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.

Description

PRIORITY APPLICATION[0001]The present application claims priority to U.S. Patent Application Ser. No. 61 / 724,556 filed on Nov. 9, 2012 entitled “All-foam Mattress Assemblies With Foam Engineered Cores Having Thermoplastic and Thermoset Materials, And Related Assemblies And Methods,” which is incorporated herein by reference in its entirety.RELATED APPLICATIONS[0002]This application is related to U.S. patent application Ser. No. 13 / 630,435, filed on Sep. 28, 2012, entitled “Cellular Mattress Assemblies and Related Methods,” which claims priority to U.S. Provisional Patent Application Ser. No. 61 / 541,434 filed on Sep. 30, 2011, entitled “Cellular Mattress Assemblies and Related Methods,” both of which are incorporated herein by reference in their entireties.[0003]This application is related to U.S. patent application Ser. No. 13 / 458,239, filed on Apr. 27, 2012, entitled “Unitary Composite / Hybrid Cushioning Structure(s) And Profile(s) Comprised Of A Thermoplastic Foam(s) And A Thermose...

AI Technical Summary

Benefits of technology

This patent is about creating mattresses using foam materials that provide cushioning and support for users. The foam can be engineered to have a reduced density compared to traditional foam mattresses, and can be made from thermoset and thermoplastic materials. The engineered foam provides similar cushioning and support as a solid thermoset layer but with a reduced weight. The technical effect is to create a mattress with improved comfort and durability that is lighter than traditional foam mattresses.

Problems solved by technology

A queen-size innerspring mattress may weigh more than sixty-five (65) pounds due to the various components required to deliver the high and low stiffness performance.

In manufacturing of a mattress, one person generally can no longer easily lift a mattress.

It is also becoming more difficult for a homemaker to make a bed given the mattress thickness and heavier weight.

Mattresses generally also require rotating and / or flipping the mattress on a regular basis and this is difficult for even two people to accomplish.

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