Mattress with a visco elastic polyurethane foam layer

Abstract

A foam mattress is provided having a body facing surface comprising a viscoelastic foam layer. The body facing surface further comprises a recess or cavity into which a layer including a core of springs may be provided. The foam mattress further having a layer of open cell foam beneath the viscoelastic foam layer. The open cell, or reticulated, foam layer provides increased breathability. Support for the mattress may further be provided by a bottom layer of conventional foam.

1 - 16 . (canceled) 
     
     
         17 . A mattress comprising, a first foam portion having a first thickness, the first foam portion comprising a viscoelastic foam, the first foam portion having a top surface comprising a recess;
 a second foam portion having a second thickness, the second foam portion comprising a reticulated cell foam structure;   a third foam portion having a third thickness greater than both the first and second thicknesses;   a foam sidewall extending from a top of the first foam portion to a bottom of the third foam portion; and   a layer of material sized to cooperatively engage with the recess, the layer comprising: a first fabric coupled to a second fabric foaming a plurality of individual pockets and a plurality of springs wherein the plurality of springs are contained in the plurality of individual pockets.   
     
     
         18 . The mattress of  claim 17  wherein the viscoelastic foam has a first density and a first hardness, the second foam portion has a second density less than the first density and a second hardness less than the first hardness, and the third foam portion has a third density and a third hardness wherein the third density and the third hardness are greater than the second density and the second hardness. 
     
     
         19 . The mattress of  claim 18  wherein the first foam portion comprises reticulated viscoelastic foam. 
     
     
         20 . The mattress of  claim 17  wherein the viscoelastic foam is infused with a polyurethane gel. 
     
     
         21 . The mattress of  claim 17  wherein the viscoelastic foam comprises a plurality of polyurethane gel beads. 
     
     
         22 . The mattress of  claim 17  wherein the viscoelastic foam is loaded with phase change materials. 
     
     
         23 . The mattress of  claim 17  wherein the viscoelastic foam is loaded with at least one antimicrobial. 
     
     
         24 . The mattress of  claim 17  wherein the first foam portion comprises a first top foam layer and a second top foam layer wherein each of the first and second top foam layers comprise viscoelastic foams. 
     
     
         25 . The mattress of  claim 24  wherein the first top foam layer and the second top foam layer comprise viscoelastic foams with an identical chemical composition. 
     
     
         26 . The mattress of  claim 24  wherein the first top foam layer comprises a plurality of first top foam layers and wherein the recess is formed in part by a gap between inner surfaces of the plurality of first top foam layers. 
     
     
         27 . The mattress of  claim 17  wherein the layer comprises a first fabric coupled to a second fabric forming a plurality of individual pockets wherein each of the plurality of individual pockets contains a single one of the plurality of springs. 
     
     
         28 . A mattress comprising,
 a first foam portion comprising a plurality of first top foam layers residing on a second top foam layer, each of the plurality of first top foam layers comprising an inner surface wherein a recess is defined in the first foam portion by at least one inner surface and a top surface of the second top foam layer, wherein the first top foam layer has a first thickness, the recess has a first depth, and the second top foam layer has a second thickness, the first and second top foam layers comprising identical chemical compositions, wherein the first thickness and the second thickness together is no more than about 2 inches thick;   a second foam layer attached to a first bottom of the first foam portion, the second foam portion comprising a reticulated foam, the second foam layer having a third thickness wherein the third thickness is greater than the first thickness and the second thickness;   a third foam portion having a fourth thickness greater than both the first, second, and third thicknesses, the third foam portion comprising a generally closed or open cell foam structure; and   a layer comprising a top textile material coupled to a bottom textile material forming at least one pocket and a spring in the at least one pocket wherein the layer has a thickness about equal to the first thickness.   
     
     
         29 . The mattress of  claim 28  wherein the spring comprises a coiled spring. 
     
     
         30 . The mattress of  claim 28  wherein the spring comprises an innerspring core. 
     
     
         31 . The mattress of  claim 28  wherein the first top foam layer and the second top foam layer comprise a viscoelastic foam. 
     
     
         32 . The mattress of  claim 31  wherein the viscoelastic foam is a reticulated viscoelastic foam. 
     
     
         33 . The mattress of  claim 28  comprising a foam sidewall substantially surrounding the first foam portion, the second foam portion, and the third foam portion and extending from a top of the first foam portion to a bottom of the third foam portion. 
     
     
         34 . The mattress of  claim 33  wherein the foam sidewall comprises a reticulated foam. 
     
     
         35 . The mattress of  claim 28  wherein the first thickness is approximately 0.75 inches thick. 
     
     
         36 . The mattress of  claim 35  wherein the second thickness is approximately 1.25 inches thick.