Purple Innovation, LLC

Brett Pearson

James Thomas Grutta

Brock Keith Harris

Russell B Whatcott

Michael Allen Pierce

Dhyey Yogesh Acharya

Robert Wayne Taylor

Aubree Carter

David Ewell

Bob Watters

Thomas Bennett

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 optional 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.

Inverting conveyor system for flexible articles of manufacture

A mattress includes one or more sensors. The sensor(s) may be positioned on a sleep surface of the mattress; for example, at locations where an individual's thorax and/or legs would be positioned when the individual assumes a sleeping position on the sleep surface. The sensor(s) may be positioned adjacent to an edge of the mattress, on the sleep surface or on the edge. A processor may be associated with the sensor(s) of the mattress. The processor may process signals received from the sensor(s) to provide information about the mattress, an individual on the mattress, and/or an environment in which the mattress is located.

Mattress with sensors

A composite mattress includes a pressurizable layer and a top layer. A coiled spring layer may also be included in the composite mattress. The composite mattress may also include a base layer and/or an intermediate layer. A foundation, or rail, may laterally surround the pressurizable layer and the top layer. The composite mattress may include a cover, including a base panel, a periphery, and a top panel. The cover may encase the other components of the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples customize a mattress by selecting one or more tops from a plurality of available for use with one or more bases from a plurality of available bases.

Composite mattresses with air chambers

An article of manufacture, such as a weighted blanket, a cushioning element, or the like, includes an elastomeric element that includes elongated elements that follow nonlinear, partially overlapping paths and voids between adjacent portions of the elongated elements. Such an elastomeric element may define a weighted layer of a weighted blanket, a cushioning layer of a cushioning element of the like. The elastomeric element may be secured directly to a substrate, such as a fabric layer. Alternatively, an adhesion layer may secure the elastomeric element to the substrate. An adhesion layer may cover only a portion of the substrate. A cover may be provided over the elastomeric element. Together, the cover and the substrate may contain the elastomeric element.

Printed elastomeric elements

A ventilated mattress includes a ventilation system with an air distribution layer and a gel cushioning layer over the air distribution layer. The air distribution layer may include channels in a surface thereof, while voids that extend through an entire thickness of the gel cushioning layer may include voids that communicate with the channels. As the ventilation system forces air into the air distribution layer, the air may flow through the channels, into and through the voids of the gel cushioning layer, and to a top of the ventilated mattress.

Air distribution for mattresses

A composite mattress includes a pressurizable layer and a top layer. A coiled spring layer may also be included in the composite mattress. The composite mattress may also include a base layer and/or an intermediate layer. A foundation, or rail, may laterally surround the pressurizable layer and the top layer. The composite mattress may include a cover, including a base panel, a periphery, and a top panel. The cover may encase the other components of the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples to customize a mattress by selecting one or more tops from a plurality of available tops for use with one or more bases from a plurality of available bases.

A cushioning element includes pressurizable cells. The pressurizable cells of the cushioning elements are grouped into a plurality of sets, with each set of pressurizable cells being independently pressurizable from every other set of pressurizable cells of the cushioning element. The pressurizable cells may extend across a widths of the cushioning element and be arranged in series along the length of the cushioning element. Such a cushioning element may be part of a cushion, such as a mattress, a mattress topper, or the like. Methods for manufacturing the cushioning elements are also disclosed.

Cushioning elements with pressurizable cells

Ventilated mattresses

A composite mattress includes a base panel of a cover, a base layer, a pressurizable layer, an intermediate layer, a top layer, and a top panel of the cover. A foundation, or rail, laterally surrounds the pressurizable layer, the intermediate layer, and the top layer. A periphery of the cover laterally surrounds the foundation and, with the top panel and the base panel, encases the other components of the composite mattress. A coiled spring layer may also be included in the composite mattress. The composite mattress may include a separable top and bottom; these elements may be modular, enabling individuals or couples customize a mattress by selecting one or more tops from a plurality of available for use with one or more bases from a plurality of available bases.

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Taylorsville, UT, United States of America

Brett Pearson