Mattresses including an elastomeric cushioning element on pocketed coils with cushioning coil toppers

Abstract

A mattress assembly includes a base layer, a coil layer over the base layer, and an elastomeric cushioning element over the upper layer. The coil layer includes a plurality of pocketed coils with a coil and a coil topper formed from a compressible, resilient material over the coil. Methods of manufacturing mattresses with elastomeric cushioning elements over pocketed coils that include coil toppers are also disclosed.

1 . A mattress assembly, comprising:
 a base layer;   a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils, a pocketed coil of the plurality of pocketed coils including:
 a coil; 
 a coil topper comprising a cushioning material over the coil; and 
 a casing packaging the coil and the coil topper together; and 
   a cushion comprising an elastomeric gel defining a plurality of interconnected walls defining an array of voids, the elastomeric gel extending over an array of pocketed coils of the coil layer.   
     
     
         2 . (canceled) 
     
     
         3 . The mattress assembly of claim  2 , wherein the cushion or a stabilizing material on a surface of the cushion contacts an upper surface of the coil layer. 
     
     
         4 . The mattress assembly of  claim 3 , wherein air can flow through the coil layer, the cushion, and any stabilizing material on the cushion. 
     
     
         5 . The mattress assembly of  claim 1 , wherein the coil topper comprises a foam. 
     
     
         6 . The mattress assembly of  claim 5 , wherein the coil topper further comprises an elastomeric gel over the foam. 
     
     
         7 . The mattress assembly of  claim 1 , wherein the coil topper comprises an elastomeric gel. 
     
     
         8 . The mattress assembly of  claim 7 , wherein the elastomeric gel defines a plurality of interconnected walls defining an array of voids. 
     
     
         9 . The mattress assembly of  claim 1 , further comprising:
 a stabilizing material on at least one surface of the cushion.   
     
     
         10 . The mattress assembly of  claim 9 , comprising a lower layer of the stabilizing material on a bottom surface of the cushion. 
     
     
         11 . The mattress assembly of  claim 10 , further comprising an upper layer of the stabilizing material on an upper surface of the cushion. 
     
     
         12 . A mattress assembly, comprising:
 a base layer;   a coil layer disposed over the base layer, the coil layer comprising a plurality of pocketed coils, a pocketed coil of the plurality of pocketed coils including:
 a coil; 
 a coil topper comprising a cushioning material over the coil; and 
 a casing packaging the coil and the coil topper together; 
   a cushion comprising a plurality of interconnected walls defining an array of voids, the cushion extending over an array of pocketed coils of the coil layer,   the cushion and the coil layer arranged with at least some voids of the voids of the cushion being at least partially aligned with gaps between pocketed coils of the plurality of pocked coils of the coil layer to enable airflow through an entire thickness of an assembly of the coil layer and the cushion.   
     
     
         13 . The mattress assembly of  claim 12 , wherein the coil topper comprises a foam. 
     
     
         14 . The mattress assembly of  claim 13 , wherein the coil topper further comprises an elastomeric gel over the foam. 
     
     
         15 . The mattress assembly of  claim 12 , wherein the coil topper comprises an elastomeric gel. 
     
     
         16 . The mattress assembly of  claim 15 , wherein the elastomeric gel defines a plurality of interconnected walls defining an array of voids. 
     
     
         17 . The mattress assembly of  claim 12 , further comprising:
 a stabilizing material on at least one surface of the cushion.   
     
     
         18 . The mattress assembly of  claim 17 , comprising a lower layer of the stabilizing material on a bottom surface of the cushion. 
     
     
         19 . The mattress assembly of  claim 18 , further comprising:
 an upper layer of the stabilizing material on an upper surface of the elastomeric cushioning element.   
     
     
         20 . A method for assembling a mattress, comprising:
 providing a coil layer including an array of pocketed coils, a pocketed coil of the array of pocketed coils including:
 a coil; 
 a coil topper comprising a cushioning material over the coil; and 
 a casing packaging the coil and the coil topper together; and 
   placing a cushion that comprises an elastomeric material defining a plurality of interconnected walls defining an array of voids over the array of pocketed coils of the coil layer and on the coil layer.   
     
     
         21 . The method of  claim 20 , wherein placing the cushion on the coil layer comprises placing a stabilizing material on a bottom surface of the cushion directly against the coil layer or placing the elastomeric material of the cushion seeping through the stabilizing material directly against the coil layer. 
     
     
         22 . The method of  claim 20 , wherein providing the coil layer comprises providing a coil layer with the coil topper of the pocketed coil comprising a foam. 
     
     
         23 . The method of  claim 20 , wherein providing the coil layer comprises providing a coil layer with the coil topper of the pocketed coil comprising an elastomeric gel.