# US 12,004,654 B2 · Compressible mattress

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- Number: US 12,004,654 B2
- Document ID: US12004654B2
- Status: Granted
- Kind: B2
- Application number: 17/340,187
- Filed: 2021-06-07
- Published: 2022-03-03
- Granted: 2024-06-11
- Earliest claimed: 2020-08-27
- Assignees: Dreamwell, Ltd.
- Applicants: Dreamwell, Ltd.
- Inventors: Richard F. Gladney; Robert Hellyer; Christopher Chunglo
- Web page: https://patentgrep.com/patent/US12004654B2

## CPC

- A47C 27/056: {with different layers of foamed material}
- A47C 21/046: {without active means, e.g. with openings or heat conductors}
- A47C 27/064: {Pocketed springs}
- A47C 27/148: {of different resilience}
- A47C 27/15: consisting of two or more layers (A47C27/16 takes precedence)
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 2266/0278: Polyurethane
- A47C: CHAIRS; SOFAS; BEDS
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

Compressible mattress assemblies for bed in a box applications generally include a first foam layer and a second foam layer, wherein the first foam layer has a thickness less than the second foam layer and has a property and/or a foam material that is different from the second foam layer. In other embodiments, the compressible mattress assemblies consist of a pocketed microcoil array intermediate the first and second polymeric foam layers.

## Claims

### Claim 1

A compressible mattress assembly for a bed in a box application, the compressible mattress assembly including a length and a width dimension, wherein the length is greater than the width, comprises:
a first foam layer;
a second foam layer underlying the first foam layer; and
a topper layer overlying the first foam layer;
wherein the first foam layer has a thickness greater than the second foam layer, a higher indention load deflection, and further comprises side rails extending only along a length on each side thereof,
wherein the side rails comprise a compressible foam having an indention force deflection greater than the indention load deflection of the first foam layer, and wherein the first foam layer and the side rails have a length and a width dimension substantially equal to a length and a width dimension of the second foam layer, and wherein the side rails are adhesively affixed to a top surface of the second foam layer and to a bottom surface of the topper layer such that vertical surfaces intermediate the side rail and the first foam layer are free from adhesive, wherein the compressible mattress is configured to be folded and rolled for packaging in a box and wherein the side rails do not bind when removed from the box and decompressed.

### Claim 2 (depends on 1)

The compressible mattress assembly of claim 1, wherein the first foam layer is a viscoelastic foam and the second foam layer is a non-viscoelastic foam.

### Claim 3 (depends on 1)

The compressible mattress assembly of claim 1, wherein the first foam layer is a non-viscoelastic foam and the second foam layer is a viscoelastic foam.

### Claim 4 (depends on 1)

The compressible mattress assembly of claim 1, wherein the first foam layer is a polyurethane foam and the second foam layer is a foam other than the polyurethane foam.

### Claim 5 (depends on 4)

The compressible mattress assembly of claim 4, wherein the indention load deflection of the first and second foam layers are within a range of 7 to 22 pounds force for viscoelastic foams and 7 to 55 pounds force for non-viscoelastic foams.

### Claim 6 (depends on 1)

The compressible mattress assembly of claim 1, wherein the second foam layer is a polyurethane foam and the first foam layer is a foam other than the polyurethane foam.

### Claim 7 (depends on 1)

The compressible mattress assembly of claim 1, wherein the second layer is about 5 percent to about 40 percent of an overall thickness of the mattress assembly.

### Claim 8 (depends on 1)

The compressible mattress assembly of claim 1, wherein a selected one of the first and second foam layers comprises a phase change material on or proximate to at least a surface thereof.

### Claim 9 (depends on 1)

The compressible mattress assembly of claim 1, wherein a selected one of the first and second foam layers comprises a thermally conductive material in and proximate to at least a surface thereof.

### Claim 10 (depends on 1)

The compressible mattress assembly of claim 1, wherein the indention force deflection for the side rails is within a range of 30 to 70 pounds force.

### Claim 11 (depends on 1)

The compressible mattress assembly of claim 1 further comprising a fabric covering encapsulating the first and second foam layers, and the side rails are adhesively affixed to portions thereof.

### Claim 12

A compressible mattress assembly for a bed in a box application, the compressible mattress assembly comprising:
a foam topper layer;
a first foam layer underlying the foam topper layer,
a second foam layer underlying the first foam layer, and
a fabric covering encapsulating the first and second foam layers, wherein a selected one of the first and second foam layers comprises a thermally conductive material and/or a phase change material in and proximate to at least a surface thereof,
wherein the first foam layer comprises compressible foam side rails extending only along a length on each side thereof, wherein the first foam layer and the side rails have a length and a width dimension substantially equal to a length and a width dimension of the second foam layer and the foam topper layer, wherein the side rails are adhesively affixed only to a top surface of the second foam layer and to a bottom surface of the topper layer such that vertical surfaces intermediate the side rail and the first foam layer are free from adhesive, and
wherein the first foam layer has a thickness greater than the second foam layer and an indention load deflection less than the second layer, and wherein the side rails have an indention force deflection greater than the indention load deflection of the first foam layer, wherein the compressible mattress is configured to be folded and rolled for packaging in a box and wherein the side rails do not bind when removed from the box and.

### Claim 13 (depends on 12)

The compressible mattress assembly of claim 12, wherein the fabric covering is adhesively affixed to portions of the topper layer, the first foam layer, the second foam layer, and the siderails.

### Claim 14 (depends on 12)

The compressible mattress assembly of claim 12, wherein the indention load deflection for the first foam layer, the second foam layer, and the siderails is within a range from 7 to 16 pounds force for viscoelastic foams and 7 to 45 pounds force for non-viscoelastic foams.

### Claim 15 (depends on 12)

The compressible mattress assembly of claim 12, wherein the first foam layer, the side rails, and the second foam layer are viscoelastic foams.

### Claim 16 (depends on 12)

The compressible mattress assembly of claim 12, wherein the first foam layer, the side rails, and the second foam layer are non-viscoelastic foams.

### Claim 17 (depends on 12)

The compressible mattress assembly of claim 12, wherein the second foam layer is about 5 percent to about 40 percent of an overall thickness of the mattress assembly.

### Claim 18 (depends on 12)

The compressible mattress assembly of claim 12, wherein the indention force deflection for the side rails is within a range of 30 to 70 pounds force.