Cellular mattress assemblies and related methods

Abstract

Embodiments disclosed herein include cellular mattress assemblies and related methods. The cellular mattresses assemblies may comprise thermoplastic material and/or thermoset material to achieve appropriate comfort and support characteristics. The cellular mattress assemblies may also comprise one or more components including a cellular thermoplastic foam profile to achieve appropriate comfort and support characteristics. The cellular mattress may include a support layer, a comfort layer, and a transition layer between the support layer and the comfort layer.

What is claimed is: 
     
         1 . A mattress assembly for bedding or seating placed under a load, comprising:
 at least one comfort layer providing cushioning characteristics;   at least one support layer providing support characteristics; and   at least one transition layer including at least one mattress member disposed between the at least one comfort layer and the at least one support layer, the at least one mattress member comprising a unitary composite cushioning structure, the unitary composite cushioning structure comprising:
 at least one cellular thermoplastic material providing support characteristics and cushioning characteristics, 
 at least one cellular thermoset material providing a resilient structure with cushioning characteristics, and 
 a stratum disposed between at least a portion of the cellular thermoplastic material and at least a portion of the cellular thermoset material to secure the at least a portion of the cellular thermoset material to the at least a portion of the cellular thermoplastic material to form the unitary composite cushioning structure exhibiting a combination of the support characteristics and the cushioning characteristics and the resilient structure with cushioning characteristics when the unitary composite cushioning structure is placed under the load. 
   
     
     
         2 . The mattress assembly of  claim 1 , further comprising at least one second comfort layer disposed between the at least one mattress member and the at least one support layer, and the second comfort layer comprises the cellular thermoset material. 
     
     
         3 . The mattress assembly of  claim 1 , wherein the stratum is configured to be formed by disposing a non-solid phase of the cellular thermoset material on a cellular thermoplastic foam profile, and the cellular thermoset material undergoes a transition into a solid phase to form a bond with the cellular thermoplastic material. 
     
     
         4 . The mattress assembly of  claim 1 , wherein the at least one mattress member includes a first layer and a second layer, the first layer configured to provide support, and the second layer configured to provide cushioning and support. 
     
     
         5 . The mattress assembly of  claim 4 , wherein the second layer comprises at least two extensions extending orthogonally from a longitudinal plane of a cellular thermoplastic foam profile. 
     
     
         6 . The mattress assembly of  claim 5 , wherein the second layer is produced integrally with the first layer. 
     
     
         7 . The mattress assembly of  claim 5 , wherein the second layer includes an open chamber at least partially formed by the at least two extensions, and the open chamber is configured to receive the cellular thermoset material. 
     
     
         8 . The mattress assembly of  claim 7 , wherein each of the at least two extensions are in a shape of a hollow cylinder including a center axis parallel to the longitudinal plane of the cellular thermoplastic foam profile, and
 each of the at least two extensions are attached to the first layer at a portion of the extension along an outer tangential surface of the shape of the hollow cylinder.   
     
     
         9 . The mattress assembly of  claim 8 , wherein the first layer includes a plurality of orifices parallel to the longitudinal plane of the cellular thermoplastic foam profile. 
     
     
         10 . The mattress assembly of  claim 9 , wherein the first layer further comprises at least one support member, wherein at least one of the at least one support member is disposed between any two of the plurality of orifices of the first layer. 
     
     
         11 . The mattress assembly of  claim 10 , wherein each of the at least one support member includes at least one support surface parallel to the load. 
     
     
         12 . The mattress assembly of  claim 11 , wherein the first layer of each of the at least one mattress member transfers the load to the second layer of each of the at least one mattress member. 
     
     
         13 . The mattress assembly of  claim 11 , wherein the second layer of each of the at least one mattress member transfers the load to the first layer of each of the at least one mattress member. 
     
     
         14 . The mattress assembly of  claim 11 , wherein the at least one mattress member includes at least one cross-cut at least partially through the second layer, the at least one cross-cut is disposed orthogonal to the longitudinal axis of the at least one mattress member, and the at least one cross-cut is configured to improve motion transfer. 
     
     
         15 . The mattress assembly of  claim 1 , wherein
 the at least one comfort layer is at least one-inch thick and at most thirteen inches thick;   the at least one support layer is at least one-inch thick and at most thirteen inches thick;   the at least one mattress member is at least one-inch thick and at most thirteen inches thick; and   the first layer of the at least one mattress member is at least a half-inch thick and at most ten inches thick.   
     
     
         16 . The mattress assembly of  claim 1 , further comprising at least one side support member disposed along a perimeter of the mattress assembly, and the at least one side support member is configured to provide a firmer outer edge of the mattress. 
     
     
         17 . The mattress assembly of  claim 16 , wherein the at least one side support member comprises at least one cellular thermoplastic side support member including at least one side support orifice parallel to a longitudinal axis of the at least one cellular thermoplastic side support member. 
     
     
         18 . The mattress assembly of  claim 17 , wherein a portion of the at least one cellular thermoplastic side support member is configured to twist under a moment created by the load. 
     
     
         19 . The mattress assembly of  claim 18 , wherein each of the at least one elongated side support member further comprises at least one groove disposed along the longitudinal axis of each of the at least one elongated side support member, the at least one groove including an opening in a side surface in each of the at least one elongated side support member. 
     
     
         20 . The mattress assembly of  claim 19 , wherein the opening of the at least one groove is at least partially directed orthogonal to the load, and the at least one groove extends into each of the elongated side support members a distance from the side surface and extends beyond the at least one side support orifice. 
     
     
         21 . The mattress assembly of  claim 20  wherein the portion of the at least one elongated side support member is disposed between the at least one groove and the at least one side support orifice. 
     
     
         22 . The mattress assembly of  claim 21 , further comprising at least one base layer including cellular thermoplastic material;
 the at least one support layer and the at least one mattress member are disposed between the at least one comfort layer and the at least one base layer; and   the at least one side support member collectively surrounds the at least one support layer and the at least one mattress member.   
     
     
         23 . The mattress assembly of  claim 22 , wherein the at least one side support member is disposed between the at least one base layer and the at least one comfort layer. 
     
     
         24 . The mattress assembly of  claim 23 , wherein the at least one side support member further comprises at least one cellular thermoset side support member. 
     
     
         25 . The mattress assembly of  claim 24 , wherein the at least one cellular thermoset side support member is disposed between the at least one cellular thermoplastic side support member and the at least one comfort layer. 
     
     
         26 . The mattress assembly of  claim 17 , wherein the at least one side support member comprises open-cell thermoplastic material. 
     
     
         27 . The mattress assembly of  claim 26 , wherein the at least one side support member further comprises at least one closed-cell thermoplastic side support portion, and the at least one open-cell thermoplastic support portion is disposed between the at least one comfort layer and the at least one closed-cell thermoplastic side support portion. 
     
     
         28 . The mattress assembly of  claim 10 , wherein the at least one side support member comprises at least one cellular thermoplastic side support member including at least one side support orifice disposed parallel to a longitudinal axis of the at least one cellular thermoplastic side support member, and each of the at least one side support orifices including at least one orifice opening on at least one distal end of the at least one cellular thermoplastic side support member. 
     
     
         29 . The mattress assembly of  claim 28 , wherein the at least one orifice opening includes an oblong-shaped cross-section elongated in a direction orthogonal to the load, and the oblong-shaped cross-section is orthogonal to the longitudinal axis of the at least one cellular thermoplastic side support. 
     
     
         30 . The mattress assembly of  claim 28 , wherein the at least one cellular thermoplastic side support member includes at least one groove parallel to the longitudinal axis of the at least one cellular thermoplastic side support member;
 each of the at least one groove includes an opening along a length of the at least one cellular thermoplastic side support member, and the opening of each of the at least one groove at least partially directed orthogonal to the load.   
     
     
         31 . The mattress assembly of  claim 30 , wherein the at least one groove includes a first groove and a second groove, the first groove on an opposite side of the at least one cellular thermoplastic side support member from a second groove, and each of the at least one groove includes an opening. 
     
     
         32 . The mattress assembly of  claim 31 , wherein a portion of the first groove and a portion of the second groove extend between the at least two side support orifices. 
     
     
         33 . The mattress assembly of  claim 32 , wherein a portion of the at least one cellular thermoplastic side support member between the first groove and the at least two side support orifices is configured to twist under a moment created by the load. 
     
     
         34 . The mattress assembly of  claim 33 , wherein a portion of the at least one cellular thermoplastic side support member between the second groove and the at least two side support orifices is configured to twist under a second moment created by the load. 
     
     
         35 . The mattress assembly of  claim 34 , wherein within a cross-section orthogonal to the longitudinal axis of the at least one cellular thermoplastic side support member, a width of the opening of each of the at least one groove is smaller than a maximum width of each of the at least one groove. 
     
     
         36 . The mattress assembly of  claim 35 , wherein within the cross-section orthogonal to the longitudinal axis of the at least one cellular thermoplastic side support member, a shape of each of the at least one groove tapers to the portion of each of the at least one groove extending between the at least two side support orifices. 
     
     
         37 . A mattress assembly for bedding or seating, comprising:
 a support layer comprising a cellular thermoplastic material;   a cushioning layer comprising a cellular thermoset material;   a transition layer comprising a cellular thermoplastic material disposed between the support layer and the cushioning layer, the transition layer comprising at least two elongated members disposed within a geometric plane and separated by a gap or abutting each other; each of the at least two elongated members include a first end and a second end opposite the first end along a longitudinal axis, and each of the at least two elongated members include at least one orifice parallel to the longitudinal axis.   
     
     
         38 . The mattress assembly of  claim 37 , wherein each of the at least two elongated members comprises at least two orifices parallel to a longitudinal axis of each of the at least two elongated members, each of the at least two orifices including two orifice openings on opposite ends of each of the at least two elongated members, the two orifice openings including an oblong-shaped cross-section elongated in a direction orthogonal to the load, the oblong-shaped cross-section is orthogonal to the longitudinal axis of each of the at least two elongated members. 
     
     
         39 . The mattress assembly of  claim 38 , wherein each of the at least two elongated members include at least one groove parallel to the longitudinal axis of each of the at least two elongated members, each of the at least one groove including an opening along a length of each of the at least two elongated members, and the opening of each of the at least one groove at least partially facing a direction orthogonal to the load. 
     
     
         40 . The mattress assembly of  claim 39 , wherein the at least one groove include a first groove on an opposite side of each of the at least two elongated members from a second groove, and each of the at least one groove include an opening. 
     
     
         41 . The mattress assembly of  claim 40 , wherein a portion of the first groove and the second groove extend between the at least two orifices,
 a portion of at least one of the at least two elongated members between the first groove and the at least two orifices is configured to twist under a moment created by the load, and   a portion of at least one of the at least two elongated members between the second groove and the at least two orifices is configured to twist under a second moment created by the load.   
     
     
         42 . The mattress assembly of  claim 41 , wherein within a cross-section orthogonal to the longitudinal axis of each of the at least two elongated members, a width of the opening of each of the at least one groove is less than a maximum width of each of the at least one groove. 
     
     
         43 . The mattress assembly of  claim 42 , wherein within a cross-section orthogonal to the longitudinal axis of each of the at least two elongated members, a shape of each of the at least one groove tapers to the portion of each of the at least one groove extending between the at least two orifices. 
     
     
         44 . A mattress assembly for sleeping or resting, comprising at least five percent and at most ninety-five percent cellular thermoplastic material by weight, and
 the mattress assembly comprises at least five percent and at most ninety-five percent cellular thermoset material by weight.   
     
     
         45 . The mattress assembly of  claim 44 , wherein the cellular thermoplastic material forms at least one support layer and a portion of a transition layer,
 the cellular thermoset material forms at least one cushioning layer and a second portion of the transition layer, and   the transition layer is disposed between one of the at least one support layer and one of the at least one cushioning layer.   
     
     
         46 . The mattress assembly of  claim 44 , wherein the mattress assembly is fully comprised of the cellular thermoset material and the cellular thermoplastic material. 
     
     
         47 . A mattress assembly for sleeping or resting, comprising at least five percent and at most ninety-five percent cellular thermoplastic material by volume, and
 the mattress assembly comprises at least five percent and at most ninety-five percent cellular thermoset material by volume.   
     
     
         48 . The mattress assembly of  claim 47 , wherein the cellular thermoplastic material forms at least one support layer and a portion of a transition layer,
 the cellular thermoset material forms at least one cushioning layer and a second portion of the transition layer, and   the transition layer is disposed between one of the at least one support layer and one of the at least one cushioning layer.   
     
     
         49 . A foam mattress assembly for sleeping or resting, comprising:
 at least two geometrically-designed thermoplastic foam members disposed within a geometric plane and separated by a gap or abutting each other, and   the at least two geometrically-designed thermoplastic foam members include progressive support characteristics configured to conform and deflect under a load, the at least two geometrically-designed thermoplastic foam members configured to distribute the load partially in a horizontal direction to resist full compression while maintaining comfortable resistance to said load;   wherein a firmness characteristic of the foam mattress assembly is configured to be provided by geometric characteristics of the at least two geometrically-designed thermoplastic foam members and the density of the at least two geometrically-designed thermoplastic foam members.   
     
     
         50 . The foam mattress assembly of  claim 49 , wherein the geometric characteristics comprise orifices. 
     
     
         51 . The foam mattress assembly of  claim 50 , wherein the geometric characteristics comprise grooves including openings. 
     
     
         52 . The foam mattress assembly of  claim 51 , wherein the geometric characteristics comprise polymers or copolymers. 
     
     
         53 . A foam mattress assembly for bedding or seating, comprising:
 at least one cellular foam comfort layer providing cushioning characteristics;   at least one cellular foam support layer providing support characteristics;   at least one transition cellular foam mattress member disposed between the at least one comfort layer and the at least one support layer and providing a stress-strain profile exhibiting cushioning and support characteristics; and   at least one side support member surrounding the at least one mattress member.   
     
     
         54 . The mattress assembly of  claim 53 , wherein the at least one side support member comprises at least one cellular thermoplastic side support member including at least one side support orifice parallel to a longitudinal axis of the at least one cellular thermoplastic side support member. 
     
     
         55 . The mattress assembly of  claim 54 , wherein a portion of the at least one cellular thermoplastic side support member is configured to twist under a moment created by the load. 
     
     
         56 . The mattress assembly of  claim 55 , wherein each of the at least one elongated side support member further comprises at least one groove disposed along the longitudinal axis, and the at least one groove including an opening in a side surface of the at least one elongated side support member. 
     
     
         57 . The mattress assembly of  claim 56 , wherein the opening of the at least one groove is at least partially directed orthogonal to the load, and the at least one groove extends into each of the elongated side support member a distance from the side surface and extends beyond the at least one side support orifice. 
     
     
         58 . The mattress assembly of  claim 57 , wherein the portion of the at least one elongated side support member is disposed between the at least one groove and the at least one side support orifice.