Mattresses including an elastomeric cushioning element and a pocketed coil layer and related methods

Abstract

A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

What is claimed: 
     
         1 . A mattress, comprising:
 a first layer comprising a plurality of coils;   a second layer over at least a portion of the first layer, the second layer comprising a foam;   an elastomeric cushioning element over at least a portion of the second layer and adhered to the second layer.   
     
     
         2 . The mattress of  claim 1 , wherein:
 the plurality of coils comprises a plurality of individually wrapped coils.   
     
     
         3 . The mattress of  claim 1 , further comprising:
 an outer covering encasing the first layer, the second layer, and the elastomeric cushioning element.   
     
     
         4 . The mattress of  claim 1 , further comprising:
 one or more side panels extending around outer perimeters of the first layer and the second layer.   
     
     
         5 . The mattress of  claim 4 , further comprising:
 an outer covering encasing the first layer, the one or more side panels, the second layer, and the elastomeric cushioning element.   
     
     
         6 . The mattress of  claim 1 , wherein the second layer comprises a polyurethane foam. 
     
     
         7 . The mattress of  claim 1 , wherein the elastomeric cushioning element comprises a grid of interconnected walls defining hollow buckling columns. 
     
     
         8 . A mattress, comprising:
 a coil layer comprising an array of coils;   a foam layer over the coil layer, the foam layer including a lower surface oriented toward the coil layer and an upper surface oriented away from the coil layer;   an elastomer layer over the upper layer, the elastomer layer including a lower surface oriented toward the foam layer and an upper surface oriented away from the foam layer, the lower surface of the elastomer layer adhered to the foam layer.   
     
     
         9 . The mattress of  claim 8 , wherein the array of coils comprises individually wrapped coils. 
     
     
         10 . The mattress of  claim 9 , wherein each coil of the array of coils is disposed within a first polypropylene bag and the first polypropylene bag is disposed within a second polypropylene bag. 
     
     
         11 . The mattress of  claim 10 , further comprising:
 a base layer beneath the coil layer.   
     
     
         12 . The mattress of  claim 11 , further comprising:
 at least one side panel surrounding an outer periphery of the coil layer.   
     
     
         13 . The mattress of  claim 12 , wherein the base layer, the at least one side panel, and the foam layer encase the coil layer, dampening sound from the coil layer. 
     
     
         14 . The mattress of  claim 13 , further comprising:
 a cover over the base layer, the coil layer, the foam layer, the at least one side panel, and the elastomer layer.   
     
     
         15 . The mattress of  claim 14 , having a maximum sound level of about 45 decibels. 
     
     
         16 . The mattress of  claim 14 , having a maximum sound level of about 40 decibels. 
     
     
         17 . The mattress of  claim 8 , wherein the foam layer has a thickness of about 0.5 inch to about 1 inch. 
     
     
         18 . The mattress of  claim 8 , wherein the upper surface of the foam layer is porous to enable the elastomer layer to adhere to the upper surface of the foam layer. 
     
     
         19 . The mattress of  claim 18 , wherein the elastomer layer includes a scrim fabric at lower surface. 
     
     
         20 . The mattress of  claim 19 , wherein an elastomeric material of the elastomer layer secures the scrim fabric in place at the lower surface. 
     
     
         21 . The mattress of  claim 20 , wherein the scrim fabric enables the elastomer layer to adhere to the upper surface of the foam layer. 
     
     
         22 . The mattress of  claim 18 , wherein the lower surface of the foam layer is porous to enable the foam layer to adhere to the coil layer. 
     
     
         23 . The mattress of  claim 8 , wherein the elastomer layer is superimposed with a central location of the foam layer but not with peripheral portions of the foam layer.