Mattresses Including Spacer Fabric and Related Methods

This application is a continuation of U.S. patent application Ser. No. 18/121,549, filed Mar. 14, 2023 and titled MATTRESSES INCLUDING GEL CUSHIONS OVER COILS, which is a continuation of U.S. patent application Ser. No. 17/142,147, filed on Jan. 5, 2021 and titled MATTRESSES INCLUDING SPACER FABRIC AND RELATED METHODS, now U.S. Pat. No. 11,602,227, issued Mar. 14, 2023, which is a continuation of U.S. patent application Ser. No. 15/662,934, filed on Jul. 28, 2017 and titled MATTRESSES INCLUDING SPACER FABRIC AND RELATED METHODS, now U.S. Pat. No. 10,881,217, issued Jan. 5, 2021, all of which are incorporated herein by reference in their entireties and for all purposes.

Embodiments of the disclosure relate generally to cushioning elements such as mattresses including spacer fabrics, and to methods of making such mattresses.

Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and/or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well suited to different applications. Cushioning materials may be used in combination with one another to achieve selected properties. For example, mattresses may include pocketed coils in combination with layers of foam, elastomer gels, etc. in order to achieve desired results in the cushioning materials.

In mattresses, springs (e.g., coil springs) may be preferable to foam for their durability and ability to withstand compression. Springs may also impart a feel that may be more desirable to users than that of foam. Despite these advantages, springs may not provide a positive aesthetic and/or tactile experience if they are seen or felt through side panels of the mattress, prompting manufacturers to conceal the feel of springs on the sides of mattresses. One solution includes a wire frame around the edge of the mattress to provide structure to a cover of the mattress. However, the metal of the wire frame may be felt through the cover of the mattress. In addition, such a wire frame may not be particularly suited to handle compression during use and to packing mattresses for shipping and/or storage, such as direct-to-consumer mattresses that are shipped in logs, boxes, etc.

An alternative to conceal the feel and/or visual appearance of springs may be to encase the springs in a foam layer around the perimeter of an inner core of the mattress. While the foam layer may mask the feel of the springs, variations in chemistry and/or manufacturing of the foam may affect quality. In addition, the foam layer may be more susceptible to compression over time due to the foam deteriorating more rapidly than springs. Further, foam encasements may bulge and/or fold during use toward a user's legs, creating both a gap between the materials as well as an undesirable feel along the side panel of the mattress. Alternatively, manufacturers have utilized thicker and/or stiffer side paneling on mattress covers to conceal the feel of springs. However, such side paneling may not entirely cover the springs and may be aesthetically and/or texturally undesirable.

In some embodiments, a mattress assembly may include a base core layer and an inner core located over the base core layer. The inner core may include coil springs. The mattress assembly may also include a side panel assembly located around at least a portion of a perimeter of the inner core. The side panel assembly may include a spacer fabric located over and extending transverse to the base core layer. The spacer fabric may include a first knit layer, a second knit layer, and an inner fibrous material located therebetween.

In other embodiments, a mattress assembly may include a base core layer and an inner core located over the base core layer, the inner core comprising one or more coil springs. The mattress assembly may also include a side panel assembly located around at least a portion of a lateral perimeter of the inner core. The side panel assembly may include a spacer fabric including a first knit layer, a second knit layer, and an inner fibrous material between the first knit layer and the second knit layer.

In further embodiments, a method of forming a mattress assembly may include providing a base core layer as a substrate for a mattress and disposing a plurality of coil springs positioned within individual casings in an inner core located over the base core layer. The method may include disposing a spacer fabric around a perimeter of the inner core. The spacer fabric may define at least a portion of a side panel assembly of the mattress and the spacer fabric may be positioned over the base core layer. The spacer fabric may include a first knit layer, a second knit layer, and an inner fibrous material located therebetween.

The following description provides specific details, such as material types, manufacturing processes, uses, and structures in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional manufacturing techniques and materials employed in the industry.

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice the disclosure. However, other embodiments may be utilized, and structural, procedural, and other changes may be made without departing from the scope of the disclosure. The illustrations presented herein are not meant to be actual views of any particular system, device, structure, or process, but are idealized representations that are employed to describe the embodiments of the disclosure. The drawings presented herein are not necessarily drawn to scale. Similar structures or components in the various drawings may retain the same or similar numbering for the convenience of the reader; however, the similarity in numbering does not mean that the structures or components are necessarily identical in size, composition, configuration, or other property.

As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially met may be at least about 90% met, at least about 95% met, or even at least about 99% met.

As used herein, any relational term, such as “first,” “second,” “top,” “bottom,” “upper,” “lower,” “front,” “back,” “above,” “below,” “horizontal,” “vertical,” “over,” “on,” etc., is used for clarity, consistency of terminology, and convenience in understanding the disclosure and accompanying drawings and does not connote or depend on any specific preference, orientation, or order, except where the context clearly indicates otherwise. For example, the disclosure includes cushioning elements (e.g., mattresses) that may be rotated or flipped in use such that the top thereof faces down and the bottom thereof faces up, and/or the front faces away from the user and the back faces toward the user. Thus, while one example orientation of mattresses is used herein for clarity, other possible orientations are contemplated by and included in the disclosure.

As used herein, the term “cushioning element” means and includes any deformable device intended for use in cushioning one body (e.g., a person, animal, or object) relative to another. As a non-limiting example, cushioning elements (e.g., mattresses, mattress toppers, seat cushions, etc.) include materials intended for use in cushioning a person, animal, or object relative to another object (e.g., a chair seat) that might otherwise abut against the person, animal or object.

As used herein, the term “elastomeric material” means and includes 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 “elastomeric cushion members,” “elastomer gels,” “gelatinous elastomers,” or simply “gels.”

In some embodiments, a spacer fabric may include material having two separate fabrics, joined by microfilament yarn, to create a breathable, 3D “microclimate” between layers. Spacer fabrics may include uncut pile fabrics including at least two layers of fabric knitted independently that are interconnected by a separate spacer yarn.

In some embodiments, a knitted or knit material may include a fabric formed by interlocking loops of threads or yarns. Such knitted fabrics may be porous and stretchable even when formed of non-stretchable fibers, because the threads can shift within a matrix of loops.

The illustrations presented herein are not actual views of any particular material or device, but are merely idealized representations employed to describe embodiments of the present disclosure. Elements common between figures may retain the same numerical designation.

Embodiments of the present disclosure describes mattresses including a spacer fabric (i.e., 3D fabric having multiple layers of varying materials in a sandwiched configuration) located in and/or defining a side panel assembly thereof. The spacer fabric can be of a sufficient thickness and having suitable compressive properties (e.g., resilience and/or resistance) for providing some cushioning effect when used in conjunction with a mattress, mattress topper, or other cushioning element having side panels. The spacer fabric may alleviate problems associated with cushioning materials (e.g., springs) being felt or seen through the side panels of the mattress. In particular, the spacer fabric located in the side panel assembly may reduce local buckling toward a user's legs during use, and thus a mattress utilizing such spacer fabric may be more comfortable and/or visually attractive to the user. In addition, use of the spacer fabric in the side panel assembly of a mattress as disclosed herein may allow compression in a particular direction (e.g., vertical) in order to facilitate packing of the mattress for shipping and/or storage.

shows a top perspective view of a mattress assembly. For case of illustration, the mattress assemblyofis shown in a cutaway view in which various portions of the cushioning materials have been removed to reveal internal components thereof. The mattress assemblymay include a base core layerhaving generally planar top and bottom surfaces and a side panel assemblylocated over (e.g., on, above, directly over) and extending in a plane generally transverse (e.g., perpendicular) to the base core layer(e.g., extending around the lateral or horizontal sides of the mattress assembly). The base core layermay be formed of a polyurethane foam, for example, although other foams may be utilized. The side panel assemblymay include a spacer fabric, which may be located proximate (e.g., at or near) an outer perimeter of the base core layer. The base core layermay also support one or more coil springs. Individual coil springs(e.g., steel coils) may be encased in respective casings(e.g., polypropylene socks) in which the casingsmay form a pocket for each of the individual coil springs, commonly referred to as “pocketed coils.” Individual casingsincluding respective coil springsmay be positioned proximate one another and may be located within an inner coreof the mattress assembly. The coil springsmay be aligned vertically (i.e., generally transverse to the base core layer) to provide cushioning support. In some embodiments, the casingsincluding the coil springsmay be further configured (e.g., encased, joined, etc.) to function as a single body in the inner core. An upper foam layerhaving generally planar top and bottom surfaces may be located over the inner coreand thus over upper ends of the casingsincluding the coil springs. In some embodiments, a lower surface of the upper foam layermay be located in direct physical contact with an upper surface of the casings. In some embodiments, the upper foam layermay be located over and at least partially extended over an upper surface of the spacer fabric. The upper foam layermay or may not be attached or adhered (e.g., sewn, glued, etc.) to the spacer fabric.

The spacer fabricmay include a spacer layer and, in some embodiments, may be utilized to transport moisture vapor and heat away while allowing air flow in addition to providing cushioning support. For example, the spacer fabricmay include at least two adjacently stacked layers of three-dimensional material. In some embodiments, the spacer fabricmay include a non-crush, three-dimensional (3D) fabric, such as a knit, cloth, polymeric film, foam, and extruded woven fibers. Further, the spacer fabricmay include a material having fibers having lateral flexibility for reducing shear forces by providing a degree of lateral flexing during movement. For example, materials of the spacer fabricmay be configured to facilitate bending and transverse movement thereof while resisting applied forces in a direction normal to the spacer fabric. The spacer fabricmay include such 3D materials (e.g., AIRSKIN® spacer fabrics) commercially available through Springs Creative Products Group, LLC of Rock Hill, SC, to provide cushioning support in at least a portion of the side panel assembly.

As shown in, one or more elastomeric cushion membersmay be located over an upper surface of the upper foam layer. The elastomeric cushion membermay include a flexible, resilient, gel cushioning media having shape memory. Such gels may be used for cushioning and/or temperature management. Gels may provide cushioning because the gels may hydrostatically flow to the shape of a cushioned object and may tend to relieve pressure peaks and/or gels may reduce stresses from shear. For example, the elastomeric material may increase comfort for a user of the cushioning elements, or may decrease resistance to shear forces which can in turn help prevent decubitus ulcers in medical patients. Such elastomeric cushion membersare summarized in U.S. Pat. No. 8,784,982, issued Jul. 22, 2014 to Pearce et al., the disclosure of which is incorporated herein in its entirety by this reference. In addition, the elastomeric cushion membersmay include interconnected buckling walls summarized in U.S. Pat. No. 8,919,750, issued Dec. 30, 2014 to Pearce et al., which is assigned to the Assignee of the present disclosure, the disclosure of which is incorporated herein in its entirety by this reference.

The elastomeric cushion membermay include a stabilizing materialon at least a bottom surface thereof. The stabilizing materialmay include a relatively thin material (e.g., cotton spandex “scrim”) and may be used to provide a surface for adhering (e.g., gluing) the elastomeric cushion memberto surrounding materials, such as another elastomeric cushion memberand/or an upper surface of the upper foam layer. In some embodiments, the stabilizing materialmay comprise a scrim fabric (e.g., a woven or non-woven fabric material) and portions of the elastomeric cushion membermay seep through (e.g., be melt-fused into, bleed through, push through, leak through, pass through, etc.) the scrim fabric of the stabilizing material. For example, when the elastomeric cushion memberincludes a gel material, portions of the gel material may be heat fused through the stabilizing material. The portions of the elastomeric cushion memberthat extend through the scrim fabric of the stabilizing materialmay create a non-slip surface or reduced slip surface on a lower surface of the stabilizing material(e.g., surface that would contact an upper surface of the upper foam layer). The non-slip surface or reduced slip surface created by the elastomeric cushion membermay help the cushioning materials stay in place relative to one another.

The mattress assemblymay also include an optional top layerover an upper surface of the elastomeric cushion member. The optional top layermay include, for example, a breathable material (e.g., a material comprising foam or batting fiber). A covermay be located over an upper surface of the optional top layeror, alternatively, over an upper surface of the elastomeric cushion memberand/or the upper foam layer. In some embodiments, the covermay include a single continuous sheet of material extending over upper surfaces, under bottom surfaces, and around side surfaces of the mattress assembly. In other words, the covermay fully encase each of the layers and/or materials within the mattress assembly. In other embodiments, the covermay include individual panels or portions that have been joined in order to provide an outer protective covering for at least a portion of the mattress assembly.

is an end view illustrating a portion of the mattress assemblyincluding the side panel assembly. The end view ofmay represent a portion of any one of side surfaces of the mattress assembly. A side surface may include a surface disposed along lateral sides (e.g., around a periphery of the mattress) and ends of the mattress assemblythat are normally in a substantially vertical orientation during use. The side panel assemblymay include the spacer fabriclocated between the base core layerand the upper foam layerin order to conceal and/or protect components of the inner core(not shown) of the mattress assembly. As shown in, the spacer fabricmay be located proximate (e.g., at or near) a perimeter of each of the base core layerand the upper foam layerin which each of the base core layerand the upper foam layermay be in direct physical contact with the spacer fabric. In some embodiments, the spacer fabricmay be positioned between the inner coreand the cover() and may be in direct physical contact with (e.g., encased only by) the cover. In other embodiments, an additional layer of material may be located between the spacer materialand the cover.

In some embodiments, each of the base core layer, the spacer fabric, the upper foam layer, and the elastomeric cushion membermay be sized and positioned such that outer vertical edges thereof define an outer wall of the side panel assembly. In such a configuration, an outer portion of the spacer fabricmay be substantially aligned with an outer end surface of each of the base core layerand the upper foam layer, defining, in part, the outer wall of the side panel assembly, and thus providing sidewall structure for the mattress assembly. For example, a lower surface of the spacer fabricmay abut the upper surface of the base core layerand an upper surface of the spacer fabricmay abut the lower surface of the upper foam layer. In other embodiments, each of the base core layer, the upper foam layer, and the elastomeric cushion membermay be sized and positioned such that outer vertical edges thereof are internal to the outer wall of the side panel assemblyby a distance substantially equal to a thickness of the spacer fabric. In such a configuration, the spacer fabricmay extend from a top to a bottom of the side panel assemblyin which the spacer fabricalone defines an outer wall of the side panel assembly.

The spacer fabricmay be coupled with other cushioning elements of the mattress assemblyin which the spacer fabricmay be attached or adhered to surrounding materials utilizing adhesives, thermal bonding, or mechanical fasteners. For example, the spacer fabricmay be attached to surrounding cushioning materials using hog rings, zippers, stitching and/or sewing, pockets, staples, buttons, heat fusing, etc. In addition, the spacer fabricmay be adhered to surrounding cushioning materials using glue (hot glue, water-based glue, etc.), hook-and-loop adhesives, or other such adhesive materials. In some embodiments, a lower surface of the spacer fabricmay be attached or adhered to an upper surfaceof the base core layerand/or an upper surface of the spacer fabricmay be adhered to a lower surfaceof the upper foam layer. In other embodiments, the spacer fabricmay not be attached or adhered to either of the base core layeror the upper foam layer, but may remain free to move relative thereto. For example, the spacer fabricmay be free floating and may rely on tension between the coverand the inner core() to hold the spacer fabricin place. In some embodiments, the spacer fabricmay be sewn into the side paneling of the coverso as to form a part thereof. In yet other embodiments, the spacer fabricmay be attached to one or more elements of the inner coreof the mattress assemblyas described in greater detail below. Further, the spacer fabricmay be attached at multiple locations using a combination of attachment and/or adherence articles. When the mattress assemblyis subjected to a process involving compression, packing, and decompression, the spacer fabricmay bulge or decompress in an unsatisfactory manner. For example, if the spacer fabricis only attached on the top and bottom, the spacer fabricmay bulge in the middle when unpacked and/or the spacer fabricmay bulge in the middle during use. Alternatively, if the spacer fabricis only attached in the middle, the top and bottom may flare out. Therefore, the spacer fabricmay be attached or adhered at strategic locations to ensure satisfactory performance and aesthetics, such as in the middle, as well as at the top and bottom thereof. It may be appreciated that other configurations for attachment may be employed.

The spacer fabricmay be wrapped along any one or all four vertical sides of the mattress assemblydefining an outer lateral periphery of the mattress assembly. In some embodiments, the spacer fabricmay be wrapped around the four vertical sides of the mattress assemblyin a single continuous piece of fabric. In such a configuration, the spacer fabricmay be aligned vertically along at least a portion of the side panel assemblywithout being aligned horizontally among other cushioning elements of the mattress assembly. In other embodiments, the spacer fabricmay be wrapped under a lower surface of the base core layerand upward along each of the four vertical sides so as to form a “bucket.” It may be appreciated that the spacer fabricmay be applied to or within the mattress assemblyin any configuration to facilitate coverage of selected portions and/or an entirety of the vertical sides thereof. In some embodiments, the spacer fabricmay be utilized in the side panel assemblyalong an entire vertical side (i.e., top to bottom) of the mattress assemblyas described in greater detail above. In other embodiments, the spacer fabricmay not extend from the top to the bottom of the mattress assembly, but may only extend along a portion of the side panel assembly. In such an embodiment, the spacer fabricmay be located to cover at least a portion of a designated area, such as to cover at least a portion of the inner corecontaining the coil springswithin the casings.

As shown in, one or more (e.g., two) elastomeric cushion membersmay be located over the upper foam layer. As described in greater detail above, the stabilizing materialmay be located on a bottom surface of each of the elastomeric cushion members. In this manner, the stabilizing materialmay be utilized as a stable surface with which to attach or adhere the elastomeric cushion membersto one another and/or to an upper surface of the upper foam layer. In some embodiments, the elastomeric cushion membersmay include a single elastomeric cushion memberof a selected thickness in which the thickness thereof may be selected for specific cushioning support. For example, the thickness of the elastomeric cushion membermay be selected based at least in part by the size of the mattress assembly. By way of non-limiting example, the elastomeric cushion membersmay have a thickness (e.g., vertical height) of about 2 in (0.0508 m), 3 in (0.0762 m), or 4 in (0.1016 m), which thickness may be dependent in part on the size of the mattress assemblyalong with desired cushioning properties thereof. The optional top layermay be located over an upper surface of an uppermost elastomeric cushion memberand the cover() may be located over the optional top layerand/or surrounding at least a portion of the mattress assembly.

In order to accommodate differing size requirements (e.g., king, queen, full, single, etc.) of the mattress assemblyand/or for desired cushioning properties thereof, the size, thickness and stiffness of cushioning materials may be adjusted. In some embodiments, the base core layermay include a foam layer (e.g., high resilience flexible polyurethane foam) having a thickness between about 0.5 in and 2 in. By way of non-limiting example, the base core layermay have a thickness of about lin. In some embodiments, the base core layermay have a bulk foam density of about 2.0 lbs/inand may have an Indentation Force Deflection (IFD) between about 40 lbs/50 inand 70 lbs/50 in. Indentation Force Deflection (IFD) is defined as a force required to compress 50 inof a 20 in by 20 in by 4 in sample by 25%, as measured in accordance with ASTM Standard D3574 (Standard Test Methods for Flexible Cellular Materials-Slab, Bonded, and Molded Urethane Foams, ASTM Int'l, West Conshohocken, PA, 2011). By way of non-limiting example, the IFD of the base core layermay be about 55 lbs/50 in. In addition, the spacer fabricmay have vertical height of between about 6 in and 9 in. By way of non-limiting example, the spacer fabricmay have a vertical height of about 7.5 in. In some embodiments, the upper foam layermay include a foam layer (e.g., high resilience flexible polyurethane foam) having a thickness between about 0.25 in and 1 in. By way of non-limiting example, the upper foam layermay have a thickness of about 0.5 in. In some embodiments, the upper foam layermay have a bulk foam density of about 2.0 lbs/inand may have an IFD between about 10 lbs/50 inand about 40 lbs/50 in. By way of non-limiting example, the IFD of the upper foam layermay be about 18 lbs/50 in.

The elastomeric cushion membermay include one or more layers of an elastomer gel material (e.g., a flexible, resilient, gel cushioning media having shape memory) having a thickness of about 2 in (0.0508 m), 3 in (0.0762 m), or 4 in (0.1016 m). Further, in order to accommodate size requirements and/or to achieve a particular look or feel of the mattress assembly, the size of the spacer fabric, including the stiffness of the micro-filaments, the yarn crimp, the weave or knit, as well as the volume fraction in the spacer fabricmay be adjusted. As understood by those of ordinary skill in the art, the durometer (hardness) of such fabric may be controlled by thickness and density of the internal fibers, and the density of the outer layers being connected by such internal fibers. By way of non-limiting example, the spacer fabricmay have a material density of about 1200 grams per square meter (g/m).

A queen mattress having a side panel height of about 10 in may include the base core layer(e.g., conventional foam) having a thickness of about 1 in, a density of about 1.8 lb/ft., and an IFD of about 55 lbs/50 in. The 10 in queen mattress may include the inner corehaving a height of about 6.5 in, the upper foam layer(e.g., conventional foam) having a thickness of about 0.5 in, a density of about 1.8 lb/ft., and an IFD of about 18 lbs/50 in, and the elastomeric cushion memberhaving a height of about 2 in in either full coverage (i.e., edge to edge) or in two 25 in by 56 in pieces while leaving a perimeter free of the elastomeric cushion member. In some embodiments, the perimeter may include a foam layer (e.g., conventional foam) having a thickness of about 1.95 in, a density of about 1.8 lb/ft., and an IFD of about 18 lbs/50 in. The lateral distance of the foam perimeter may be between about 3 in to about 9 in.

A queen mattress having a side panel height of about 12 in may include the base core layerhaving a thickness of about 1 in, a density of about 1.8 lb./ft., and an IFD of about 55 lbs/50 in. The 12 in queen mattress may include the inner corehaving a height of about 7.5 in the upper foam layerhaving a thickness of about 0.5 in, a density of about 1.8 lb/ft., and an IFD of about 18 lbs/50 in, and the elastomeric cushion memberhaving a height of about 3 in in full coverage.

A queen mattress having a side panel height of about 14 in may include the base core layerhaving a thickness of about 1 in, a density of about 1.8 lb/ft., and an IFD of about 55 lbs/50 in. The 14 in queen mattress may include the inner corehaving a height of about 8.5 in, the upper foam layerhaving a thickness of about 0.5 in, a density of about 1.8 lb/ft., and an IFD of about 18 lbs/50 in, and the elastomeric cushion memberhaving a height of about 4 in in full coverage.

is a cross-sectional side view illustrating a portion of the mattress assemblyincluding the spacer fabric. The spacer fabricmay include a first knit layer, an inner fibrous material, and a second knit layer. The first knit layerand the second knit layermay be generally aligned (e.g., perpendicular) with one another to support the inner fibrous materiallocated (e.g., sewn) therebetween. As shown in, the first knit layermay be located proximate the outermost edge of the mattress assembly. In other words, the first knit layermay define at least a portion of the outer boundary of the side panel assemblyand, thus, be located proximate (e.g., at) an outer boundary of the mattress assembly, and may further lack cushioning materials (e.g., foam material) in a region between the spacer fabricand the cover(). The second knit layermay be located inward from the outer boundary of the mattress assemblyand may be located proximate (e.g., at a boundary of) the inner coreof the mattress assembly. Further, the second knit layermay be proximate to (e.g., in direct physical contact with) an outer surface of the outermost casingsincluding the coil springsand may lack cushioning materials (e.g., foam) between the spacer fabricand the inner coreincluding the casingsand the coil springs.

Portions of the spacer fabricmay be attached or adhered to surrounding cushioning materials of the mattress assembly. In some embodiments, portions of the spacer fabric(e.g., the second knit layer) may be attached or adhered to the outer surface of the casingsand/or the coil springs. For example, at least a portion of the second knit layerand/or at least a portion of the inner fibrous materialmay be coupled to a rung of the outermost coil spring. By way of non-limiting example, the spacer fabricmay be coupled to the rung of the outermost coil springusing fasteners. In some embodiments, fasteners(e.g., hog rings) are only attached or attached primarily to the second knit layerof the spacer fabricso as to prevent unnecessary divots and/or indentations along the side panel assemblythat would be caused by the fastenerpulling an outside edge of the spacer fabricinward. In other embodiments, the fastenersmay be attached or adhered (e.g., sewn, glued, heat fused, etc.) to other surrounding materials, such as the base core layer, the casings, and/or the upper foam layer, for example.

is a cross-sectional top view illustrating a portion of the mattress assembly. An upper end view of the casingsincluding the coil springsis depicted from looking downward toward the base core layer. The casingsincluding the coil springsmay be located within the inner coreof the mattress assemblyas described in greater detail with reference to. The spacer fabricincludes the first knit layerand the second knit layerhaving the inner fibrous materialtherebetween. In some embodiments, portions of the spacer fabric(e.g., the second knit layer) may be attached or adhered to the outer surface of the casingsand/or the coil springs. For example, the fastenersmay extend through at least a portion of the second knit layerand/or at least a portion of the inner fibrous material, through at least a portion of the casings, and coupled to a rung of the outermost coil spring. By way of non-limiting example, the spacer fabricmay be coupled to the rung of the outermost coil springusing the fasteners(e.g., hog rings). In other embodiments, at least a portion of the spacer fabricmay be adhered (e.g., sewn, glued, etc.) to surrounding materials, such as the casings, for example.

In some embodiments, the spacer fabricmay be formulated such that the spacer fabricis more readily compressible in a direction that is generally transverse (e.g., perpendicular) to threads of the inner fibrous material. For example, the spacer fabricmay be relatively more compressible along a first axis (e.g., vertical axis) than that of a second axis and a third axis (e.g., horizontal axes), which axes are located generally transverse (e.g., perpendicular) to the first axis. In other words, the spacer fabricmay be configured and positioned to exhibit a first elasticity along the first axis (e.g., vertical axis) having a relatively greater elasticity (e.g., modulus of elasticity) than that of a second and third elasticity along each of the second axis and the third axis. In this manner, the mattress assemblyincluding the side panel assemblymay allow deformation (e.g., compression) in a designated direction (e.g., vertical direction) in order to facilitate packing of the mattress assemblyfor shipping and/or storage. Such relative elasticity properties may be determined by an inherent knitted pattern in each of the first knit layerand the second knit layer. For example, each of the first knit layerand the second knit layermay include a knitted pattern having an increased elasticity (e.g., a lower relative stiffness, more susceptible to buckling) along the first axis (e.g., vertical axis) while having a reduced elasticity (e.g., a higher relative stiffness, less susceptible to buckling) along the second axis (e.g., lateral). In such an embodiment, the fibers of the inner fibrous materialare disposed along the third axis (e.g., lateral axis) extending from the outermost edge of the side panel assemblyinward toward the inner corethereof. In some embodiments, the compressibility (e.g., decrease of an initial thickness due to an increase of compressive force) of the spacer fabricalong the first axis may be greater than the compressibility of the spacer fabricalong the second axis, which in turn is greater than the compressibility of the spacer fabricalong the third axis (i.e., aligned with the fibers of the inner fibrous material) in order to facilitate compression of the mattress assembly. Upon delivery and use thereof, the mattress assemblymay be decompressed and restored to a full extent (e.g., may recover from an elastic deformation). In such an embodiment, the spacer fabricmay be configured to be decompressed and restored to a full extent without deforming or harming the cushioning materials thereof. Thus, foam products may be reduced (e.g., minimized or eliminated) in the side panel assemblyto facilitate compressibility during shipping and/or storing while providing a positive aesthetic and/or tactile experience during use.

Additional non-limiting example embodiments of the disclosure are described below.

Embodiment 1: 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.

Embodiment 2: The mattress assembly of Embodiment 1, further comprising: at least one elastomeric cushion member located over the inner core; and a stabilizing material located on a lower surface of the at least one elastomeric cushion member.

Embodiment 3: The mattress assembly of Embodiment 2, wherein the stabilizing material comprises a thin material comprising cotton spandex adhered to the lower surface of the at least one elastomeric cushion member.

Embodiment 4: The mattress assembly of Embodiment 2, further comprising: an upper foam layer located between the inner core and the at least one elastomeric cushion member; a cover located over the upper foam layer, the cover disposed around at least a portion of the side panel assembly; and a top layer located between an upper surface of an uppermost elastomeric cushion member and the cover.

Embodiment 5: The mattress assembly of Embodiment 4, wherein a lower surface of the spacer fabric abuts an upper surface of the base core layer and an upper surface of the spacer fabric abuts a lower surface of the upper foam layer.

Embodiment 6: The mattress assembly of Embodiment 5, wherein a region located between the upper surface of the base core layer and the lower surface of the upper foam layer is substantially free of foam material.

Embodiment 7: The mattress assembly of Embodiment 4, wherein an outer surface of each of the base core layer, the spacer fabric, the upper foam layer, and the at least one elastomeric cushion member defines an outer surface of the mattress assembly.

Embodiment 8: The mattress assembly of Embodiment 4, further comprising fasteners coupled between the spacer fabric and at least one of the base core layer, the coil springs, or the upper foam layer, wherein the fasteners comprise at least one of hog rings, zippers, stitching, sewing, pockets, staples, buttons, heat fusing, or adhesives.

Embodiment 9: The mattress assembly of Embodiment 4, wherein the spacer fabric is sewn into a side paneling of the cover.

Embodiment 10: 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, a second knit layer, and an inner fibrous material between the first knit layer and the second knit layer.

Embodiment 11: The mattress assembly of Embodiment 10, further comprising at least one elastomeric cushion member located over the inner core.