Elastomeric grid including discrete cushioning elements

Abstract

The present application relates to a thermoplastic elastomer grid for use in a mattress assembly. The thermoplastic elastomeric grid can be designed to provide lateral stability utilizing a simple structure. The thermoplastic elastomer grid may include a first zone with first and second cushion elements, a second zone with third and fourth cushion elements, and a third zone with fifth and sixth cushion elements. In certain examples, the first, second, and third zones may be configured to respectively support a head/should region, a hip region, and a leg region of a human body.

What is claimed is: 
     
         1 . A mattress assembly, comprising:
 a base having a base surface;   a support layer having a first support surface and a second support surface, the support layer extending across the base surface such that the first support surface of the support layer interfaces with the base surface of the base;   an elastomeric layer, including:
 a flex foam panel defining a plurality of cut out portions; and 
 a plurality of individual cushion elements each being disposed respectively within a cut out portion of the plurality of cut out portions of the flex foam panel, wherein the second support surface of the support layer interfaces with the elastomeric layer, wherein the elastomeric layer comprises a composition that includes graphene; 
   a memory foam layer having a first surface and a second surface, the memory foam layer extending across the elastomeric layer such that the first surface of the memory foam layer interfaces with the elastomeric layer; and   a cover having a cover surface that interfaces with the second surface of the memory foam layer, wherein the cover attaches to the base.   
     
     
         2 . The mattress assembly of  claim 1 , wherein the memory foam layer is connected to the elastomeric layer by adhesive. 
     
     
         3 . The mattress assembly of  claim 1 , wherein the support layer is connected directly to the elastomeric layer by adhesive. 
     
     
         4 . The mattress assembly of  claim 1 , wherein the plurality of individual cushion elements are isolated from each other in the flex foam panel. 
     
     
         5 . The mattress assembly of  claim 1 , wherein the plurality of cut out portions are formed to match a size and shape of the plurality of individual cushion elements. 
     
     
         6 . The mattress assembly of  claim 1 , wherein the mattress does not include a fabric layer. 
     
     
         7 . A graphite thermoplastic elastomer grid, comprising:
 a first zone including first and second cushion elements;   a second zone including third and fourth cushion elements; and   a third zone including fifth and sixth cushion elements;   wherein the first, second, third, fourth, fifth, and sixth cushion elements each includes two major sides extending parallel to one another, wherein the two major sides of the respective first, second, third, fourth, fifth, and sixth cushion elements are interconnected by two minor sides, extending parallel to one another.   
     
     
         8 . The graphite thermoplastic elastomer grid of  claim 7 , further comprising a fabric that extends across the graphite thermoplastic elastomer grid. 
     
     
         9 . The graphite thermoplastic elastomer grid of  claim 8 , wherein the fabric is attached to the graphite thermoplastic elastomer grid by an adhesive. 
     
     
         10 . The graphite thermoplastic elastomer grid of  claim 7 , wherein the graphite thermoplastic elastomer grid has a hardness on the Shore A scale of less than 35. 
     
     
         11 . The graphite thermoplastic elastomer grid of  claim 10 , wherein the first, second, and third zones of the graphite thermoplastic elastomer grid each includes a different hardness on the Shore A scale. 
     
     
         12 . The graphite thermoplastic elastomer grid of  claim 7 , wherein the first and second cushion elements in the first zone are attached together at a respective one of the two minor sides thereof, the third and fourth cushion elements in the second zone are attached together at a respective one of the two minor sides thereof, and the fifth and sixth cushion elements in the third zone are attached together at a respective one of the two minor sides thereof. 
     
     
         13 . The graphite thermoplastic elastomer grid of  claim 7 , wherein the first and third cushion elements are attached together at a respective one of the two major sides thereof, the third and fifth cushion elements are attached together at a respective one of the two major sides thereof, the second and fourth cushion elements are attached together at a respective one of the two major sides thereof, and the fourth and sixth cushion elements are attached together at a respective one of the two major sides thereof. 
     
     
         14 . A mattress assembly, comprising:
 a base layer having a base surface;   a support layer having a first support surface and a second support surface, the support layer extending across the base surface such that the first support surface of the support layer interfaces with the base surface of the base layer;   a gel layer having a first gel surface and a second gel surface, the gel layer extending across the support layer such that the first gel surface of the gel layer interfaces with the second support surface of the support layer;   an adaptive foam layer having a first foam surface and a second foam surface, the adaptive foam layer extending across the gel layer such that the first foam surface of the adaptive foam layer interfaces with the second gel surface of the gel layer; and   an elastomeric layer, including:
 a flex foam encasement; 
 a first thermoplastic elastomer grid zone including first and second cushion elements configured to attach together; 
 a second thermoplastic elastomer grid zone including third and fourth cushion elements configured to attach together; and 
 a third thermoplastic elastomer grid zone including fifth and sixth cushion elements configured to attach together, wherein the flex foam encasement provides a perimeter around the first, second and third thermoplastic elastomer grid zones; 
 wherein the elastomeric layer extends across the adaptive foam layer such that a first surface of the elastomeric layer interfaces with the second foam surface of the adaptive foam layer; and 
 wherein the first, second and third thermoplastic elastomer grid zones of the elastomeric layer comprises a composition that includes graphene. 
   
     
     
         15 . The mattress assembly of  claim 14 , wherein the flex foam encasement is formed by a plurality of flex foam encasement parts. 
     
     
         16 . The mattress assembly of  claim 14 , wherein the flex foam encasement and the first, second, third, fourth, fifth, and sixth cushion elements each have the same height. 
     
     
         17 . The mattress assembly of  claim 14 , wherein the first, second, third thermoplastic elastomer grid zones extend laterally across the center opening of the flex foam encasement. 
     
     
         18 . The mattress assembly of  claim 14 , wherein the first, second, and third thermoplastic elastomer grid zones of the elastomeric layer each includes different material compositions. 
     
     
         19 . The mattress assembly of  claim 14 , further comprising a spring layer between the gel layer and the support layer, wherein the spring layer includes a plurality of coils each individually pocketed in casings made of non-woven bags. 
     
     
         20 . The mattress assembly of  claim 14 , further comprising a first divider separating the first and second thermoplastic elastomer grid zones of the elastomeric layer and a second divider separating the second and third thermoplastic elastomer grid zones of the elastomeric layer, wherein the first and second dividers are separate parts from the flex foam encasement. 
     
     
         21 . A mattress assembly, comprising:
 a first mattress cover having a cover surface;   a first support layer having a first support surface and a second support surface, the support layer extending across the cover surface such that the first support surface of the support layer interfaces with the cover surface of the base;   a spring layer including a plurality of coils each individually pocketed in casings made of non-woven bags, wherein the second support surface of the support layer interfaces with the spring layer;   a second support layer having a support surface that interfaces with the spring layer, wherein the support surface of the second support layer is connected directly to the spring layer by adhesive;   an elastomeric layer, including:
 a flex foam panel defining a plurality of cut out portions; and 
 a plurality of individual cushion elements each being disposed respectively within one of the plurality of cut out portions of the flex foam panel, wherein the second support layer is positioned between the elastomeric layer and the spring layer, wherein the elastomeric layer comprises a composition that includes graphene; 
   a memory foam layer having a first surface and a second surface, the memory foam layer extending across the elastomeric layer such that the first surface of the memory foam layer interfaces with the elastomeric layer; and   a second mattress cover having a cover surface that interfaces with the second surface of the memory foam layer, wherein the first mattress cover attaches to the second mattress cover.   
     
     
         22 . A mattress assembly including a tri-fold mattress, the mattress assembly comprising:
 a first segment, a second segment, and a third segment, the first, second, and third segments each including:
 an elastomeric layer that includes a flex foam panel defining a plurality of cut out portions and a plurality of individual cushion elements disposed respectively within a cut out portion of the plurality of cut out portions of the flex foam panel, the cut out portions and the plurality of individual cushion elements having the same shape; 
 a support layer; 
 a first mattress cover; and 
 a second mattress cover; 
   wherein the elastomeric layer, the support layer, and the first and second mattress covers are respectively concealed within the first, second, and third segments by a zip-fastener;   wherein the first, second, and third segments are connected together by a fabric cover; and   wherein the first, second, and third segments are pivotable and foldable along seams provided in the fabric cover of the mattress assembly.