MATTRESSES INCLUDING A ZONED CUSHIONING LAYER AND RELATED METHODS

[0001] The present disclosure relates generally to mattress assemblies and related methods. More particular, the present disclosure relates to mattress assemblies including a zoned cushioning layer and related methods.

[0009] Mattress assemblies are disclosed herein. In some embodiments, the mattress assemblies are multilayered assemblies that include a base layer, a coil layer, and a zoned cushioning layer. One or more additional layers can also be included depending on the mattress design and/or configuration. For example, in certain embodiments, the mattress assemblies include a base layer, a coil layer, a zoned cushioning layer, and one or more support and/or comfort layers. In a particular embodiment, the one or more support and/or comfort layers comprise one or more foam layers. These and other embodiments are further detailed below.

[0010] As set forth herein, embodiments may be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood by one of ordinary skill in the art having the benefit of this disclosure that the components of the embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the disclosure but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

[0011] It will be appreciated that various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. Many of these features may be used alone and/or in combination with one another.

[0012] The phrases “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be coupled to or in communication with each other even though they are not in direct contact with each other. For example, two components may be coupled to or in communication with each other through an intermediate component.

[0013] The phrase “elastomeric polymer” refers to a polymer capable of recovering or substantially recovering its original size and shape after deformation. In other words, an elastomeric polymer is a polymer having elastic or viscoelastic properties. Elastomeric polymers may also be referred to as “elastomers.” Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).

[0014] The phrase “elastomeric block copolymer” refers to an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B).

[0015] The phrase “elastomeric material” refers to elastomeric polymers and mixtures of elastomeric polymers with plasticizers and/or other materials. Elastomeric materials are elastic (i.e., capable of recovering size and shape after deformation). Elastomeric materials include, without limitation, materials referred to in the art as “elastomer gels,” “gelatinous elastomers,” or simply “gels.”

[0016] Any relational and/or directional term, such as “first,” “second,” “top,” “bottom” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise. For example, these terms may refer to an orientation of elements of a mattress when oriented for sleeping in a conventional manner. Furthermore, these terms may refer to an orientation of elements of a mattress assembly as illustrated in the drawings.

[0017] FIGS. 1-3 depict various views of a mattress assembly 100 according to an embodiment of the present disclosure. More particularly, FIG. 1 is a perspective view of the mattress assembly 100; FIG. 2 is a cut-away perspective view of the mattress assembly 100; and FIG. 3 is an exploded cross-sectional view of the mattress assembly 100.

[0018] As shown in the illustrated embodiment, the mattress assembly 100 includes a multilayered construction. For instance, the mattress assembly 100 includes a base layer 110, a coil layer 120, and a zoned cushioning layer 130. One or more additional layers can also be included depending on the mattress design and/or configuration. For example, in certain embodiments the mattress assemblies 100 include a base layer 110, a coil layer 120, a zoned cushioning layer 130, and one or more support and/or comfort layers 140, 150, 160. In particular embodiments, the one or more support and/or comfort layers 140, 150, 160 comprise one or more foam layers.

[0019] With continued reference to FIGS. 1-3, the base layer 110 is generally disposed on the bottom of the mattress assembly 100 and provides a base or foundation upon which the remaining layers are disposed. The base layer 110 can comprise various materials, including, but not limited to, a foam material such as a polyurethane foam or latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used. In some embodiments, the base layer 110 comprises a foam material (e.g., polyurethane foam) having a density of between about 1 lbs/ft³ and about 5 lbs/ft³, between about 1 lbs/ft³ and about 4 lbs/ft³, between about 1 lbs/ft³ and about 3 lbs/ft³, or between about 1 lbs/ft³ and about 2 lbs/ft³. The base layer 110 can also comprise an indentation load deflection (ILD) of between about 20 lbs and about 100 lbs, between about 30 lbs and about 70 lbs, or between about 40 lbs and about 60 lbs. As used herein, the indentation load deflection (ILD) is the amount of force (in pounds) required to indent the foam or layer a total of 25 percent of its original thickness. The thickness T₁ of the base layer 110 can also vary. In some embodiments, the base layer 110 comprises a thickness of between about 1 inch and about 18 inches, between about 1 inch and about 12 inches, between about 1 inch and about 5 inches, or between about 1 inch and about 3 inches. For instance, greater thicknesses can be used in instances in which the base layer 110 serves as a core layer and the mattress assembly 100 is devoid of a coil layer 120. In such embodiments, the zoned cushioning layer 130 can be disposed on the base layer 110.

[0020] The coil layer 120 is disposed on the base layer 110. As shown in FIGS. 2 and 3, the coil layer 120 can include a plurality of coils 122, each of which may be encased in at least one respective casing or cover 124. For example, each casing 124 may form a pocket for a respective coil 122. In such embodiments, the plurality of coils 122 may be referred to as a plurality of pocketed cods 122. In some embodiments, each coil 122 may include a relatively thin-gauge, barrel-shaped (e.g., helical-shaped), knotless coil. The coils 122 may comprise a metal material, such as steel. In other embodiments, the coils 122 are formed from a polymeric material such as a foam or gel. Further, in certain embodiments each coil 122 may be encased in multiple casings 124. For instance, each coil 122 may be double bagged or triple bagged. In some embodiments, the casings 124 may include a polypropylene material. Other materials can also be used. For instance, in some embodiments, the plurality of cons 122 are encased in a foam material, which may or may not include an additional casing 124.

[0021] As further illustrated, in some embodiments each casing 124 and each coil 122 of the plurality of cons 122 may be individual and discrete. In certain embodiments, the casings 124 of the plurality of coils 122 may be coupled or otherwise joined to one another. Further, each coil 122 of the plurality of cons 122 may extend longitudinally in a direction at least substantially orthogonal (i.e., normal) to an upper surface of the base layer 110. The plurality of cods 122 may be oriented next to each other in an array (e.g., rows and columns or a grid pattern) to form the coil layer 120. In other embodiments, the coil layer 120 does not comprise coils 122 that are individual and discrete units. Rather, the coil layer 120 can comprise a continuous wire unit, or coil or spring-like structures that are not barrel shaped. Any such innerspring units can be used in the coil layer 120. Further in particular embodiments, the coils 122 of the coil layer 120 are substituted with gel structures or air pockets that can function as the coil layer 120.

[0022] The number of coils 122 in the coil layer 120 can vary depending on the size and/or shape of the mattress assembly 100. The height or thickness T₂ of the coil layer 120 can also vary. In some embodiments, the coil layer 120 comprises a thickness of between about 4 inches and about 10 inches, or between about 5 inches and about 8 inches. Other thicknesses are also contemplated. For instance, coil layers 122 comprising other types of innerspring units, foam or gel coils, or air pockets can have a thickness T₂ that is less than about 5 inches, about 4 inches, about 3 inches, or about 2 inches.

[0023] The coil layer 120 can further comprise a rail or sidewall 126 extending around the plurality of coils 122 or innerspring units. For example, as shown in the illustrated embodiment, the sidewall 126 extends around a perimeter or periphery of the coil layer 120. The sidewall 126 can be configured to retain the coils 122 or innerspring units within a central region of the coil layer 120. In some embodiments, the sidewall 126 comprises a foam material, such as a polyurethane foam or a latex foam. The sidewall 126 can also comprise wood, metal, or other reinforcing members if desired. Other types of materials can also be used, including, but not limited to, foams and other forms of polyethylene, polypropylene, fiber, and/or latex. The thickness of the sidewall 126 can be substantially the same thickness as the coils 122 within the coil layer 120. The width W₂ of the sidewall 126 can be between about 1 inch and about 10 inches.

[0024] As previously discussed, the mattress assembly 100 further includes a zoned cushioning layer 130. This zoned cushioning layer 130 includes a plurality of individual or discrete regions or zones of cushioning members 132 so as to provide a zoned arrangement. As shown in the illustrated embodiment, the regions of cushioning members 132 extend laterally across the mattress assembly 100. The regions of cushioning members 132 are also spaced along a longitudinal length of the mattress assembly 100. Regions of a support material 134, such as a polyurethane foam or latex foam, are disposed between and around the regions of the cushioning members 132. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used as the support material 134. Flat foams or convoluted foams can be used. In some embodiments, the zoned cushioning layer 130 includes two or more regions of cushioning member 132. In further embodiments, the zoned cushioning layer 130 includes three or more regions of cushioning member 132. In yet further embodiments, the zoned cushioning layer 130 includes four or five or more regions of cushioning member 132.

[0025] In some embodiments, the regions of cushioning member 132 can be disposed at areas of which increased pressure or weight is expected to be applied from a subject during use of the mattress assembly 100. For instance, a first region of cushioning member 132a can be disposed in a hip region and a second region of cushioning member 132b can be disposed at a shoulder region. In some embodiments, a third region of cushioning member 132c can be disposed at a leg region. This is exemplified in FIG. 4, which depicts a subject 10 laying on the mattress assembly 100. As shown in FIG. 4, the subject's hips 12 are generally aligned within the first region of the cushioning member 132a, the subject's shoulders 14 are generally aligned within the second region of the cushioning member 132b, and a portion of the subject's lower legs 16 are generally aligned within the third region of the cushioning member 132c. Providing the cushioning members 132a, 132b, 132c in such areas can increase the comfort of the mattress assembly 100 as the hips, shoulders, and lower legs are known to exhibit increased pressure on the mattress assembly 100. In some embodiments, the regions of cushioning member 132 are symmetrically disposed along a longitudinal length of the mattress assembly 100. In such embodiments, the mattress assembly 100 can be rotated 180 degrees such that the subject's shoulders 14 generally align with the third region of the cushioning member 132c, and the subject's lower legs 16 generally align with the second region of the cushioning member 132b.

[0026] The width W₃ of the cushioning members 132 can vary. For instance, the width W₃ of the cushioning members 132 can be between about 6 inches and about 20 inches, between about 8 inches and about 20 inches, or between about 12 inches and about 20 inches. In some embodiments, each of the cushioning members 132 comprises the same width W₃. In other embodiments, the cushioning members 132 can comprise different widths W₃. For instance, in some embodiments, the width W₃ of the cushioning member 132a in the hip region is greater than the width W₃ of the cushioning members 132b, 132c in the shoulder region and/or leg region. In some of such embodiments, the width W₃ of the cushioning member 132a in the hip region is between about 12 inches and about 20 inches, and the width W₃ of the cushioning members 132b, 132c in the shoulder region and/or leg region is between 8 inches and about 15 inches. Other widths W₃ and/or sizes are also contemplated.

[0027] Various materials can be used in the cushioning members 132. In some embodiments, each region of cushioning member 132 comprises an elastomeric cushioning material. Each region of elastomeric cushioning member 132 may also include buckling walls. The buckling walls of the elastomeric cushioning member 132 may be interconnected to one another and may define hollow columns or voids in an expanded form. The term “expanded form” can refer to a state in which the elastomeric cushioning member 132 has its original size and shape and wherein the buckling walls are separated and define hollow columns.

[0028] The buckling walls may extend in two directions, intersecting at right angles, and defining square or rectangular voids. The buckling walls may define a grid structure. However, in some embodiments, the buckling walls may intersect at other angles and define voids of other shapes, such as triangles, parallelograms, hexagons, etc. The elastomeric cushioning member 132 may comprise additional structures and configurations such as those structures and configurations described in, for example, U.S. Pat. No. 5,749,111, titled “Gelatinous Cushions with Buckling Columns,” issued May 12, 1998; U.S. Pat. No. 6,026,527, titled “Gelatinous Cushions with Buckling Columns,” issued Feb. 22, 2000; and U.S. Pat. No. 7,076,822, titled “Stacked Cushions,” issued Jul. 18, 2006, the entire disclosure of each of which is incorporated herein by reference.

[0029] The buckling walls may be formed of an elastomeric material. Exemplary elastomeric materials are described in, for example, U.S. Pat. No. 5,994,450, titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom,” issued Nov. 30, 1999, and U.S. Pat. No. 7,964,664, titled “Gel with Wide Distribution of MW in Mid-Block” issued Jun. 21, 2011, the disclosures of each of which are incorporated herein by reference in theft entirety. In some embodiments, the elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (which can also be referred to as a gel, an elastomer gel, or an elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc.

[0030] In some embodiments, the elastomeric polymer may be a block copolymer. For instance, the elastomeric polymer may be an A-B diblock copolymer. In some embodiments, the elastomeric polymer may be an A-BA triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEPS), and styrene ethylene propylene styrene (SEEPS). The elastomeric material may also include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers. The elastomeric material may optionally include one or more plasticizers, such as hydrocarbon fluids.

[0031] The elastomeric material may include any type of gelatinous elastomer. The elastomeric material may include a material that may return to its original shape after deformation, and that may be elastically stretched. The elastomeric material may be rubbery in feel, but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials, and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5.

[0032] With continued reference to FIGS. 2 and 3, the areas or regions of the zoned cushioning layer 130 between and around the cushioning members 132 can comprise a support material 134, such as a polyurethane foam or latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used as the support material 134. Flat foams or convoluted foams can be used. In further embodiments, the areas or regions 134 of the zoned cushioning layer 130 between and around the cushioning members 132 comprise an elastomeric cushioning material or gel having one or more different properties than the material in the cushioning members 132. In such embodiments, the materials identified above for the regions of zoned cushioning member 132 can also be used as the support material 134, but with one or more different properties such as a different firmness, hardness, structure, chemical composition, etc. In certain embodiments, the width W₄ of support material 134 between adjacent regions of zoned cushioning members 132 is at least about 4 inches, at least about 6 inches, or more. As illustrated, the support material 134 can extend around a perimeter or periphery of the zoned cushioning layer 130. The support material 134 can also extend between the various regions of cushioning member 132. The properties of the support material 134 can also differ from the properties of the cushioning member 132. For instance, in some embodiments the support material 134 can have a stiffness or rigidity that is different from or greater than the cushioning member 132. In certain embodiments, the support material 134 can be configured to aid in maintaining the structural conformation of the zoned cushioning layer 130. For instance, the support material 134 along the perimeter or periphery of the zoned cushioning layer 130 can provide increased support for a subject to sit on a side or edge of the mattress assembly 100. In other embodiments, the stiffness or rigidity of the support material 134 is substantially the same as that of the cushioning members 132.

[0033] The thickness T₃ of the zoned cushioning layer 130 can vary as desired. In some embodiments, the zoned cushioning layer 130 may have a thickness T₃ of within a range of about 0.75 inches to about 5 inches, about 1 inch to about 4 inches, or between about 1.5 inches to about 3 inches. Other thicknesses are also contemplated. It will further be appreciated that in some embodiments the mattress assembly 100 can include two or more zoned cushioning layers 130. These two more zoned cushioning layers 130 can be stacked vertically, either directly adjacent one another or with one or more additional layers in between.

[0034] As previously discussed, the mattress assembly 100 can further comprise one or more optional and/or additional layers depending on the mattress design and/or configuration. For example, one or more support and/or comfort layers 140, 150, 160 can be included on either or both sides of the zoned cushioning layer 130. In some embodiments, such as the illustrated embodiment, one or more support and/or comfort layers 140, 150, 160 are optionally disposed between the coil layer 120 and the zoned cushioning layer 130. With reference to FIGS. 2 and 3, for example, at least one or a first support layer 140 is disposed between the coil layer 120 and the zoned cushioning layer 130. This first support layer 140 can provide additional support and structural conformation to the mattress assembly 100. For instance, the first support layer 140 can comprise a stiffness or rigidity that is greater than that of the zoned cushioning layer 130. The first support layer 140 can also provide a different feel to the mattress assembly 100. In certain embodiments, the first support layer 140 comprises a foam material, such as a polyurethane foam or a latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used. Flat foams or convoluted foams can be used. In particular embodiments, the first support layer 140 comprises a foam material (e.g., polyurethane foam) having a density of between about 1 lbs/ft³ and about 5 lbs/ft³, between about 1 lbs/ft³ and about 4 lbs/ft³, between about 1 lbs/ft³ and about 3 lbs/ft³, or between about 1 lbs/ft³ and about 2 lbs/ft³. The first support layer 140 can also comprise an indentation load deflection (ILD) of between about 20 lbs and about 100 lbs, between about 10 lbs and about 40 lbs, or between about 10 lbs and about 30 lbs. The thickness T₄ of the first support layer 140 can also vary. In some embodiments, the thickness T₄ of the first support layer 140 is between about 0.5 inches and about 2 inches, or between about 0.5 inches and about 1.5 inches. Other thicknesses T₄ can also be used, such as between about 1 inch and about 18 inches, between about 1 inch and about 12 inches, between about 1 inch and about 5 inches, or between about 1 inch and about 3 inches.

[0035] One or more additional support and/or comfort layers can also be disposed between the coil layer 120 and the zoned cushioning layer 130 if desired. The one or more additional support and/or comfort layers can comprise a different material than the first support layer 140, such as a different foam material or foam having a different density and/or indentation load deflection (ILD) to impart additional properties to the mattress assembly 100.

[0036] One or more additional layers 150, 160 can also be disposed above the zoned cushioning layer 130 if desired. For instance, in the illustrated embodiment, the mattress assembly 100 comprises two additional layers 150, 160 disposed above the zoned cushioning layer. In some embodiments, the mattress assembly 100 comprises at least one comfort layer 150 disposed above the zoned cushioning layer 130. In particular embodiments, the at least one comfort layer 150 comprises a memory material, such as a polyurethane memory foam material. The memory foam material can include polyurethane material that is viscoelastic and can be configured to contour to the body of a subject during use. Flat foams or convoluted foams can be used. The thickness T₅ of the comfort layer 150 can also vary. In some embodiments, the comfort layer 150 comprises a thickness T₅ of between about 0.5 inches and about 3 inches, or between about 0.75 inches and about 2 inches.

[0037] One or more additional support and/or comfort layers can also be disposed above the zoned cushioning layer 130. For instance, in some embodiments, one or more support layers 160 are also disposed between the zoned cushioning layer 130 and the comfort layer 150. In such embodiments, the support layer 160 can comprise a different material than the comfort layer 150, such as a different foam material or foam having a different density to impart additional properties to the mattress assembly 100. In certain embodiments, the support layer 160 comprises a material having a higher stiffness or rigidity than the comfort layer 150 and can provide additional support and structural conformation to the mattress assembly 100, similar to the first support layer 140. In some embodiments, the second support layer 160 comprises a foam material, such as a polyurethane foam or a latex foam. Foams and other forms of polyethylene, polypropylene, fiber, and/or latex can also be used. Flat foams or convoluted foams can be used. In particular embodiments, the support layer 160 comprises a foam material (e.g., polyurethane foam) having a density of between about 1 lbs/ft³ and about 5 lbs/ft³, between about 1 lbs/ft³ and about 4 lbs/ft³, between about 1 lbs/ft³ and about 3 lbs/ft³, or between about 1 lbs/ft³ and about 2 lbs/ft³. The support layer 160 can also comprise an indentation load deflection (ILD) of between about 20 lbs and about 100 lbs, between about 10 lbs and about 70 lbs, such as between about 10 lbs and about 25 lbs, or between about 40 lbs and about 60 lbs depending on the desired firmness. The thickness T₆ of the support layer 160 can also vary. In some embodiments, the support layer 160 comprises a thickness of between about 0.5 inches and about 3 inches, or between about 0.75 inch and about 2 inches. Other thicknesses T₆ can also be used, such as between about 1 inch and about 18 inches, between about 1 inch and about 12 inches, between about 1 inch and about 5 inches, or between about 1 inch and about 3 inches.

[0038] In certain embodiments, one or more of the additional support and/or comfort layers 140, 150, 160 comprises a layer of elastomeric cushioning material or gel. In such embodiments, the materials and structures (e.g., buckling walls defining hollow columns) identified above for the regions of zoned cushioning member 132 can also be used in the one or more additional support and/or comfort layers 140, 150, 160. The one or more additional support layers 140, 150, 160 comprising a layer of elastomeric cushioning material or gel can be stacked vertically on one or both sides of the zoned cushioning layer 130, either directly adjacent the zoned cushioning layer 130 or with one or more additional layers in between.

[0039] With reference to FIG. 1, the mattress assembly 100 can also comprise a cover 105 disposed at least partially around or encapsulating the entirety of multilayered construction. Various types of covers 105 can be used, including quilted or padded covers 105 and the like. The cover 105 can also comprise various materials or fabrics, including, but not limited to, cotton materials, polyester materials, polymeric materials, water resistant materials, synthetic materials, and combinations thereof. The cover 105 can be flexible and stretchable (or elastic) such that it can stretch and return to its original size and/or shape.

[0040] The mattress assembly 100 can further include adhesives, stitching, or other fasteners for coupling the one or more layers 110, 120, 130, 140, 150, 160 together. In some embodiments, stabilization materials are also disposed between the layers. Stabilization materials can include non-slip materials or adhesive materials such that lateral or longitudinal movement between the layers is minimized. In certain embodiments, each of the cushioning members 132 includes a stabilization material coupled on one or both of the top and bottom surfaces of the cushioning member 132. The stabilization material can include a relatively thin material (e.g., a scrim) and may be used to provide structural conformation to the cushioning member 132 and/or aid in adhering the cushioning member 132 to surrounding materials or layers. In certain embodiments, the stabilization material can include a scrim or fabric (woven or non-woven) and portions of the cushioning member 132 can seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the stabilization material to thereby couple the cushioning member 132 to the stabilization material. For instance, a cushioning member 132 comprising a gelatinous elastomer can be heat fused through the stabilization material.

[0041] FIG. 5 depicts a mattress assembly 200 according to another embodiment. As shown in FIG. 5, the mattress assembly 200 includes a base layer 210, a coil layer 220, and a zoned cushioning layer 230. The mattress assembly 200 further includes one or more additional support and/or comfort layers 240, 250, 260.

[0042] In particular, the mattress assembly 200 of FIG. 5 includes two support and/or comfort layers 240, 260 disposed between the coil layer 220 and zoned cushioning layer 230. An additional support and/or comfort layer 250 is also disposed above the zoned cushioning layer 230. Thus, as illustrated in FIG. 5, the arrangement and number of support and/or comfort layers 240, 250, 260 can vary depending on the mattress configuration.

[0043] FIG. 6 depicts a mattress assembly 300 according to yet another embodiment. As shown in FIG. 6, the mattress assembly 300 includes a base layer 310, a coil layer 320, and a zoned cushioning layer 330. The mattress assembly 300 further includes one or more additional support and/or comfort layers 340, 350.

[0044] In particular, the mattress assembly 300 of FIG. 6 includes one support and/or comfort layer 340 disposed between the coil layer 320 and zoned cushioning layer 330. An additional support and/or comfort layer 350 is also disposed above the zoned cushioning layer 330. Thus, as illustrated in FIG. 6, the arrangement and number of support and/or comfort layers 340, 350 can vary depending on the mattress configuration.

[0045] Without limitation, it will be appreciated that the zoned cushioning layer of the present disclosure can be incorporated into various types of mattress assemblies and configurations. For instance, the zoned cushioning layer can be incorporated into traditional mattress assemblies and configurations. The zoned cushioning layer can also be incorporated into mattress assemblies that can be folded or rolled into packaging materials. Incorporation of the zoned cushioning layer into other types of mattress assemblies is also within the scope of this disclosure.

[0046] It will further be appreciated that any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified. Methods contemplated by the present disclosure include methods of manufacturing a mattress assembly having a base layer, a coil layer, and a zoned cushioning layer. Other methods can also be employed.

[0047] References to approximations are made throughout this specification, such as by use of the term “about.” For each such reference, it is to be understood that, in some embodiments, the value, feature, or characteristic may be specified without approximation. For example, where qualifiers such as “about” and “substantially” are used, these terms include within their scope the qualified words in the absence of their qualifiers. All ranges also include both endpoints.

[0048] Similarly, in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment.

[0049] The claims following this written disclosure are hereby expressly incorporated into the present written disclosure, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims. Moreover, additional embodiments capable of derivation from the independent and dependent claims that follow are also expressly incorporated into the present written description.

[0050] Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art, with the aid of the present disclosure, that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. Moreover, the order of the steps or actions of the methods disclosed herein may be changed by those skilled in the art without departing from the scope of the present disclosure. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order or use of specific steps or actions may be modified. The scope of the invention is therefore defined by the following claims and their equivalents.