Purple Innovation, LLC

A mattress assembly includes a base layer, a coil layer disposed over the base layer, an upper layer disposed over the coil layer, and an elastomeric cushioning element disposed over the upper layer. The coil layer may include a plurality of pocketed coils. Furthermore, the elastomeric cushioning element may have a thickness within a range of about 2.0 inches to about 4.5 inches. Furthermore, the elastomeric cushioning element may form between about 15.0% and about 32.0% of an overall thickness of the mattress assembly. A method of forming a mattress assembly includes disposing a coil layer over a base layer, disposing an upper layer over the coil layer, disposing an elastomeric cushioning element over the upper layer, and disposing an outer covering over at least the upper layer.

A cushion member includes a cushioning layer and a cap at surrounding the cushioning layer. The cushioning layer includes a cushion element such as an elastomeric polymer. The cap includes a top panel with a fire-retardant material configured to bond with the cushion element. The cap further includes a periphery extending downwardly from an edge of the top panel and surrounding the cushioning layer. The cushion member can also include a plurality of cushioning layers and in such case, the periphery surrounding the plurality of cushioning layer. To bond the cap to the cushioning layer with the cushion element, heat can be applied to the cushion element at a contact point between the top panel and the cushioning layer.

An active airflow system includes a cushion assembly and an air circulation device. The cushion assembly includes a base layer, a coil layer, an upper layer, an elastomeric cushioning element, and an outer cover. The coil layer includes a plurality of coils arranged in an array and spaced apart. The elastomeric cushioning element includes a plurality of interconnected buckling walls that define a plurality of hollow columns. The air circulation device directs air to flow through the array of the plurality of pocketed coils of the cushion assembly. Additionally, the coil layer includes a plurality of internal barriers that forms a plurality of regions in the coil layer. The upper layer comprises a foam with a plurality of perforations. The perforations have a diameter greater than the thickness of the upper layer.

The present disclosure is directed to an elastomeric cushioning element. The elastomeric cushioning element may include about 5 wt. % to about 50 wt. % elastomeric polymer network comprising a triblock copolymer having an average molecular weight of about 100,000 Da to about 500,000 Da; and about 50 wt. % to about 95 wt. % plasticizer disposed in the elastomeric polymer network. The plasticizer may include a first plasticizer having an average molecular weight of about 300 Da to about 800 Da and a viscosity at 40° C. of about 20 cSt to about 10,000 cSt.

A cushion assembly includes a plurality of layers, including a plurality of buckling layers, arranged in a stack. The plurality of buckling layers includes a first buckling layer, and a second buckling layer disposed over the first buckling layer. The plurality of buckling layers includes a plurality of buckling points such that the plurality of buckling layers buckle under different loading conditions. For example, the first buckling layer is configured with a first buckling point and the second buckling layer is configured with a second buckling point different than the first buckling point. The cushion assembly may further include a first intermediate layer disposed over a coil layer, the plurality of buckling layers disposed over the first intermediate layer, and a microgrid layer disposed over the second intermediate layer. The intermediate layers include a foam, and the buckling layers and the microgrid layer include an elastomeric cushioning element.

Systems and methods for a cushion with at least one firmness feature are provided. A cushion may include an array of interconnected columns having a height extending through at least a portion of a thickness of the cushion. At least one column of the array of interconnected columns may include at least one wall defined from a compressible, resilient material and a firmness-defining feature structured as a spine protruding from the at least one wall and extending uniformly along a height of the at least one wall.

An inverting conveyor system includes a series of conveyors that can invert a flexible article of manufacture, such as a cushioning element (e.g., a cushioning element of a mattress, etc.) formed from an elastomeric gel. The inverting conveyor system includes a first conveyor, a second conveyor, and an optional third conveyor. The first conveyor receives the flexible article of manufacture in an inverted orientation. The second conveyor is associated with the first conveyor in a manner that enables inversion of the flexible article of manufacture from the inverted orientation to an upright orientation. The third conveyor receives the flexible article of manufacture from the second conveyor and transports it to a desired destination. Methods for inserting flexible articles of manufacture are also disclosed.

A smart bed with a mattress that detects the one or more physical inputs, identifies at least one function corresponding to each physical input, and responds to each physical input by executing the at least one function. The physical input may be provided as a tap, pat, slap, stomp, or kick on a surface of the mattress. One or more sensors of the mattress may detect each physical input. A processor of the smart bed may identify and execute the at least one function associated with the at least one physical input. In addition, the processor may identify an individual who provided the physical input(s) and execute the corresponding function(s) in a manner tailored to the individual who provided the physical input(s). Methods of using such a smart bed are also disclosed.

A method for forming a cushioning element comprises molding a first cushioning element on a first side of a fabric and molding a second cushioning element on a second side of the fabric. The first cushioning element and second cushioning element may be superimposed. The fabric may include a first layer and a second layer that are superimposed, with the first cushioning element secured to and protruding from the first layer and the second cushioning element secured to and protruding from the second layer. Each of the first cushioning element and second cushioning element may include a plurality of interconnected walls formed from an elastomeric gel material. The walls of the first cushioning element and second cushioning element may be aligned or offset.

A cushioning system may include sensor strip coupled to a cushion. The sensor strip may include a first textile layer, at least one sensor supported by the first textile layer, a second textile layer superimposed with the first textile layer and covering the at least one sensor. At least a portion of a perimeter of the second textile layer coupled to at least a portion of a perimeter of the first textile layer. The sensor strip may be coupled to the cushion by an anchor. The anchor may include a base positionable beneath the sensor strip, a first wing extending from a first side of the base and coupled to the sensor strip, a second wing extending from a second side of the base opposite from the first side and coupled to the sensor strip, and a fastener configured to removable couple the anchor between the cushion and a cover.