US2023309708A1PendingUtilityA1

Hybrid mattress core assemblies

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Assignee: DREAMWELL LTDPriority: Mar 31, 2022Filed: Mar 31, 2022Published: Oct 5, 2023
Est. expiryMar 31, 2042(~15.7 yrs left)· nominal 20-yr term from priority
Inventors:Dishant Purani
A47C 27/22A47C 27/121A47C 27/15A47C 27/127A47C 27/148A47C 27/122
52
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Claims

Abstract

Mattress assemblies including a hybrid mattress core assembly having a bilayer structure including a fiber layer laminated to a foam layer. Also disclosed are mattress assemblies including a hybrid mattress core assembly having a trilayer structure including a fiber layer sandwiched between first and second foam layers.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A one-sided mattress assembly, comprising:
 a mattress core comprising a bilayer laminate structure consisting of a foam layer and a fiber layer, wherein the foam layer is defined by one or multiple stackedly arranged foam layers and wherein the fiber layer is defined by one or multiple stackedly arranged fiber layers, wherein the mattress core is oriented such that the foam layer is proximate to a sleeping surface of the mattress assembly and the fiber layer is distally located to the sleeping surface.   
     
     
         2 . The one-sided mattress assembly of  claim 1 , wherein the fiber layer comprises polyester fibers and recycled polyester fibers. 
     
     
         3 . The one-sided mattress assembly of  claim 1 , wherein the fiber layer comprises vertically oriented fibers. 
     
     
         4 . The one-sided mattress assembly of  claim 1  further comprising a side rail assembly disposed about at least a portion of a perimeter of the mattress core, wherein the side rail assembly is configured with a greater firmness than the mattress core. 
     
     
         5 . The one-sided mattress assembly of  claim 4 , wherein the side rail assembly has a planar top surface coplanar to a top planar surface of the mattress core. 
     
     
         6 . The one-sided mattress assembly of  claim 1 , wherein the fiber layer has an indention load deflection within a range of about 30 pounds force to 60 pounds force. 
     
     
         7 . The one-sided mattress assembly of  claim 1 , wherein the foam layer defined by multiple stackedly arranged foam layers comprise different properties. 
     
     
         8 . The one-sided mattress assembly of  claim 1 , wherein the foam layer defined by multiple stackedly arranged foam layers comprise different materials. 
     
     
         9 . The one-sided mattress assembly of  claim 1 , wherein the foam layer defined by multiple stackedly arranged foam layers comprises a viscoelastic foam layer proximate to the sleeping surface. 
     
     
         10 . A two-sided mattress assembly, comprising:
 a mattress core comprising a trilayer laminate structure consisting of a fiber layer sandwiched between first and second foam layers, wherein the fiber layer is defined by one or multiple stackedly arranged fiber layers, wherein the first foam layer is defined by one or multiple stackedly arranged foam layers, and wherein the second foam layer is defined by one or multiple stackedly arranged foam layers.   
     
     
         11 . The two-sided mattress assembly of  claim 10 , wherein the fiber layer comprises polyester fibers and recycled polyester fibers. 
     
     
         12 . The two-sided mattress assembly of  claim 10 , wherein the fiber layer comprises vertically oriented fibers. 
     
     
         13 . The two-sided mattress assembly of  claim 10  further comprising a side rail assembly disposed about at least a portion of a perimeter of the mattress core, wherein the side rail assembly is configured with a greater firmness than the mattress core. 
     
     
         14 . The two-sided mattress assembly of  claim 13 , wherein the side rail assembly has a planar top surface coplanar to a top planar surface of the mattress core. 
     
     
         15 . The two-sided mattress assembly of  claim 10 , wherein the fiber layer has an indention load deflection within a range of about 30 pounds force to 60 pounds force. 
     
     
         16 . The two-sided mattress assembly of  claim 10 , wherein the foam layer defined by multiple stackedly arranged foam layers comprise different properties. 
     
     
         17 . The two-sided mattress assembly of  claim 10 , wherein the foam layer defined by multiple stackedly arranged foam layers comprise different materials. 
     
     
         18 . The two-sided mattress assembly of  claim 10 , wherein the foam layer defined by multiple stackedly arranged foam layers comprises a viscoelastic foam layer proximate to the sleeping surface. 
     
     
         20 . A mattress assembly comprising:
 a mattress core;   an upholstery layer overlaying the mattress core comprising a bilayer laminate structure consisting of a foam layer and a fiber layer, wherein the foam layer is proximately located to a sleeping surface of the mattress assembly and the fiber layer is distally located to the sleeping surface; and   a fabric ticking layer encapsulating the mattress core and the upholstery layer to form the mattress assembly.   
     
     
         21 . The mattress assembly of  claim 20 , wherein the foam layer comprises a viscoelastic foam. 
     
     
         22 . The mattress assembly of  claim 20 , wherein the fiber layer comprises a vertically oriented fiber.

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