All-foam mattress assemblies with foam engineered cores having thermoplastic and thermoset materials, and related assemblies and methods

Abstract

All-foam mattress assemblies with foam engineered cores having thermoplastic and thermoset materials, and related assemblies and methods are disclosed. All-foam mattress assemblies use foam-based materials, such as thermoplastic and thermoset, to provide cushioning and support characteristics for a user in the sleeping area of a mattress during sleep or rest. The all-foam mattress assemblies may include foam comfort layer(s), foam transitional layer(s), and a foam engineered core. The all-foam engineered core may lessen a density of a mattress assembly by comprising thermoset member(s), and engineered geometric thermoplastic material profile(s) adjacent to the thermoset member(s). The engineered geometric thermoplastic material profile(s) may be disposed in a parallel or substantially parallel arrangement. In this manner, the all-foam engineering core may provide cushioning and support characteristics with reduced density compared to a foam mattress providing similar cushioning and support through solid thermoset layers.

We claim: 
     
         1 . An all-foam mattress assembly, comprising:
 at least one foam comfort layer to receive a load of a user;   at least one foam transitional layer receiving the load from the at least one foam comfort layer, the at least one foam transitional layer having a density more than a density of the at least one foam comfort layer; and   a foam engineered core comprising a plurality of engineered geometric thermoplastic material profiles disposed in a parallel arrangement, a plurality of thermoset members disposed in the parallel arrangement and adjacent to the plurality of engineered geometric thermoplastic material profiles, bulk-free volume, and a deck,   wherein the plurality of engineered geometric thermoplastic material profiles and the plurality of thermoset members are collectively configured to receive the load conveyed from the at least one foam transitional layer and to convey the load to the deck.   
     
     
         2 . The all-foam mattress assembly of  claim 1 , wherein the foam engineered core further comprises a load distribution member configured to receive the load conveyed by the at least one foam transitional layer,
 wherein the plurality of engineered geometric thermoplastic material profiles and the plurality of thermoset members are configured to collectively receive the load from the load distribution member.   
     
     
         3 . The all-foam mattress assembly of  claim 2 , wherein the at least one foam transitional layer is configured to move in a horizontal plane with respect to the load distribution member. 
     
     
         4 . The all-foam mattress assembly of  claim 3 , wherein the at least one foam transitional layer comprises a planar surface configured to communicate with a planar surface of the load distribution member. 
     
     
         5 . The all-foam mattress assembly of  claim 4 , wherein the foam engineered core further comprises a plurality of thermoplastic support members arranged in the parallel arrangement and disposed between the plurality of engineered geometric thermoplastic material profiles and the plurality of thermoset members. 
     
     
         6 . The all-foam mattress assembly of  claim 5 , wherein the plurality of thermoplastic support members, the plurality of engineered geometric thermoplastic material profiles, and the plurality of thermoset members are collectively configured to receive the load conveyed from the at least one foam transitional layer and to convey the load to the deck. 
     
     
         7 . The all-foam mattress assembly of  claim 1 , wherein the at least one foam comfort layer comprises thermoset. 
     
     
         8 . The all-foam mattress assembly of  claim 1 , wherein the deck comprises thermoplastic. 
     
     
         9 . The all-foam mattress assembly of  claim 8 , wherein the at least one engineered geometric thermoplastic material profile comprises polyethylene. 
     
     
         10 . The all-foam mattress assembly of  claim 1 , wherein the foam engineered core abuts against the at least one foam transitional layer. 
     
     
         11 . The all-foam mattress assembly of  claim 1 , wherein the deck includes at least one channel configured to be orthogonal to the load. 
     
     
         12 . The all-foam mattress assembly of  claim 11 , wherein the at least one channel may be filled or substantially filled with thermoset material. 
     
     
         13 . The all-foam mattress assembly of  claim 2 , wherein the plurality of engineered geometric thermoplastic material profiles may be disposed between the load distribution member and the deck, and secured to the load distribution member. 
     
     
         14 . The all-foam mattress assembly of  claim 1 , wherein the plurality of thermoset members and the at least one foam comfort layer include a same material composition. 
     
     
         15 . The all-foam mattress assembly of  claim 8 , wherein the thermoplastic of the deck and the plurality of engineered geometric thermoplastic material profiles include a same material composition. 
     
     
         16 . The all-foam mattress assembly of  claim 1 , wherein each of the plurality of engineered geometric thermoplastic material profiles comprises an arch-shaped thermoplastic profile surrounding a thermoset core of the plurality of thermoset members. 
     
     
         17 . The all-foam mattress assembly of  claim 2 , wherein the plurality of engineered geometric thermoplastic profiles extends from the load distribution member to the deck, the plurality of engineered geometric thermoplastic profiles include a plurality of grooves configured to be orthogonal to the load and configured to gradually close when subjected to the load. 
     
     
         18 . The all-foam mattress assembly of  claim 17 , wherein the plurality of engineered geometric thermoplastic profiles includes at least one spring bore therethrough, the at least one spring bore configured to gradually close when subjected to the load. 
     
     
         19 . The all-foam mattress assembly of  claim 17 , wherein the plurality of grooves each comprises a V-groove shape. 
     
     
         20 . The all-foam mattress assembly of  claim 2 , wherein each of the plurality of engineered geometric thermoplastic material profiles comprises a hollow circular profile secured to and protruding from the load distribution member, the hollow circular profile includes an inner thermoplastic surface forming a hollow passageway and an outer thermoplastic surface surrounding at least one of the plurality of thermoset members. 
     
     
         21 . The all-foam mattress assembly of  claim 20 , wherein each of the hollow circular profiles abuts against the deck. 
     
     
         22 . The all-foam mattress assembly of  claim 1 , wherein each of the plurality of thermoset members are secured to complementary ones of the plurality of engineered geometric thermoplastic material profiles with an adhesive, cohesive, or thermal bond. 
     
     
         23 . The all-foam mattress assembly of  claim 1 , wherein each of the plurality of thermoset members is secured to complementary ones of the plurality of engineered geometric thermoplastic material profiles with a chemical bond agent. 
     
     
         24 . The all-foam mattress assembly of  claim 1 , wherein each of the plurality of thermoset members is secured to complementary ones of the plurality of engineered geometric thermoplastic material profiles with a stratum. 
     
     
         25 . The all-foam mattress assembly of  claim 24 , wherein the stratum includes a chemical bond agent. 
     
     
         26 . The all-foam mattress assembly of  claim 25 , wherein the chemical bond agent comprises N-(2-aminoethyl)-3-aminopropyltrimethoxysilane. 
     
     
         27 . An all-foam mattress assembly, comprising:
 at least one foam comfort layer to receive a load of a user;   at least one foam transitional layer receiving the load from the at least one foam comfort layer, the at least one foam transitional layer having a density more than a density of the at least one foam comfort layer; and   a foam engineered core comprising a plurality of engineered geometric thermoplastic material profiles disposed in a parallel arrangement, a plurality of thermoset members disposed in the parallel arrangement and adjacent to the plurality of engineered geometric thermoplastic material profiles, and a deck,   wherein the plurality of engineered geometric thermoplastic material profiles and the plurality of thermoset members are collectively configured to receive the load conveyed from the at least one foam transitional layer and to convey the load to the deck, and   wherein, collectively, an unloaded density of the at least one foam comfort layer, the at least one foam transitional layer, and the foam engineered core comprise a density between 0.8 pounds per cubic foot and 3.0 pounds per cubic foot.   
     
     
         28 . The all-foam mattress assembly of  claim 27 , wherein an unloaded density of the plurality of engineered geometric thermoplastic material profiles is greater than 1.3 pounds per cubic foot and less than 1.7 pounds per cubic foot. 
     
     
         29 . The all-foam mattress assembly of  claim 27 , wherein an unloaded density of the plurality of thermoset members is greater than 1.7 pounds per cubic foot and less than 2.5 pounds per cubic foot. 
     
     
         30 . The all-foam mattress assembly of  claim 28 , wherein, while unburdened by the load, the foam engineered core comprises at least 25 percent thermoplastic by volume, at least 25 percent of at least one thermoset material by volume, and at least 25 percent bulk-free volume. 
     
     
         31 . An all-foam mattress assembly, comprising:
 at least one foam comfort layer to receive a load of a user;   at least one foam transitional layer receiving the load from the at least one foam comfort layer, the at least one foam transitional layer having a density more than a density of the at least one foam comfort layer; and   a foam engineered core being less dense than the at least one foam transitional layer, the foam engineered core comprises a plurality of engineered geometric thermoplastic material profiles, bulk-free volume, a deck, and plurality of thermoset members collectively configured with the plurality of engineered geometric thermoplastic material profiles to receive the load conveyed from the at least one foam transitional layer and to convey the load to the deck.   
     
     
         32 . The all-foam mattress assembly of  claim 31 , wherein each of the plurality of engineered geometric thermoplastic material profiles at least partially surrounds at least a portion of the bulk-free volume. 
     
     
         33 . The all-foam mattress assembly of  claim 31 , wherein the foam engineered core further comprises a portion of the bulk-free volume between adjacent members of the plurality of engineered geometric thermoplastic material profiles. 
     
     
         34 . The all-foam mattress assembly of  claim 31 , wherein the foam engineered core abuts against the at least one foam transitional layer. 
     
     
         35 . The all-foam mattress assembly of  claim 31 , wherein the deck includes at least one channel configured to be orthogonal to the load. 
     
     
         36 . An all-foam mattress assembly, comprising:
 at least one foam comfort layer to receive a load of a user;   at least one foam transitional layer receiving the load from the at least one foam comfort layer, the at least one foam transitional layer having a density more than a density of the at least one foam comfort layer; and   a foam engineered core comprising a plurality of engineered geometric thermoplastic material profiles disposed in a parallel arrangement, a plurality of thermoset members disposed in the parallel arrangement and adjacent to the plurality of engineered geometric thermoplastic material profiles, and a deck,   wherein the plurality of engineered geometric thermoplastic material profiles and the plurality of thermoset members are collectively configured to receive the load conveyed from the at least one foam transitional layer and to convey the load to the deck, and   wherein the foam engineered core comprises between fifteen (15) percent and fifty (50) percent bulk-free volume, and the foam engineered core is configured to support the load through the at least one foam comfort layer and the at least one transitional layer.   
     
     
         37 . The all-foam mattress assembly of  claim 36 , wherein the foam engineered core, when free of the load, comprises at least 25 percent thermoplastic by volume, at least 25 percent thermoset by volume, and at least 25 percent bulk-free volume. 
     
     
         38 . The all-foam mattress assembly of  claim 36 , wherein the foam engineered core, the at least one transitional layer, and the at least one foam comfort layer, collectively and free of the load, comprise at least 25 percent bulk-free volume. 
     
     
         39 . An all-foam mattress assembly, comprising:
 at least one foam comfort layer to receive a load of a user;   at least one foam transitional layer receiving the load from the at least one foam comfort layer, the at least one foam transitional layer having a density more than a density of the at least one foam comfort layer; and   a foam engineered core comprising a plurality of engineered geometric thermoplastic material profiles disposed in a parallel arrangement, a plurality of thermoset members disposed in the parallel arrangement and adjacent to the plurality of engineered geometric thermoplastic material profiles, and a deck,   wherein the plurality of engineered geometric thermoplastic material profiles and the plurality of thermoset members are collectively configured to receive the load conveyed from the at least one transitional layer and to convey the load to the deck, and   wherein the foam engineered core includes bulk-free volume.   
     
     
         40 . The all-foam mattress assembly of  claim 39 , wherein the foam engineered core abuts against the at least one foam transitional layer. 
     
     
         41 . The all-foam mattress assembly of  claim 40 , wherein each of the plurality of engineered geometric thermoplastic material profiles comprises a hollow circular profile secured to and protruding from a load distribution member, the hollow circular profile includes an inner thermoplastic surface forming a hollow passageway and an outer thermoplastic surface surrounding at least one of the plurality of thermoset members. 
     
     
         42 . The all-foam mattress assembly of  claim 41 , wherein each of the hollow circular profiles abuts against the deck. 
     
     
         43 . An all-foam mattress assembly, comprising:
 at least one foam comfort layer to receive a load of a user;   at least one foam transitional layer receiving the load from the at least one foam comfort layer, the at least one foam transitional layer having a density more than a density of the at least one foam comfort layer; and   a foam engineered core comprising a plurality of engineered geometric thermoplastic material profiles disposed in a parallel arrangement, a plurality of thermoset members disposed in the parallel arrangement and adjacent to the plurality of engineered geometric thermoplastic material profiles, a load allocation member, and a deck,   wherein the plurality of engineered geometric thermoplastic material profiles and the plurality of thermoset members are collectively configured to receive the load conveyed from the at least one foam transitional layer via the load allocation member and to convey the load to the deck,   wherein a strain of a combined height of the load allocation member, plurality of engineered geometric thermoplastic material profiles, and the plurality of thermoset members have a stress-strain relationship represented by Y being less than or equal to 0.012143*X̂4−0.7467*X̂3+10.03761*X̂2+346.196*X−123.5391,   wherein X being strain measured in percent of the foam engineered core, and Y being a corresponding stress in pascals for values of X between 15 to 42 percent.   
     
     
         44 . The all-foam mattress assembly of  claim 43 , wherein the stress-strain relationship represented by Y being greater than or equal to 0.0029545*X̂4−0.187879*X̂3+2.174242*X̂2+98.9177*X+11.4719 for values of X between 15 to 42 percent. 
     
     
         45 . The all-foam mattress assembly of  claim 44 , wherein the stress-strain relationship represented by Y being greater than or equal to 0.0029924*X̂4−0.1118687*X̂3+0.5568182*X̂2+171.3276*X+44.3723 for values of X between 15 to 42 percent. 
     
     
         46 . The all-foam mattress assembly of  claim 44 , wherein the stress-strain relationship represented by Y being less than or equal to 0.0013636*X̂4+0.13636*X̂3−7.06061*X̂2+273.182*X−39.3939 for values of X between 15 to 42 percent.