Mattress assembly with high airflow

Abstract

Mattress assemblies that provide user comfort and increased airflow generally include multilayered foams having open celled structures. Viscoelastic foams can be utilized having intact windows between adjacent cells of less than 50 percent.

1 . A mattress assembly, comprising:
 a non-viscoelastic first foam layer comprising planar top and bottom surfaces;   a second foam layer overlaying top planar surface of the first foam layer, the second foam layer comprising a pre-stressed foam having planar top and bottom surfaces; and   a viscoelastic third foam layer overlaying the top planar surface of the second foam layer, the second foam layer comprising planar top and bottom, wherein the viscoelastic third foam layer is the uppermost layer of the mattress assembly.   
     
     
         2 . The mattress assembly of  claim 1 , wherein the viscoelastic third foam layer has intact windows between adjacent cells of less than 50 percent. 
     
     
         3 . The mattress assembly of  claim 1 , wherein the non-viscoelastic first foam layer is an open celled polyurethane foam. 
     
     
         4 . The mattress assembly of  claim 1 , wherein the non-viscoelastic first foam layer has a thickness of 4 to 10 inches, a hardness of 20 to 40 pounds-force, and a density of 1 to 5 lb/ft 3 ; the second pre-stressed foam layer has a thickness of 0.5 to 1 inch, a hardness of 10 to 30 pounds-force, and a density of 0.5 to 2.5 lb/ft 3 ; and the viscoelastic third foam layer has a thickness of 0.5 to 3 inches, a hardness of 5 to 15 pounds-force, and a density of 1 to 3 lb/ft 3 . 
     
     
         5 . The mattress assembly of  claim 1 , wherein the non-viscoelastic first foam layer has a thickness of 6.5 inches, a hardness of 32-35 pounds-force, and a density of 1.65 lb/ft 3 ; the second pre-stressed foam layer has a thickness of 1.5 inches, a hardness of 22 pounds-force, and a density of 1.5 lb/ft 3 ; and the viscoelastic third foam layer has a thickness of 1 to 2 inches, a hardness of 12 pounds-force, and a density of 2.5 lb/ft 3 . 
     
     
         6 . The mattress assembly of  claim 1 , further comprising a side rail assembly formed of open cell polyurethane foam. 
     
     
         7 . The mattress assembly of  claim 1 , further comprising a fabric layer about a perimeter to the mattress assembly, wherein at least a portion of the fabric layer is formed of a spacer fabric. 
     
     
         8 . A mattress assembly, comprising:
 a non-viscoelastic first foam layer having top and bottom planar surfaces;   a non-viscoelastic second foam layer overlaying the top planar surface of the non-viscoelastic first foam layer having planar top and bottom surfaces;   a viscoelastic third foam layer overlaying the top planar surface of the second foam layer having planar top and bottom surfaces; and   a viscoelastic fourth foam layer overlaying the top planar surface of the third foam layer, wherein the fourth foam layer is the uppermost layer of the mattress assembly.   
     
     
         9 . The mattress assembly of  claim 8 , wherein the viscoelastic third and fourth foam layer have intact windows between adjacent cells of less than 50 percent. 
     
     
         10 . The mattress assembly of  claim 8 , wherein the non-viscoelastic first and second foam layers are an open celled polyurethane foam. 
     
     
         11 . The mattress assembly of  claim 8 , wherein the non-viscoelastic first foam layer has a thickness of 4 to 10 inches, a hardness of 20 to 40 pounds-force, and a density of 1 to 5 lb/ft 3 ; the non-viscoelastic second foam layer has a thickness of 0.5 to 1 inch, a hardness of 10 to 15 pounds-force, and a density of 1 to 4 lb/ft 3 ; the viscoelastic third foam layer has a thickness of 0.5 to 1 inches, a hardness of 10 to 15 pounds-force, and a density of 1 to 3 lb/ft 3 ; and the viscoelastic fourth layer has a thickness of 0.5 to 2 inches, a hardness of 10 to 15 pounds-force, and a density of 1 to 3.5 lb/ft 3 . 
     
     
         12 . The mattress assembly of  claim 8 , wherein the non-viscoelastic first foam layer has a thickness of 6.5 inches, a hardness of 24 pounds-force, and a density of 1.65 lb/ft 3 ; the non-viscoelastic second foam layer has a thickness of 1 inch, a hardness of 12 pounds-force, and a density of 3 lb/ft 3 ; the viscoelastic third foam layer has a thickness of 1 inch, a hardness of 12 pounds-force, and a density of 2.5 lb/ft 3 ; and the viscoelastic fourth layer has a thickness of 1.5 inches, a hardness of 12 pounds-force, and a density of 2.5 lb/ft 3 . 
     
     
         13 . The mattress assembly of  claim 8 , further comprising a side rail assembly formed of open cell polyurethane foam. 
     
     
         14 . The mattress assembly of  claim 8 , further comprising a fabric layer about a perimeter to the mattress assembly, wherein at least a portion of the fabric layer is formed of a spacer fabric. 
     
     
         15 . A mattress assembly, comprising:
 a non-viscoelastic first foam layer having planar top and bottom surfaces;   a non-viscoelastic second foam layer overlaying the top planar surface of the first foam layer having planar top and bottom surfaces;   a viscoelastic foam third layer overlaying the top planar surface of the second foam layer having planar top and bottom surfaces; and   a gel infused viscoelastic fourth foam layer overlaying the top planar surface of the third foam layer having equal to or less than 50 percent by weight gel loading; and   a viscoelastic fifth foam layer overlaying the top planar surface of the fourth foam layer, wherein the fifth foam layer is the uppermost layer of the mattress assembly.   
     
     
         16 . The mattress assembly of  claim 15 , wherein the viscoelastic third, fourth and fifth foam layers have intact windows between adjacent cells of less than 50 percent. 
     
     
         17 . The mattress assembly of  claim 15 , wherein the non-viscoelastic first and second foam layers are an open celled polyurethane foam. 
     
     
         18 . The mattress assembly of  claim 15 , wherein the non-viscoelastic first foam layer has a thickness of 4 to 10 inches, a hardness of 20 to 40 pounds-force, and a density of 1 to 5 lb/ft 3 ; the non-viscoelastic second foam layer has a thickness of 0.5 to 1 inch, a hardness of 10 to 15 pounds-force, and a density of 1 to 4 lb/ft 3 ; the viscoelastic third foam layer has a thickness of 1 to 3 inches, a hardness of 10 to 15 pounds-force, and a density of 1 to 4 lb/ft 3 ; the gel infused viscoelastic fourth foam layer has a thickness of 1 to 2 inches, a hardness of 10 to 15 pounds-force, and a density of 3 to 6 lb/ft 3 ; and the viscoelastic fifth layer has a thickness of 0.5 to 2 inches, a hardness of 10 to 15 pounds-force, and a density of 1 to 3.5 lb/ft 3 . 
     
     
         19 . The mattress assembly of  claim 15 , wherein the non-viscoelastic first foam layer has a thickness of 6.5 inches, a hardness of 24 pounds-force, and a density of 1.65 lb/ft 3 ; the non-viscoelastic second foam layer has a thickness of 0.5 inch, a hardness of 12 pounds-force, and a density of 3 lb/ft 3 ; the viscoelastic third foam layer has a thickness of 1.5 inches, a hardness of 12 pounds-force, and a density of 2.5 lb/ft 3 ; the gel infused viscoelastic fourth foam layer has a thickness of 1 inch, a hardness of 11 pounds-force, and a density of 4.5 lb/ft 3 ; and the viscoelastic fifth layer has a thickness of 1.5 inches, a hardness of 11 pounds-force, and a density of 2.5 lb/ft 3 . 
     
     
         20 . The mattress assembly of  claim 15 , further comprising a side rail assembly formed of open cell polyurethane foam. 
     
     
         21 . The mattress assembly of  claim 15 , further comprising a fabric layer about a perimeter to the mattress assembly, wherein at least a portion of the fabric layer is formed of a spacer fabric. 
     
     
         22 . The mattress assembly of  claim 15 , wherein the gel infused viscoelastic fourth foam layer further comprises activated carbon. 
     
     
         23 . The mattress assembly of  claim 15 , wherein the non-viscoelastic first foam layer has a thickness of 8 inches, a hardness of 24 pounds-force, and a density of 1.65 lb/ft 3 ; the non-viscoelastic second foam layer has a thickness of 0.5 inch, a hardness of 12 pounds-force, and a density of 3 lb/ft 3 ; the viscoelastic third foam layer has a thickness of 1.5 inches, a hardness of 12 pounds-force, and a density of 3.5 lb/ft 3 ; the gel infused viscoelastic fourth foam layer has a thickness of 1.5 inches, a hardness of 11 pounds-force, and a density of 4.5 lb/ft 3 ; and the viscoelastic fifth layer has a thickness of 1.5 inches, a hardness of 11 pounds-force, and a density of 3.5 lb/ft 3 .