Mattresses including spacer fabric and related methods
AssigneePurple Innovation, LLC
InventorsShawn David Moon, Lars C. Hamilton, Tanner R. Wheadon
Life of this patent
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Abstract
A mattress assembly includes a base core layer and an inner core located over the base core layer. The inner core includes coil springs. The mattress assembly also includes a side panel assembly located around a perimeter of the inner core. The side panel assembly includes a spacer fabric located over and transverse to the base core layer. The spacer fabric includes a first knit layer, a second knit layer, and an inner fibrous material located therebetween. Methods of forming the mattress assembly are disclosed.
Claims15
A mattress assembly, comprising
- a base core layer;
- an inner core located over the base core layer, the inner core comprising coil springs;
- and
- a side panel assembly located around at least a portion of a perimeter of the inner core, the side panel assembly comprising a spacer fabric located over and extending transverse to the base core layer, wherein the spacer fabric comprises a first knit layer, a second knit layer, and an inner fibrous material located therebetween, the first knit layer and the second knit layer having a greater elasticity along a vertical axis of the side panel assembly relative to an elasticity along a lateral axis of the side panel assembly, transverse to the vertical axis.
A mattress assembly, comprising:
- a base core layer;
- an inner core located over the base core layer, the inner core comprising at least one coil spring;
- and
- a side panel assembly located around at least a portion of a lateral perimeter of the inner core, the side panel assembly comprising a spacer fabric including:
- a first knit layer comprising at least one of a knit, a cloth, or a polymeric film and having a greater elasticity along a vertical axis of the side panel assembly relative to an elasticity along a lateral axis of the side panel assembly, transverse to the vertical axis;
- a second knit layer comprising at least one of a knit, a cloth, or a polymeric film and having a greater elasticity along a vertical axis of the side panel assembly relative to an elasticity along a lateral axis of the side panel assembly, transverse to the vertical axis;
- and
- an inner fibrous material comprising extruded woven fibers between the first knit layer and the second knit layer.
A method of forming a mattress assembly, comprising:
- providing a base core layer as a substrate for a mattress;
- disposing a plurality of coil springs positioned within individual casings in an inner core located over the base core layer;
- disposing an upper foam layer over the inner core;
- disposing at least one elastomeric cushion member over the upper foam layer;
- disposing a spacer fabric around at least a portion of a perimeter of the inner core, including abutting a lower surface of the spacer fabric against an upper surface of the base core layer and abutting an upper surface of the spacer fabric against a lower surface of the upper foam layer, a thickness of the spacer fabric being substantially equal to a distance that each of the base core layer, the spacer fabric, the upper foam layer, and the at least one elastomeric cushion member extend beyond the inner core, the spacer fabric defining at least a portion of a side panel assembly of the mattress, the spacer fabric comprising a first knit layer, a second knit layer, and an inner fibrous material located therebetween, the first knit layer and the second knit layer exhibiting a first compressibility along a vertical axis of the mattress having a relatively greater compressibility than that of a second compressibility along a first horizontal axis of the mattress, transverse to the vertical axis, and a third compressibility along a second horizontal axis of the mattress, transverse to the vertical axis and the first horizontal axis.
Dependencies are inferred from the claim text.