Mattress or mattress pad with gel section

Abstract

The invention generally relates to a mattress or a mattress pad with one or more gel sections. The gel section may provide improved support and comfort at a localized area of a mattress or a mattress pad.

1 . A mattress topper pad, comprising 
 a padding layer having an inner perimeter and a top surface and having a recessed region formed in the top surface and defining a recess bottom wall, and    a gel layer having a top surface and an outer perimeter bordering the inner perimeter of the padding layer and adhered to at least one of the inner perimeter of the padding layer and the recess bottom wall, wherein the top surface of the padding layer and the top surface of the gel layer are substantially flush.    
     
     
         2 . The mattress topper pad of  claim 1 , wherein the padding layer comprises at least one of foam, latex, visco-elastic foam, plastic, polymer, natural fiber, synthetic fiber.  
     
     
         3 . The mattress topper pad of  claim 1 , wherein the gel layer comprises at least one of a silicone gel, a PVC gel, a polyorganosiloxane gel, a NCO-prepolymer gel, a polyol gel, a polyurethane gel, a polyisocyanate gel, and a gel including a pyrogenically produced oxide.  
     
     
         4 . The mattress topper pad of  claim 1 , wherein the gel layer comprises a solid gel material.  
     
     
         5 . The mattress topper pad of  claim 1 , wherein the gel layer comprises a viscous gel material.  
     
     
         6 . The mattress topper pad of  claim 1 , wherein the gel layer comprises a visco-elastic gel material.  
     
     
         7 . The mattress topper of  claim 1 , wherein the gel layer comprises a foam gel.  
     
     
         8 . The mattress topper of  claim 1 , wherein the gel layer comprises a dimensionally stable gel.  
     
     
         9 . The mattress topper pad of  claim 1 , wherein the gel layer further comprises a bladder.  
     
     
         10 . The mattress topper pad of  claim 1 , wherein the padding layer includes a first zone having a convoluted surface and a second zone having a smooth surface.  
     
     
         11 . The mattress topper of  claim 1 , wherein the recessed region is positioned at a location that is adjacent to at least one of a lumbar region, a center region and a head and neck region.  
     
     
         12 . The mattress topper pad of  claim 1 , wherein the gel layer is joined to the padding layer by a bond formed during a gel curing process.  
     
     
         13 . The mattress topper pad of  claim 1 , further comprising a thin film sheet disposed over the gel layer.  
     
     
         14 . The mattress topper pad of  claim 1 , comprising a fabric layer covering the padding layer and the gel layer.  
     
     
         15 . A method of manufacturing a mattress topper pad comprising 
 providing a padding material;    forming a recessed region in the padding material having a sidewall and a bottom wall;    providing a gel material into the recessed region and bonding the gel material to at least one of the side wall and the bottom wall,    wherein the top surface of the padding material and the top surface of the gel material are substantially flush.    
     
     
         16 . The method of  claim 15 , wherein providing a gel material into the recessed region includes pouring a liquid gel material into the recessed region and curing the liquid gel  
     
     
         17 . The method of  claim 15 , comprising covering the padding material and the gel layer with a fabric layer.  
     
     
         18 . The method of  claim 15 , comprising forming an outer perimeter of a gel layer into a shape.  
     
     
         19 . The method of  claim 15 , wherein forming the recessed region in the padding material included forming the recessed region at a location adjacent at least one of the lumbar, center or head and neck.  
     
     
         20 . The method of  claim 15 , comprising connecting side rails to either end of the recessed region.  
     
     
         21 . The method of  claim 20 , comprising attaching a fabric layer to the side rails.  
     
     
         22 . A mattress, comprising 
 a mattress core;    a padding layer positioned on top of the mattress core, having an inner perimeter and a top surface and having a recessed region formed in the top surface and defining a recess bottom wall, and    a gel layer having a top surface and an outer perimeter bordering the inner perimeter of the padding layer and adhered to at least one of the inner perimeter of the padding layer and the recess bottom wall, wherein the top surface of the padding layer and the top surface of the gel layer are substantially flush.    
     
     
         23 . The mattress of  claim 19 , wherein the gel layer comprises at least one of a silicone gel, a PVC gel, a polyorganosiloxane gel, a NCO-prepolymer gel, a polyol gel, a polyurethane gel, a polyisocyanate gel, and a gel including a pyrogenically produced oxide.  
     
     
         24 . The mattress of  claim 22 , wherein the gel layer comprises one of a solid gel material, a viscous gel material, a visco-elastic gel material, and a foam gel material.  
     
     
         25 . The mattress of  claim 22 , wherein the gel layer comprises a dimensionally stable gel.  
     
     
         26 . The mattress of  claim 22 , wherein the gel layer further comprises a bladder.  
     
     
         27 . The mattress of  claim 22 , wherein the padding layer includes a first zone having a convoluted surface and a second zone having a smooth surface.  
     
     
         28 . The mattress topper of  claim 22 , wherein the recessed region is positioned at a location that is adjacent to at least one of a lumbar region, a center region and a head and neck region.  
     
     
         29 . The mattress of  claim 22 , wherein the gel layer is joined to the padding layer by a bond formed during a gel curing process.  
     
     
         30 . The mattress of  claim 22 , further comprising a thin film sheet disposed over the gel layer.  
     
     
         31 . The mattress of  claim 22 , comprising a fabric layer covering the padding layer and the gel layer.