundation, and comprising an elastomer gel to support at least a part of the individual's body; and

pressurizing at least a portion of a pressurizable layer positioned beneath the top layer and over a base layer positioned within the receptacle, the pressurizable layer contacting at least a portion of the base layer within the receptacle.

23. The cushioning method of claim 22 , wherein pressurizing at least the portion of the pressurizable layer comprises individually pressurizing a plurality of pressurizable chambers of the pressurizable layer.

24. The cushioning method of claim 22 , further comprising:

adjusting a pressure within the pressurizable layer after positioning at least part of the individual's body on the top layer positioned within the receptacle.

25. The cushioning method of claim 24 , wherein adjusting the pressure comprises adjusting the pressure in accordance with a program.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 24, 2024
From: HARRIS, BROCK KEITH; GRUTTA, JAMES T.; PEARSON, BRETT; PIERCE, MICHAEL ALLEN
To: PURPLE INNOVATION, LLC
Reel/Frame 067521/0517 →
SECURITY INTEREST Recorded Jan 25, 2024
From: PURPLE INNOVATION, INC.; PURPLE INNOVATION, LLC; INTELLIBED, LLC
To: DELAWARE TRUST COMPANY
Reel/Frame 066369/0610 →