Foam mattress assembly with increased airflow and independent suspension

Abstract

Mattress assemblies that provide user comfort via independent suspension and increased airflow generally include a first foam layer; a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about similar lengths from the floor; and a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly. In some embodiments, the first foam layer further includes a plurality of channels extending from a top planar surface to a bottom planar surface.

1 . A mattress assembly comprising:
 a first foam layer;   a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about similar lengths from the floor; and   a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly.   
     
     
         2 . The mattress assembly of  claim 1 , wherein the first, second and third foam layers comprise natural latex foam. 
     
     
         3 . The mattress assembly of  claim 1 , wherein the first foam layer has a density equal to or less than 4 lb/ft 3  and a hardness equal to or less than about 30 pounds-force. 
     
     
         4 . The mattress assembly of  claim 1 , wherein the spaced apart support structures comprises a truncated cone. 
     
     
         5 . The mattress assembly of  claim 1 , wherein the first foam layer is at a thickness within a range of 4 inches to 10 inches; the second foam layer is at a thickness within a range of 1 inch to 4 inches; and the third foam layer is at a thickness within a range of 0.5 to 2 inches. 
     
     
         6 . The mattress assembly of  claim 1 , wherein the first foam layer has a density within a range of 1 pound per cubic foot (lb/ft 3 ) to 6 lb/ft 3  and a hardness within a range of 20 to 40 pounds-force; the second foam layer has a density within a range of 2 to 6 lb/ft 3  and a hardness within a range of 10 to 20 pounds-force; and the third layer has a density within a range of 1 to 5 lb/ft 3  and hardness within a range of 10 to 20 pounds-force. 
     
     
         7 . The mattress assembly of  claim 1 , further comprising a foam side rail assembly disposed about a perimeter of the first, second and third foam layers, wherein the side rail assembly has a thickness about equal a total thickness of the first, second and third layers. 
     
     
         8 . The mattress assembly of  claim 7 , wherein the side rail assembly is formed of natural latex foam. 
     
     
         9 . The mattress assembly of  claim 1 , wherein the first foam layer includes planar top and bottom surfaces, and a plurality of channels extending from the planar top surface to the planar bottom surface. 
     
     
         10 . The mattress assembly of  claim 1 , wherein the second foam layer comprises a recessed portion defining a perimeter wall about the floor and the upright support structures. 
     
     
         11 . The mattress assembly of  claim 1 , further comprising a spacer fabric about a perimeter of the first, second and third foam layers. 
     
     
         12 . The mattress assembly of  claim 1 , further comprising a spacer fabric overlaying the third foam layer and extending about a perimeter of the first, second and third foam layers. 
     
     
         13 . The mattress assembly of  claim 1 , wherein the upright support structures are oriented to face a user resting on the mattress assembly. 
     
     
         14 . A mattress assembly, comprising:
 a latex first foam layer having planar top and bottom surfaces;   a latex second foam layer overlaying the latex first foam layer, the second foam layer comprising a planar bottom surface and a top surface configured with a recessed portion defining a perimeter wall, and a plurality of upright foam support structures extending from a floor of the recessed portion to a height substantially equal to that of the perimeter wall, wherein the upright foam support structures comprise a truncated cone shape to provide motion separation to a user of the mattress assembly during use thereof; and   a latex third foam layer having top and bottom planar surfaces overlaying the second foam layer, the third foam layer.   
     
     
         15 . The mattress assembly of  claim 14 , wherein the latex first foam layer further comprises a plurality of open channels extending from the top planar surface to the bottom planar surface. 
     
     
         16 . The mattress assembly of  claim 14 , further comprising a side rail assembly formed of a latex material comprising one or more layers disposed about a perimeter of the first, second, and third foam layers. 
     
     
         17 . The mattress assembly of  claim 14 , wherein the layers defining the side rail assembly and the latex first foam layer are pre-stressed. 
     
     
         18 . The mattress assembly of  claim 14 , wherein the upright foam support structures comprise a truncated cone shape to provide motion separation to a user of the mattress assembly during use thereof 
     
     
         19 . The mattress assembly of  claim 14 , wherein the first foam layer further comprises a plurality of channels extending from the planar top surface to the planar bottom surface. 
     
     
         20 . The mattress assembly of  claim 14 , further comprising a spacer fabric overlaying the third foam layer and extending about a perimeter of the first, second and third foam layers. 
     
     
         21 . A mattress assembly comprising:
 a first foam layer comprising top and bottom planar surfaces, the first foam layer further comprising a plurality of channels extending from the top to the bottom planar surfaces;   a second foam layer configured with an independent response system overlaying the first foam layer, wherein the second foam layer comprises a floor and a plurality of spaced apart support structures extending at about equal lengths from the floor; and   a third foam layer overlaying the second foam layer having a planar top surface facing a user resting on the mattress assembly.   
     
     
         22 . The mattress assembly of  claim 21 , wherein the plurality of channels are at a density of about 100 to about 800 open channels per square foot. 
     
     
         23 . The mattress assembly of  claim 21 , wherein each one of the plurality of channels has circularly shaped cross section. 
     
     
         24 . The mattress assembly of  claim 21 , the first, second and third foam layers comprise natural latex foam. 
     
     
         25 . The mattress assembly of  claim 21 , wherein the spaced apart support structures comprises truncated cones. 
     
     
         26 . The mattress assembly of  claim 21 , wherein the first foam layer is at a thickness within a range of 4 inches to 10 inches; the second foam layer is at a thickness within a range of 1 inch to 4 inches; and the third foam layer is at a thickness within a range of 0.5 to 2 inches. 
     
     
         28 . The mattress assembly of  claim 21 , further comprising a foam side rail assembly disposed about a perimeter of the first, second and third foam layers, wherein the side rail assembly has a thickness about equal a total thickness of the first, second and third layers. 
     
     
         29 . The mattress assembly of  claim 28 , wherein the side rail assembly is formed of natural latex foam. 
     
     
         30 . The mattress assembly of  claim 21 , further comprising a spacer fabric about a perimeter of the first, second and third foam layers. 
     
     
         31 . The mattress assembly of  claim 30 , further comprising a spacer fabric overlaying the third foam layer and extending about a perimeter of the first, second and third foam layers. 
     
     
         32 . The mattress assembly of  claim 21 , wherein the upright support structures are oriented to face a user resting on the mattress assembly.