Note: Descriptions are shown in the official language in which they were submitted.
MATTRESS AND SIDE RAIL ASSEMBLIES HAVING HIGH AIRFLOW
BACKGROUND
[0001] The present disclosure generally relates to foam mattress assemblies;
specifically side rail assemblies of the mattress that exhibit increased
airflow.
[0002] One of the ongoing problems associated with mattress assemblies is user
comfort. To address user comfort, mattresses are often fabricated with
multiple layers having
varying properties such as density and hardness, among others, to suit the
needs of the intended
user. One particular area of concern to user comfort is the level of heat
buildup in the mattress
and experienced by the user after a period of time. Additionally, some
mattresses can retain a
high level of moisture, further causing discomfort to the user and potentially
leading to foul
odors. The problems can be experienced, to some extent, in pocketed coil and
innerspring
assembly mattresses, as well as foam mattresses. For example, foam mattresses
such as those
formed of polyurethane foam, latex foam, and the like, are generally known in
the art.
Manufacturers have employed so called memory foam, also commonly referred to
as
viscoelastic foams, which are generally a combination of polyurethane and one
or more
additives that increase foam density and viscosity, thereby increasing its
viscoelasticity. These
foams are often open cell foam structures having both closed and open cells
but in some
instances may be reticulated foam structures. The term "reticulated" generally
refers to a
cellular foam structure in which the substantially all of the membrane windows
are removed
leaving a skeletal structure. In contrast, open cell structures include both
open cell
(interconnected cells) and closed cells.
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[0003] Unfortunately, the high density of foams used in current mattress
assemblies, particularly those employing memory foam layers, generally
prevents
proper ventilation. As a result, the foam material can exhibit an
uncomfortable level
of heat to the user after a period of time. Reticulated memory foams, i.e.,
foams in
which the cellular walls are substantially removed, are known to provide
greater
airflow. However, because substantially all of the cellular walls have been
removed
leaving behind a skeletal structure, these foams are inherently weak, provide
less load-
bearing capabilities relative to other non-reticulated viscoelastic foams, and
are
subject to fatigue at a rate faster than partially or completely closed cell
foam
structures. Moreover, reticulated viscoelastic foams require special
processing to
remove the cellular walls to form the skeletal structure making these foams
relatively
expensive.
[0004] Moreover, much like the mattresses described above, the current side
rail assemblies, used in the mattress assemblies for edge support, also tend
to act as an
air dam blocking the flow of air out of the mattress. This can further reduce
the
ventilation of the mattress assembly and increase the amount of heat and/or
moisture
retained in the mattress. These side rail assemblies can redirect the flow of
air (and
heat and moisture) back through the top sleeping surface, thereby adding to
the
discomfort experienced by the user.
[0005] Accordingly, it would be desirable to provide a mattress assembly,
especially a side rail assembly with an improved airflow to aid in the
dissipation of
user heat.
BRIEF SUMMARY
[0006] Disclosed herein are rail systems and mattress assemblies exhibiting
increased airflow. In one embodiment, a mattress assembly includes an inner
core
comprising a base core layer comprising planar top and bottom surfaces, and at
least one
comfort layer comprising planar top and bottom surfaces disposed on the top
surface of
the base core layer; a side rail assembly disposed about a perimeter of the
inner core; and
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a plurality of air channels extending from a central region of the inner core
to the side
rail assembly configured to permit the flow of fluid from and to the inner
core.
[0007] In another embodiment, a side rail assembly for supporting an edge of
a mattress includes a layer of foam comprising at least one channel and/or a
plurality
of orifices, wherein the layer is configured to be disposed about a perimeter
of an
inner core of the mattress, wherein the at least one channel extends through a
length of
the layer and the plurality of orifices extend through a width of the layer,
and wherein
the at least one channel and/or the plurality of orifices are configured to
permit the
flow of fluid from and to the inner core through the layer.
[0008] In still another embodiment, a mattress assembly includes an inner core
comprising a base core layer comprising planar top and bottom surfaces, and at
least
one additional layer comprising planar top and bottom surfaces disposed on the
top
surface of the base core layer; a side rail assembly disposed about a
perimeter of the
inner core, wherein the side rail assembly comprises a layer of a foam
comprising at
least one channel and/or a plurality of orifices configured to permit the flow
of fluid
from and to the inner core through the layer; and a plurality of inner core
air channels
extending from a central region of the inner core to the at least one channel
and/or
plurality of orifices of the side rail assembly, wherein the plurality of
inner core air
channels are configured to permit the flow of fluid from and to the inner core
through
the side rail assembly.
[0009] In still another embodiment, a mattress assembly includes an inner core
comprising a base core layer comprising planar top and bottom surfaces, and at
least
one additional layer comprising planar top and bottom surfaces disposed on the
top
surface of the base core layer, wherein the base core layer and/or the at
least one
additional layer further comprises a plurality of air channels extending
across a width
of the layer configured to permit the flow of fluid from and to the inner
core.
[0010] The disclosure may be understood more readily by reference to the
following detailed description of the various features of the disclosure and
the
examples included therein.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Referring now to the figures wherein the like elements are numbered
alike:
[0012] Figure (FIG.) 1 illustrates a cross-sectional view of a mattress
assembly
in accordance with an embodiment of the present disclosure;
[0013] FIG. 2 illustrates a perspective view of a mattress layer for a
mattress
assembly in accordance with an embodiment of the present disclosure;
[0014] FIG. 3 illustrates a cross sectional view of a mattress assembly taken
in
accordance with another embodiment of the present disclosure;
[0015] FIGS. 4 and 5 illustrate perspective views of a foam side rail assembly
in
accordance with an embodiment of the present disclosure; and
[0016] FIGS. 6 and 7 illustrate perspective views of a foam side rail assembly
in
accordance with another embodiment of the present disclosure.
DETAILED DESCRIPTION
[0017] Disclosed herein are side rail assemblies (and mattress assemblies
including the side rails), which provide user comfort with improved airflow to
effectively dissipate user heat during use. Also disclosed are methods of
improving
the airflow throughout the mattress assemblies and dissipating user generated
heat and
moisture therein. In one embodiment, the side rail assemblies advantageously
include
air channels configured to permit the flow of air and moisture from inner
layers of the
mattress assembly through the side rail assembly and out to the surrounding
environment. Such removal of warm air and moisture can improve the sleeping
experience of the mattress user.
[0018] In another embodiment, air channels are formed in one or more layers
of the mattress assembly to permit the flow of air and moisture from the one
or more
layers to the side rail assemblies. In certain embodiments, the air channels
formed in
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the mattress assembly correspond to air channels formed in the side rail
assemblies,
thereby permitting a continuous air channel from the interior of the mattress
to
exterior. In other embodiments, the air channels formed in the mattress
assembly
extend in a downward angle through one or more layers of the mattress to a
side rail
assembly formed of a high airflow foam; the foam being configured to permit
the
passage of air and moisture there through to the environment.
[0019] Current mattress assemblies include one or more comfort layers
disposed on top of a base core. Ventilation is often added down in the base
core, such
as through, for example, convolution. However, the more comfort layers in the
design
of the mattress assembly, the more barriers there are to movement of air
between the
layers. This prevents air flow and traps the heat and humidity near the sleep
surface of
the bed. As such, air channels can be formed through these comfort layers to
permit
the flow of air from all layers in the mattress assembly out through the
channels. This
allows the warm moist air to move away from the sleeper, allowing for a cooler
and
dryer sleep environment.
[0020] Turning now to FIG. 1, a cross-sectional view representative of the
various mattress assemblies is illustrated, which are generally designated by
reference
numeral 10. As will be discussed herein, the various embodiments of the
mattress
assemblies disclosed herein have in common the following components: multiple
stacked layers, and a side rail assembly 12 about at least a portion of the
perimeter of
the stacked mattress layers. The mattress assembly 10 includes a base core 14,
with
three stacked mattress layers disposed thereon ¨ a support layer 16, a middle
comfort
layer 18, and a top comfort layer 20. The uppermost top comfort layer 20 has a
planar
top surface adapted to substantially face the user resting on the mattress
assembly and
having length and width dimensions sufficient to support a reclining body of
the user.
A plurality of air channels 22 extend through the four layers of the mattress
assembly
from a central region of the mattress out through the side rail assembly.
[0021] In another embodiment, the plurality of air channels 22 may extend
through less than all the layers of the mattress, such as, for example, from
the top
comfort layer down through the support layer and out through the side rail
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assembly 12. In still another embodiment, the plurality of air channels 22 may
extend
through one or more of the layers of the mattress assembly 10, but do not
extend out
through the side rail assembly 12. Rather, the side rail assembly may include
a high
air flow foam in the region where the plurality of air channels 22 meet the
side rail
assembly 12, such that the air flow from the channels is permitted to flow
through the
high airflow foam and exit to the environment.
[0022] As used herein, a high airflow foam is generally intended to be a foam
having an open cell structure with a large cellular or a random cell
structure, wherein
movement of moisture and air through one or more of the side rails in the
assembly
can occur. The open cell foam structure includes a plurality of interconnected
cells,
wherein the percentage of intact windows (i.e., cell walls) between adjacent
cells is
less than about 50 percent; specifically less than about 40 percent; more
specifically
less than about 30 percent; and still more specifically less than about 20
percent. The
large cell structure can also be defined by the number of cells per linear
inch. In one
embodiment, the large cell structure is about 10 to 40 cells per inch, with
about 15 to
30 cells per inch in other embodiments, and with about 20 cells per inch in
still other
embodiments. The hardness of the high airflow foam, also referred to as the
indention
load deflection (ILD) or indention force deflection (TED), is within a range
of about 35
to about 100 pounds-force, wherein the hardness is measured in accordance with
ASTM D-3574. In one embodiment, the hardness is about 40 to about 90 pounds-
force; and specifically about 50 to about 75 pounds-force. The high air flow
foam can
further include a density of about 1.0 to about 3.0 pounds per cubic foot; and
specifically about 1.2 to about 2.0 pounds per cubic foot.
[0023] The plurality of air channels 22 can have any size and shape configured
to adequately permit the flow of air and moisture from the layers of the
mattress and
enable the dissipation of heat and moisture on the sleep surface of the
mattress
assembly. In the embodiment of FIG. 1, the plurality of air channels 22 have a
downward orientation, beginning at the top comfort layer 20 in an
interior/central
region of the mattress and extending down through the three layers beneath
while
extending from the interior region out to the side rail assembly 12. In this
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embodiment, the plurality of air channels 22 extend through the side rail
assembly 12,
forming apertures therein in a vertical position of the side rail assembly
adjacent to the
base core 14. By angling the plurality of air channels 22 downwardly as
described
herein, ventilation is permitted to the mattress lower layers (e.g., support
layer 16,
base core 14) even if a user's bodyweight closes off the plurality of air
channels 22
near the surface of the mattress (e.g., the top comfort layer 20).
[0024] Again, if a side rail assembly at least partially formed of high air
flow
foam is used, or part of' the rail is designed to allow air flow through the
rail, the
plurality of air channels need not be cut through the side rails. Rather, the
plurality of
air channels can be cut into the mattress inner core before the rails are
attached to the
mattress inner core to form the mattress assembly. When the side rails are
attached,
the section(s) of the side rail that will be used to channel the air out of
the bed, such as
the high airflow foam portion, will be masked to prevent the application of
adhesive
in this area. Masking this area will prevent the adhesive from blocking the
air flow
through this region of the side rails.
[0025] In another embodiment, an entire layer of the mattress assembly can
form the plurality of air channels, rather than channels being diagonally cut
through
one or more layers. FIG. 2 illustrates an exemplary embodiment of a mattress
layer
150 comprising a plurality of air channels 152. The plurality of air channels
52 extend
across the full width of the layer 150 and permit air to flow out of the
various layers in
the mattress into the air channels and out through the sides of the mattress.
In one
embodiment, the mattress layer 150 can be used in a mattress assembly without
side
rail assemblies. In such an embodiment, the mattress layer 150 can be
disposed, for
example, as a base core layer in the mattress assembly. In another embodiment,
the
mattress layer 150 can be disposed in the mattress assembly as a base core
layer or any
intermediate/middle layer(s) below the comfort layers, wherein the mattress
assembly
further includes high airflow side assemblies. The mattress layer 150 can be
positioned in the mattress such that the plurality of air channels 152 channel
air out of
the mattress to a high airflow section of the rail, as will be described in
greater detail
below. The mattress layer 150 can be formed of a polyethylene foam.
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[0026] While discussion will continue with respect to the side rail assemblies
and their use in mattresses having foam base cores, it is to be understood
that the base
core 14 of the mattress assemblies described herein can be any suitable base
known to
those having skill in the art. The base core layer 14 can be a standard spring
support
unit (e.g., a pocketed coil base or an innerspring assembly) or,
alternatively, the layer
can be formed of polyurethane foam, although other foams can be used,
including
without limitation, viscoelastic foams. In one embodiment, the base core foam
layer
is an open cell polyurethane foam. In other embodiments, the base core foam
layer is
closed cell polyurethane foam.
[0027] The side rail assemblies can be disposed about a perimeter of the
mattress inner core and provide support to the edge of a mattress. FIG. 3
shows a cross
sectional view of a mattress assembly having a side rail assembly in
accordance with
one embodiment. The mattress assembly 100 includes a base core layer 102
configured with generally planar top and bottom surfaces. For this as well as
the other
embodiments disclosed herein, the base core layer 102 is chosen to have a
thickness
greater than or equal to the overall thickness of the mattress assembly.
Generally, the
thickness of the base core layer 102 is 4 inches to 10 inches, with about 6
inches to 8
inches thickness in other embodiments, and about 6.5 inches in still other
embodiments. In one embodiment, the base core layer is an open cell
polyurethane
foam. In other embodiments, the base core layer is a closed cell polyurethane
foam.
In still other embodiments, the base core layer 102 includes a plurality of
spring coils.
As a foam, the base core layer 102 has a density of 1 pound per cubic foot
(1b/113) to 5
lb/ft3. In other embodiments, the density is 1 lb/ft3 to 3 lb/ft3 and in still
other
embodiments, from 1 lb/113 to 2 lb/fI3. By way of example, the density can be
1.65
lb/ft3. The hardness of the base core layer, also referred to as the indention
load
deflection (1LD) or indention force deflection (IFD), is within a range of 20
to 40
pounds-force, wherein the hardness is measured in accordance with ASTM D-3574
and is generally defined as the amount of force in pounds required to indent a
50" disc
into a 15" x 15" x 4" foam sample and make a 1" indentation. In one
embodiment,
the hardness is about 32 to 35 pounds-force.
8
[0028] A relatively thin pre-stressed polyurethane foam layer 104 including
planar top
and bottom surfaces is disposed on the base core layer 102. Suitable pre-
stressed polyurethane
foams are generally formed in the manner disclosed in US Pat. No. 7,690,096 to
Gladney et al.
By way of example, a force can be applied to at least a section of a standard
polyurethane foam
layer in an amount sufficient to temporarily compress its height so as to
permanently alter a
mechanical property of the foam layer to provide a pre-stressed foam layer
having a firmness
that is different from the firmness of a similar polyurethane foam that was
not pre-stressed.
The pre-stressed polyurethane foam layer is a standard polyurethane foam as
noted above (i.e.,
not viscoelastic) and generally has a pre-stressed thickness of less than 1
inch. The density is
generally less than 2.5 lb/ft3 in some embodiments, and less than 2 lb/ft3 in
still other
embodiments.
The hardness is generally less than 30 pounds-force in some embodiments, and
less than
pounds-force in still other embodiments. In one embodiment, the thickness is
0.5 inches, the
hardness is 22 pounds-force, and the density is 1.5 lb/ft3.
[0029] A cover panel 106 is formed of a viscoelastic foam and disposed on the
polyurethane foam layer 104. The viscoelastic polyurethane foam has an open
cell structure,
wherein the percentage of intact windows (i.e., cell walls) between adjacent
cells is less than
50 percent in one embodiment, and less than 40 percent in other embodiments,
and less than
30 percent in still other embodiments. The cover panel 106 has planar top and
bottom surfaces.
The thickness of the cover panel is generally less than 3" in some
embodiments, and less than
2" in other embodiments. The density of the cover panel layer 106 is less than
6 lb/ft3 in some
embodiments, and less than 2.5 lb/ft3 in other embodiments. In one embodiment,
the hardness
is generally less than 15 pounds-force. In one embodiment, the cover panel is
at a thickness of
1.5", a density of 2.5 lb/ft3, and a hardness is 12 pounds-force.
[0030] The various multiple stacked mattress layers 102, 104, and 106 may be
adjoined
to one another using an adhesive or may be thermally bonded to one another or
may be
mechanically fastened to one another.
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[0031] The mattress assembly further includes a foam side rail assembly 120
about all or a portion of the perimeter of the mattress layers 102, 104, 106.
The side
rails that define the assembly may be attached or placed adjacent to at least
a portion
of the perimeter of the mattress layers 102, 104, 106. Side rails may be
placed on
opposing sides of the stacked mattress layers, on all four sides of the
stacked mattress
layers, or only on one side of the stacked mattress layers. In certain
embodiments, the
side rails may comprise edge supports with a firmness greater than that
provided by
the stacked mattress layers. The side rails may be fastened to the stacked
mattress
layers via adhesives, thermal bonding, or mechanical fasteners.
[0032] The side rail assembly 120 is formed of a foam having a plurality of
air
channels 122 formed therein. In one embodiment, the foam is polyethylene foam.
The plurality of air channels 122 can be formed by cutting out portions of the
foam, or
the foam side rail assembly 120 can be extruded with the plurality of air
channels 122
formed therein. In this embodiment, the foam side rail assembly is a single
layer of
foam. In other embodiments, as will be discussed in more detail below, the
foam side
rail assembly can have multiple layers of the same or different foams. The
plurality of
air channels 122 create airflow pathways wherein movement of moisture and air
from
the mattress through one or more of the side rails in the assembly 120 can
occur.
[0033] FIGS. 4 and 5 further illustrate two different perspective views of an
exemplary embodiment of a foam side rail assembly 200. FIG. 4 is a cross-
sectional
end view of the foam side rail assembly 200 and illustrates a plurality of
channels 202
that extend through the length of the foam side rail. The number of channels
extending through the length of the foam side rail can depend on several
factors, such
as, for example, the height of the rail, the type of foam used, the desired
firmness of
the mattress assembly, and the like. The shape and number of the channels will
depend on the desired properties and air flow rates of the mattress assembly
and can
be properly configured by one of skill in the art. In this embodiment, the
foam side
rail assembly 200 includes four distinct channels 202, extending the length of
the side
rail. The channels have a generally semi-circular shape to provide a desired
level of
structure and support to the foam side rail assembly 202.
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[0034] The foam side rail assembly 200 further includes a plurality of
orifices
204 disposed along the height of the rail on a side 206 of the rail in
physical
communication with the mattress and a side 208 of the rail opposite the
mattress. In
this embodiment, the plurality of orifices 204 are equidistantly spaced apart
and are
disposed in the foam side rail between each of the plurality of air channels.
The
plurality of orifices extend through the rail in a substantially perpendicular
direction to
the length of the rail and the plurality of air channels. Three orifices are
disposed on
either side of the rail and can extend there through to permit flow of air
through the
width of the side rail. In other embodiments, the foam side rail assembly can
include
more or less orifices and the number of orifices on each side of the rail can
be the
same or different. Like the plurality of air channels 202, the plurality of
orifices 204
provide additional openings into the foam side rail and permit more airflow
out of the
side rail from the mattress. The plurality of orifices 204 can have any size
and shape
and will depend on the desired properties and air flow rates of the mattress
assembly
and can be properly configured by one of skill in the art.
[0035] FIG. 5 illustrates another perspective view of the foam side rail
assembly 200, this time looking at the surface of the side 208, which would be
the
outward facing side of the rail, opposite the mattress inner core. As can be
seen, the
plurality of orifices 204 disposed in the side 208 are spaced equidistantly
apart in both
the vertical and horizontal direction. The plurality of orifices 204 can be
vertically
offset, as shown in FIG. 5, or they can be aligned vertically. In this
embodiment, each
of the plurality of orifices 204 has a generally square shape. In other
embodiments,
each orifice can have a different shape, such as circular, rectangular,
polygonal, and
the like. The side 208 further includes ridges 210 that extend through each
line of
orifices 204 on the surface of side 208. Ridges can also be formed on the
opposite
side 206, extending through each of the three lines of orifices on that side.
[0036] In certain embodiments, the foam side rail assembly 200 can include
additional layer or layers disposed above and/or below the side rail. For
example, the
foam side rail assembly 200 could further include a bottom layer and a top
layer (not
shown). Each of the bottom layer and top layers could be hollow, or in other
words,
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also have an air channel formed therein extending the length of the rail. The
hollow
bottom and top layers provide material savings, reduce weight, and allow
additional
airflow there through, while also providing support around the middle portion
of the
foam side rail assembly 200. The bottom and top layers can be formed of the
same
foam as the foam side rails assembly 200 or it can be different foam. Also,
the bottom
layer can be formed of the same foam as the top layer, or the foams can be
different.
In one embodiment, the bottom layer and top layers are formed of a reticulated
polyurethane foam.
[0037] The foam side rail assemblies described herein can be used with a
mattress inner core, as illustrated in FIG. 3. The foam side rail assemblies
can also be
used with a mattress inner core having a plurality of air channels disposed
therein,
such as the mattress inner core embodiment illustrated in FIG. 1. In such an
embodiment, the plurality of air channels in the mattress inner core can be
configured
to generally align with the plurality of channels and/or the plurality of
orifices formed
in the foam side rail assemblies. Such a combination could provide additional
airflow
through the mattress, and thereby further improve the heat and moisture
dissipation
within the mattress assembly.
[0038] Turning now to FIGS. 6 and 7, another exemplary embodiment of a
foam side rail assembly 300 is illustrated. FIG. 6 is a perspective view of
the foam
side rail assembly taken along the length of the rail. The foam side rail
assembly 300
includes a bottom layer 302, a middle layer 304, and a top layer 306. Each of
the
three layers are formed of foam. In one embodiment, each layer is formed of a
different foam. In another embodiment, the top and bottom layers are formed of
one
type of foam, while the middle layer is formed of another. In still another
embodiment, all three layers are formed of the same foam.
[0039] The middle layer 304 is formed of repeated sections 305 of foam that
are attached together, such as with an adhesive. Each section 305 includes an
upper
307 and lower 308 air channel. The section 305 further includes an orifice 309
on
each end of the section 305, such that when the sections are adhered together,
another
air channel 310 is formed therebetween. Each of the air channels are
configured to
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allow air flow through the foam side rail assembly 300, so that air, heat,
moisture, and
the like, formed in a mattress inner core to which the assembly can be
attached, is
permitted to flow out through the middle layer 304. In one embodiment, the
middle
layer 304 is formed of a reticulated or large open cell structure polyurethane
foam,
such as the high airflow foam described herein. In another embodiment, the
middle
layer 304 is formed of a polyethylene foam.
[0040] The bottom layer 302 and the top layer 306 are disposed below and
above the middle layer 304, respectively. The bottom and top layer can have
the same
thickness or they can have different thicknesses, depending on the height of
the
mattress inner core and the desired position of the middle layer 304 with
respect to the
mattress inner core. In this embodiment, each of the bottom layer 302 and the
top
layer 306 are hollow, as illustrated in the FIG. 7 by the channels 312
extending
through both layers. The hollow bottom and top layers provide material
savings,
reduce weight, and allow additional airflow therethrough, while also providing
support around the middle layer 304 of the foam side rail assembly 300. In one
embodiment, the bottom layer 302 is formed of a polyethylene foam and the top
layer
306 is formed of a polyurethane foam. In another embodiment, both the bottom
layer
302 and the top layer 306 are formed of a reticulated polyurethane foam.
[0041] In an exemplary embodiment, the top layer 306 and the bottom layer
302 are adhered to the mattress inner core. The middle layer 304 is
advantageously
free from the adhesive, thereby ensuring the adhesive does not adversely
affect the air
flow through the side rail, specifically through the middle layer. As used
herein, the
term adhesive generally means the side rail assemblies may be fastened to the
stacked
mattress layers via adhesives, thermal bonding, or mechanical fasteners.
Again, if the
rails are adhesively or thermally attached to the mattress layers, it is
desirable that the
portions of the foam side rail assembly having the plurality of channels
and/or
plurality of orifices are free from the adhesive or thermal attachment points
such that
air and moisture transfer is uninterrupted by the thermal bonding process or
adhesive
and airflow from the mattress layers through the side rails to the environment
is
maintained.
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[0042] For ease in manufacturing the mattress assembly, the foam side rail
assembly may be assembled in linear sections that are joined to one another to
form
the perimeter about the mattress layers. An optional fabric layer (not shown)
can be
disposed about the perimeter of the side rail, i.e., serves as a mattress
border. The
fabric border layer is attached at one end to the top planar surface of the
uppermost
mattress layer and at the other end to the bottom planar surface of the bottom
most
layer. In one embodiment, at least a portion of the fabric layer is formed of
a spacer
fabric to provide a further increase in airflow. As used herein, spacer
fabrics are
generally defined as pile fabrics that have not been cut including at least
two layers of
fabric knitted independently that are interconnected by a separate spacer
yarn. The
spacer fabrics generally provide increased breathability relative to other
fabrics, crush
resistance, and a three dimensional appearance. The at least two fabric layers
may be
the same or different, i.e., the same or different density, mesh, materials,
and like
depending on the intended application. When employing the spacer fabric, a
lightweight flame retardant barrier layer may be disposed intermediate to the
mattress
foam layers and the spacer fabric about the perimeter of the side rail
assembly.
[0043] The mattress assemblies described herein may further include
additional layers and the embodiments described herein are not intended to be
limited
with respect to number, type, or arrangement of layers in the mattress and
side rail
assembly. For example, an embodiment of a mattress assembly can further
include a
gel infused viscoelastic foam layer disposed within the mattress, such as on
the
support layer. In another embodiment, the mattress assembly further includes a
cover
panel formed of a viscoelastic foam disposed, for example, on the top layer of
the
mattress having a planar top surface and a convoluted bottom surface. The
convoluted bottom surface, such as an egg crate structure, is in contact with
the top
planar surface of the mattress, which may be in one embodiment, the gel
infused
viscoelastic layer.
[0044] This written description uses examples to disclose the invention,
including the best mode, and also to enable any person skilled in the art to
make and
use the invention. The patentable scope of the invention is defined by the
claims, and
14
CA 02802310 2013-01-15
SSB0394US
may include other examples that occur to those skilled in the art. Such other
examples
are intended to be within the scope of the claims if they have structural
elements that
do not differ from the literal language of the claims, or if they include
equivalent
structural elements with insubstantial differences from the literal languages
of the
claims.
