BODY SUPPORT STRUCTURE COMPRISING TOPPER HAVING OPPOSED SURFACES WITH VARYING FIRMNESS

Abstract

A body support structure comprising a support layer; and at least one topper layer above the support layer and comprising a first material, a first surface, a second surface, and gel bodies embedded in the first material. Each gel body may have a first portion in proximity to the first surface that has a first firmness and a second portion in proximity to the second surface that has a second firmness, and/or the gel bodies are a plurality of first gel bodies and a plurality of second gel bodies, wherein each first gel body has a first firmness and is closer than any second gel body to the first surface, and each second gel body has a second firmness and is closer than any first gel body to the second surface. I also disclose methods and systems for manufacturing such body support structures.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

Generally, the present disclosure relates to body support structures, such as mattresses, cushions, pillows, and the like, comprising a topper having opposed surfaces that vary in firmness.

Description of the Related Art

Foam body support structures, e.g., pillows, cushions, mattress toppers, and mattresses, such as viscoelastic or so-called “memory foam” mattresses, provide desirably high levels of firmness and support for many users. However, mattresses comprising only viscoelastic foam may lack sufficient support for some users. Also, mattresses comprising only one particular type of foam may lack desired levels of support for certain regions of a user's body.

Attempts to resolve these issues include the use of mattress toppers, including toppers comprising gel bodies embedded in a suitable material and/or bonded to upper and/or lower fabric layers. However, existing gel toppers provide uniform support to all users of a mattress, and thus, if the partners sharing a mattress have different support preferences, one of the partners may be dissatisfied by a mattress topper providing support preferred by the other, or both partners may be dissatisfied if, in an effort to compromise, they select a mattress topper that is “neither fish nor fowl,” providing too little support for one and too much support for the other.

The present disclosure may address and/or at least reduce one or more of the problems identified above.

SUMMARY OF THE INVENTION

The following presents a simplified summary of the disclosure in order to provide a basic understanding of some aspects of the disclosure. This summary is not an exhaustive overview of the disclosure. It is not intended to identify key or critical elements of the disclosure, or to delineate the scope of the disclosure. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.

In one embodiment, the present disclosure is directed to a body support structure, comprising a support layer; and at least one topper layer above the support layer and comprising a first material, a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has a first firmness and a second portion in proximity to the second surface that has a second firmness.

In one embodiment, the present disclosure is directed to a method, comprising forming a support layer of a body support structure; forming from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has a first firmness and a second portion in proximity to the second surface that has a second firmness; and affixing the at least one topper layer to the body support structure above the support layer.

In one embodiment, the present disclosure is directed to a system, comprising a user interface configured to receive a first user preference between at least a first firmness and a second firmness; and a manufacturing system configured to: form a support layer of a body support structure; form from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has the first firmness and a second portion in proximity to the second surface that has the second firmness; and affix the at least one topper layer to the body support structure above the support layer, such that (a) the first surface is in proximity to the support layer if the first user preference is for the second firmness or (b) the second surface is in proximity to the support layer if the first user preference is for the first firmness.

In one embodiment, the present disclosure is directed to a body support structure, comprising a support layer; and at least one topper layer above the support layer and comprising a first material, a first surface, a second surface, a plurality of first gel bodies embedded in the first material, and a plurality of second gel bodies embedded in the first material, wherein each first gel body has a first firmness and is closer than any second gel body to the first surface, and each second gel body has a second firmness and is closer than any first gel body to the second surface.

In one embodiment, the present disclosure is directed to a method, comprising forming a support layer of a body support structure; forming from a first material at least one topper layer comprising a first surface, a second surface, a plurality of first gel bodies embedded in the first material, and a plurality of second gel bodies embedded in the first material, wherein each first gel body has a first firmness and is closer than any second gel body to the first surface, and each second gel body has a second firmness and is closer than any first gel body to the second surface; and affixing the at least one topper layer to the body support structure.

In one embodiment, the present disclosure is directed to a system, comprising a user interface configured to receive a first user preference between at least a first firmness and a second firmness; and a manufacturing system configured to: form a support layer of a body support structure; form from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, a plurality of first gel bodies embedded in the first material, and a plurality of second gel bodies embedded in the first material, wherein each first gel body has a first firmness and is closer than any second gel body to the first surface, and each second gel body has a second firmness and is closer than any first gel body to the second surface; and affix the at least one topper layer to the body support structure above the support layer, such that (a) the first surface is in proximity to the support layer if the first user preference is for the second firmness or (b) the second surface is in proximity to the support layer if the first user preference is for the first firmness.

The present disclosure may provide for body support structures, e.g., mattresses, pillows, and cushions, with improved comfort for users reclining thereon, even if multiple users have different firmness preferences.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:

FIG. 1 illustrates a stylized top view of a first mattress, in accordance with embodiments herein;

FIG. 2A illustrates a stylized cross-sectional view of a first embodiment of the first mattress of FIG. 1 taken along the A-A′ line in FIG. 1, in accordance with embodiments herein;

FIG. 2B illustrates a stylized cross-sectional view of a second embodiment of the first mattress of FIG. 1 taken along the A-A′ line in FIG. 1, in accordance with embodiments herein;

FIG. 3 illustrates a stylized cross-sectional view of a third embodiment of the first mattress of FIG. 1 taken along the A-A′ line in FIG. 1, in accordance with embodiments herein;

FIG. 4A illustrates a stylized top plan view of a first gel body, in accordance with embodiments herein;

FIG. 4B illustrates a stylized top plan view of a second gel body, in accordance with embodiments herein;

FIG. 4C illustrates a stylized top plan view of a third gel body, in accordance with embodiments herein;

FIG. 4D illustrates a stylized top plan view of a fourth gel body, in accordance with embodiments herein;

FIG. 4E illustrates a stylized top plan view of a fifth gel body, in accordance with embodiments herein;

FIG. 4F illustrates a stylized top plan view of a sixth gel body, in accordance with embodiments herein;

FIG. 4G illustrates a stylized top plan view of a seventh gel body, in accordance with embodiments herein;

FIG. 4H illustrates a stylized top plan view of an eighth gel body, in accordance with embodiments herein;

FIG. 4I illustrates a stylized top plan view of a ninth gel body, in accordance with embodiments herein;

FIG. 5A illustrates a stylized cross-sectional view of a first embodiment of a second mattress corresponding to the view taken along the A-A′ line in FIG. 1, in accordance with embodiments herein;

FIG. 5B illustrates a stylized cross-sectional view of a second embodiment of the second mattress corresponding to the view taken along the A-A′ line in FIG. 1, in accordance with embodiments herein;

FIG. 6 provides a flowchart of a first method, in accordance with embodiments herein;

FIG. 7 provides a flowchart of a second method, in accordance with embodiments herein;

FIG. 8 conceptually depicts a manufacturing system, in accordance with embodiments herein.

FIG. 9 illustrates a stylized top view of a third mattress, in accordance with embodiments herein;

FIG. 10 illustrates a stylized cross-sectional view of a first embodiment of the third mattress of FIG. 9 taken along the B-B′ line in FIG. 9, in accordance with embodiments herein; and

FIGS. 11-14 illustrate stylized isometric views of alternative embodiments of topper layers comprised of a plurality of gel bodies disposed within a first material in accordance with embodiments herein.

For the avoidance of doubt, and in accordance with practice before the United States Patent and Trademark Office, none of the present figures are to scale.

While the subject matter disclosed herein is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood; however, that the description herein of specific embodiments is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.

INCORPORATION BY REFERENCE

The following U.S. patents and published applications are hereby incorporated herein by reference: U.S. Pat. Nos. 10,721,992; 9,775,403; 9,717,304; 9,320,317; 8,434,748; 7,138,079; 7,076,822; 6,865,759; 6,413,458; 6,026,527; 5,994,450; 5,881,409; 5,749,111; 5,626,657; 5,549,743; 5,421,874; 2018/0295941; 2018/0295934; 2015/0230549; 2014/0259748; and 2014/0259743.

DETAILED DESCRIPTION

Various illustrative embodiments of the disclosure are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will, of course, be appreciated that, in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

The present subject matter will now be described with reference to the attached figures. Various structures, systems and devices are schematically depicted in the drawings for purposes of explanation only and to not obscure the present disclosure with details that are well known to those skilled in the art. Nevertheless, the attached drawings are included to describe and explain illustrative examples of the present disclosure. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.

Embodiments herein are directed to body support structures, and methods and systems for manufacturing such body support structures, wherein the body support structures have improved support for multiple users having different support preferences. In some embodiments, body support structures may include pillows, cushions, mattress toppers, and mattresses.

Turning to FIG. 1, a stylized top view of a top layer 110 of a body support structure 100, in accordance with embodiments herein, is illustrated. The body support structure 100 has a generally rectangular profile in top view. For example, the body support structure 100 may be a mattress.

As shown in FIG. 2A and FIG. 2B, the body support structure 100 may comprise a support layer 250, and at least one topper layer 110 above the support layer 250. The topper layer(s) 110 comprise a first material 112, a first surface 110-1, a second surface 110-2, and a plurality of gel bodies (collectively, 120; individual gel bodies 121 and 123 identified) embedded in the first material 112. Each of the gel bodies 120 has a first portion in proximity to the first surface 110-1 that has a first firmness and a second portion in proximity to the second surface 110-2 that has a second firmness. In FIG. 2A and FIG. 2B, the first portions and the second portions of each of the gel bodies 120 are shown in gradient, though this does not indicate that the gel bodies 120 must have a continuous variation in firmness. The gel bodies 120 may be separated by the first material 112, which may take the form of a non-gel material.

In FIG. 2A, the gel bodies 120 are in proximity to, but do not form a part of, the first surface 110-1 and the second surface 110-2. In FIG. 2B, the gel bodies 120 are in proximity to and form a part of the first surface 110-1 and the second surface 110-2.

FIG. 4A-FIG. 4I show particular top views of different embodiments of the individual gel bodies 120 that may be used in the at least one topper layer 110. In one embodiment, each gel body 120 has a shape in top view selected from the group consisting of squares, rectangles, diamonds, parallelograms, other quadrilaterals, triangles, polygons with other than four sides, circles, ellipses, raindrops, and other curved shapes. For example, in FIG. 4A, the gel body has a square shape in top view. In FIG. 4B, the gel body has a rectangular shape in top view. In FIG. 4C, the gel body has a diamond shape in top view. In FIG. 4D, the gel body has a parallelogram shape in top view. In FIG. 4E, the gel body has a triangular shape in top view. In FIG. 4F, the gel body has a hexagonal shape in top view. In FIG. 4G, the gel body has a circular shape in top view. In FIG. 4H, the gel body has an elliptical shape in top view. In FIG. 4I, the gel body has a raindrop shape in top view.

In each gel body shown in FIG. 4A-FIG. 4I, the gel bodies 120 comprise an inner gel portion 442 and an outer, non-gel portion 444. The outer, non-gel portion 444 may be co-integral with the non-gel material 112 shown in FIGS. 1 and 2A-2B. As should be apparent, the firmness of each gel body will depend on the intrinsic firmness per unit volume of the inner gel portion 442, the intrinsic firmness per unit volume of the outer, non-gel portion 444, and the relative proportions of each. For example, the greater the volume of the outer, non-gel portion 444 relative to the volume of the inner gel portion 442, the closer the overall firmness of the gel body will be the intrinsic firmness of the outer, non-gel portion 444.

More information regarding gel bodies, including shapes, structures, components, and manufacturing techniques, can be found in patents incorporated herein by reference.

In one embodiment, the inner gel portions 442 comprise the following components by weight: Styrene block copolymer 2-80%, plasticized oil 10-90%, thermoplastic polystyrene—polybutadiene-polystyrene block copolymer 5-80%, toner 0.03-3%. The formulation may also be characterized in the Chinese language as:

• • 2-80%, : 10-90%
  • 5-80%,
  • 0.3%

In a further embodiment, the inner gel portions 442 may comprise an essential oil additive from 0.01%-5% by weight. In one embodiment, the essential oil component of the essential oil additive is selected from the group consisting of green tea oil, sweet orange oil, menthol oil, peppermint oil, cedarwood oil, lemon oil, eucalyptus oil, aromatic litsea/mountain pepper oil, clove oil, spearmint oil, rose oil, lemongrass oil, lavender oil, thyme oil, alfalfa oil, allspice oil, ambrette (seed) oil, angelica root oil, angelica seed oil, angelica stem oil, angostura (cusparia bark) oil, anise oil, asafetida-foetida oil, balm (lemon balm) oil, balsam of peru oil, basil oil, bay leaves oil, bay (myrcia oil) oil, bergamot (bergamot orange) oil, bitter almond oil, bois de rose oil, cacao oil, camomile (chamomile) flowers oil, cananga oil, capsicum oil, caraway oil, cardamom seed (cardamon) oil, carob bean oil, carrot oil, cascarilla bark oil, cassia bark oil, chinese oil, cassia bark oil, padang or batavia oil, cassia bark oil, saigon oil, celery seed oil, cherry oil, wild oil, bark oil, chervil oil, chicory oil, cinnamon bark oil, ceylon oil, cinnamon bark oil, chinese oil, cinnamon bark oil, saigon oil, cinnamon leaf oil, ceylon oil, cinnamon leaf oil, chinese oil, cinnamon leaf oil, saigon oil, citronella oil, citrus peels oil, clary (clary sage) oil, clover oil, coca (decocainized) oil, coffee oil, cola nut oil, coriander oil, cumin (cummin) oil, curacao orange peel (orange oil, bit oil, cusparia bark oil, dandelion oil, dandelion root oil, dog grass (quackgrass oil, triticum) oil, elder flowers oil, estragole (esdragol oil, esdragon oil, t oil, estragon (tarragon) oil, fennel oil, sweet oil, fenugreek-gr oil, galanga (galangal) oil, geranium oil, geranium oil, east indian oil, geranium oil, rose oil, ginger oil, grapefruit oil, guava oil, hickory bark oil, horehound (hoarhound) oil, hops oil, horsemint oil, hyssop oil, immortelle oil, jasmine oil, juniper (berries) oil, kola nut oil, laurel berries oil, laurel leaves oil, lavender oil, lavender oil, spike oil, lavandin oil, lemon(l.) burm. oil, lemon balm oil, lemongrass oil, lemon peel(l.) oil, lime oil, linden flowers oil, locust bean oil, oil, lupulin oil, mace oil, mandarin oil, marjoram oil, sweet oil, yerba mate oil, melissa (see balm) oil, menthol oil, menthyl acetate oil, molasses (extract) oil, mustard oil, naringin oil, neroli oil, bigarade oil, nutmeg oil, onion oil, orange oil, bitter oil, flowers oil, orange oil, bitter oil, peel oil, orange leaf(l.) oil, orange oil, sweet oil, orange oil, sweet oil, flowers oil, orange oil, sweet oil, peel oil, origanum oil, palmarosa oil, paprika oil, parsley(mi oil, pepper oil, black oil, pepper oil, white oil, peppermint oil, peruvian balsam oil, petitgrain oil, petitgrain lemon oil, petitgrain mandarin or tangerine oil, pimenta oil, pimenta leaf oil, pipsissewa leaves oil, pomegranate oil, prickly ash bark oil, rose absolute oil, rose (otto of roses oil, attar of roses) oil, rose buds oil, rose flowers oil, rose fruit (hips) oil, rose geranium oil, rose leaves oil, rosemary oil, saffron oil, sage oil, sage oil, greek oil, sage oil, spanish oil, St. John's bread oil, savory oil, summer oil, savory oil, winter oil, schinus molle oil, sloe berries (blackthorn berries) oil, spearmint oil, spike lavender oil, tamarind oil, tangerine oil, tarragon oil, tea oil, thyme oil, thyme oil, white oil, thyme oil, wild or creeping oil, tuberose oil, turmeric oil, vanilla oil, violet flowers oil, violet leaves oil, violet leaves absolute oil, wild cherry bark oil, ylang-ylang oil, zedoary bark oil, and combinations thereof.

In one embodiment, the essential oil is green tea oil.

Although the figures show all gel bodies 120 in FIGS. 1 and 2A-2B having the same shape, a person of ordinary skill in the art having the benefit of the present disclosure will readily comprehend that gel bodies 120 may include individual gel bodies of more than one shape. Also, orientations of shapes may be routinely modified as desired. For example, if all gel bodies 120 have a raindrop shape, the orientations of shapes may alternate 180°.

As stated, the body support structure 100 comprises at least one topper layer 110. FIG. 9 and FIG. 10 depict an embodiment comprising two topper layers, a first topper layer 110 and a second topper layer 910. One side 110r of the first topper layer 110 is adjacent to one side 9101 of the second topper layer 910.

The first firmness of the first portions of the gel bodies 120 of the first topper layer 110 is substantially the same as the first firmness of the first portions of the gel bodies 920 of the second topper layer 910, and the second firmness of the second portions of the gel bodies 120 of the first topper layer 110 is substantially the same as the second firmness of the second portions of the gel bodies 920 of the second topper layer 910.

In a further embodiment, as depicted in FIG. 10, the first surface 110-1 of the first topper layer 110 is closer than the second surface 110-2 of the first topper layer 110 to the support layer 250, and the second surface 910-2 of the second topper layer 910 is closer than the first surface 910-1 of the second topper layer 910 to the support layer 250. Accordingly, the first and second topper layers 110 and 910 may be combined such that two partners with different preferences for firmness from a topper layer 110, 910 may share the support layer 250 and each experience their desired firmness.

The topper layer(s) 110 and 910 are not the only possible arrangement of one or more topper layers. For example, a topper layer (not shown) may be positioned in discontinuous portions under the expected location of a first user's head and torso and a second user's head and torso, and a sublayer, such as a sublayer consisting essentially of a viscoelastic foam, a non-viscoelastic foam, a polyurethane foam, etc. may fill in spaces between and around the topper layer, e.g. under the expected position of the users' legs, in a median location between the users, and/or around the perimeter of the body support structure.

Turning to FIG. 3, an embodiment is shown wherein the body support structure 100 further comprises at least one layer 360 below the support layer 250. The body support structure 100 shown in FIG. 3 also further comprises at least one layer 370 between the support layer 250 and the at least one topper layer 110.

FIGS. 5A and 5B present side cross-sectional views of a second body support structure 500 in accordance with embodiments herein. Many features of the second body support structure 500 are identical to or similar to corresponding features of the first body support structure 100 shown in FIG. 1-FIG. 3, FIG. 9, and FIG. 10. For the sake of brevity, such identical or similar features need not be described in detail.

In the embodiment shown in FIG. 5A and FIG. 5B, the body support structure 500 comprises at least one topper layer 110 comprising a first material 112, a first surface 110-1, a second surface 110-2, a plurality of first gel bodies 520 embedded in the first material 112, and a plurality of second gel bodies 530 embedded in the first material 112. Each first gel body (e.g., 521, 523) has a first firmness and is closer than any second gel body 530 to the first surface 110-1. Each second gel body (e.g., 531, 533) has a second firmness and is closer than any first gel body 520 to the second surface 110-2.

Although FIG. 5A and FIG. 5B depict all gel bodies 520 and 530 with graphical elements of the same size, with different firmness represented by different interior shadings, this depiction is made for convenience alone. Specifically, in one embodiment, the first gel bodies 520 and the second gel bodies 530 may have different shapes. If the gel bodies 520 and 530 all provide the same amount of firmness per unit volume of inner gel material, but differ in the relative portion of inner gel material to an outer, non-gel portion of the gel body (see FIG. 4A-4I and accompanying description above), then the first firmness and the second firmness will differ.

FIG. 11 and FIG. 12 show perspective views of two sets of gel bodies, gel bodies 1120 (FIG. 11) and gel bodies 1230 (FIG. 12). The gel bodies 1120 have a larger volume of inner gel material 1142 to outer, non-gel portions 1144 than is the case for the gel bodies 1230, inner gel material 1242, and outer, non-gel portions 1244. If the inner gel material 1142 and 1242 has lower firmness than the outer, non-gel portions 1144 and 1244, then the gel bodies 1120 will have lower firmness than the gel bodies 1230.

It is anticipated that the gel bodies 1120 and 1230 may be located within the topper 110 singularly or as a plurality arranged in a side-by-side arrangement (as shown in FIGS. 5A and 5B) or atop one another (as shown in FIGS. 9 and 10). Additionally, in the configuration set forth in FIGS. 5A and 5B the order of the gel bodies 1120 and 1230 may be varied to provide different levels of support. For example, in one embodiment, the gel bodies 1120 may be located on top, or alternatively, the gel bodies 1230 may be located on the top.

FIG. 13 and FIG. 14 show perspective views of two sets of gel bodies, gel bodies 1320 (FIG. 13) and gel bodies 1420 (FIG. 14). The gel bodies 1320 have a larger volume of inner gel material 1342 to outer, non-gel portions 1344 than is the case for the gel bodies 1420, inner gel material 1442, and outer, non-gel portions 1444. If the inner gel material 1442 and 1342 has lower firmness than the outer, non-gel portions 1344 and 1444, then the gel bodies 1320 will have lower firmness than the gel bodies 1420.

It is anticipated that the gel bodies 1320 and 1420 may be located within the topper 110 singularly or as a plurality arranged in a side-by-side arrangement (as shown in FIGS. 5A and 5B) or atop one another (as shown in FIGS. 9 and 10). Additionally, in the configuration set forth in FIGS. 5A and 5B the order of the gel bodies 1320 and 1420 may be varied to provide different levels of support. For example, in one embodiment, the gel bodies 1320 may be located on top, or alternatively, the gel bodies 1420 may be located on the top.

The person of ordinary skill in the art will understand that the second body support structure 500 (shown in FIG. 5A-5B) may comprise two topper layers, similar to topper layers 110 and 910 shown in FIG. 9 and FIG. 10. Accordingly, the second body support structure 500 may allow two partners with different preferences for firmness from a topper layer to share the body support structure 500 and each experience their desired firmness.

In any of the foregoing embodiments, the support layer 250 is formed of any appropriate material. The material may be a polymeric material, such as polyurethane; a viscoelastic material; a non-viscoelastic material; an elastomeric material; a gel; any material disclosed by any document incorporated herein by reference; or the like.

The first material, from which the topper layer(s) 110 is/are formed, may be a polymeric material, such as polyurethane; a viscoelastic material; a non-viscoelastic material; an elastomeric material; a gel; combinations thereof, any material disclosed by any document incorporated herein by reference; or the like.

Any layer(s) above or below the support layer 250, such as layers 360 and 370 shown in FIG. 3, may be formed of any appropriate material, such as a polymeric material, such as polyurethane; a viscoelastic material; a non-viscoelastic material; an elastomeric material; a gel; combinations thereof, any material disclosed by any document incorporated herein by reference; or the like. The various layers may be bonded together by any suitable adhesive, may be coextruded, or may be fabricated and/or assembled using any process and/or equipment known in the art.

Although known materials and structures may be used for the gel bodies 120, in embodiments, at least one of the gel bodies 120 may have one or more of the following properties:

The gel bodies may comprise a material which transfers heat away from a surface of the body support structure 100 configured for contact with a user's body;

The gel bodies may have a coiled structure;

The gel bodies may have a structure comprising an inner gel and an outer skin, wherein the outer skin forms substantially the entire side wall of the gel spring;

The gel bodies may comprise openings or orifices for the escape of heat from the interior thereof.

Regarding gel bodies comprising a material which transfers heat away from a surface of the body support structure 100 configured for contact with a user's body, such materials are known, and the determination of an optimal material and concentration thereof to be included in the gel bodies is a matter of routine experimentation for the person of ordinary skill in the art having the benefit of the present disclosure.

Whether or not gel bodies comprise such a material, in one embodiment, not shown, the body support structure 100 may comprise at least one heat escape pathway from an interior of the body support structure 100 to a surface of the body support structure 100 other than a surface configured for contact with a user's body.

Alternatively or in addition, the gel bodies may comprise openings or orifices for the escape of heat from the interior thereof.

The use of gel bodies comprising a material which transfers heat away from a surface of the body support structure, gel bodies comprising openings or orifices for the escape of heat from the interior thereof, and/or at least one heat escape pathway from an interior of the body support structure to a surface of the body support structure other than a surface configured for contact with a user's body may improve user comfort by reducing the perception of a mattress comprising foam as “sleeping hot.”

FIG. 6 presents a flowchart of a first method 600 according to embodiments of the present disclosure. The first method 600 comprises forming (at 610) a support layer of a body support structure. The first method 600 also comprises forming (at 620) from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has a first firmness and a second portion in proximity to the second surface that has a second firmness.

In one embodiment, forming (at 620) the at least one topper layer may comprise forming each gel body to have a shape selected from the group consisting of squares, rectangles, diamonds, parallelograms, other quadrilaterals, triangles, polygons with other than four sides, circles, ellipses, raindrops, and other curved shapes.

Alternatively, or in addition, in one embodiment, forming (at 620) the at least one topper layer may comprise forming (at 625) a first topper layer and a second topper layer, wherein one side of the first topper layer is adjacent one side of the second topper layer. In a further embodiment, the first firmness of the first portions of the gel bodies of the first topper layer may be substantially the same as the first firmness of the first portions of the gel bodies of the second topper layer, and the second firmness of the second portions of the gel bodies of the first topper layer may be substantially the same as the second firmness of the second portions of the gel bodies of the second topper layer

The first method 600 also comprises affixing (at 630) the at least one topper layer to the support layer.

In one embodiment, wherein forming (at 620) the topper layer comprises forming a first topper layer and a second topper layer as described above, the affixing (at 630) may comprise affixing the first surface of the first topper layer in proximity to the support layer, and affixing the second surface of the second topper layer in proximity to the support layer.

In additional embodiments, the first method 600 may further comprise forming (at 640) at least one layer of the body support structure below the support layer. Alternatively or in addition, the first method 600 may further comprise forming (at 650) at least one layer of the body support structure between the support layer and the at least one topper layer.

FIG. 7 presents a flowchart of a second method 700 according to embodiments of the present disclosure. The second method 700 contains numerous elements similar to elements of the first method 600, which will generally be referred to by reference numerals that are equal in the ones and tens digits and differ in the hundreds digit. Similarities between similar elements will not be described in detail.

The second method 700 comprises forming (at 710) a support layer of a body support structure. The second method 700 also comprises forming (at 720) from a first material at least one topper layer comprising a first surface, a second surface, a plurality of first gel bodies embedded in the first material, and a plurality of second gel bodies embedded in the first material, wherein each first gel body has a first firmness and is closer than any second gel body to the first surface, and each second gel body has a second firmness and is closer than any first gel body to the second surface.

The second method 700 also comprises affixing (at 730) the at least one topper layer to the support layer.

The second method 700 may, in embodiments, further comprise one or more of forming (at 725), forming (at 740), and forming (at 750), similar to elements described with reference to the first method 600.

Particular techniques for forming (at 610 or 710), forming (at 620 or 720), and affixing (at 630 or 730) will be known to the person of ordinary skill in the art having the benefit of the present disclosure, including the documents incorporated herein by reference. In one embodiment, forming (at 610 or 710) and forming (at 620 or 720) may comprise injection molding.

Turning now to FIG. 8, a stylized depiction of a system 800 for fabricating a body support structure in accordance with embodiments herein is illustrated. The system 800 of FIG. 8 may comprise a manufacturing system 810, a processing controller 820, and a user interface 830. The manufacturing system 810 may manufacture body support structures based upon one or more designs generated and/or provided by processing controller 820 and input received from the user interface 830.

The manufacturing system 810 may comprise various processing stations, such as injection molding stations, layer affixing stations, material handling stations, final product handling stations, etc. Each of the processing stations may comprise one or more processing tools 814.

The manufacturing system 810 may also comprise an interface 812 that is capable of providing communications between two or more of the processing tools 814, the processing controller 820, and the user interface 830. One or more of the processing steps performed by the manufacturing system 810 may be controlled by the processing controller 820. The processing controller 820 may be a workstation computer, a desktop computer, a laptop computer, a tablet computer, or any other type of computing device comprising one or more software products that are capable of controlling processes, which may comprise receiving process feedback, receiving test results data, performing learning cycle adjustments, performing process adjustments, etc.

The user interface 830 may be configured to receive any desired input from one or more users. The user(s) may be manufacturing worker(s) and/or consumer(s). In one embodiment, the input is a first user preference between at least a first firmness and a second firmness. The user interface 830 may be instantiated in hardware or software at a location remote from the manufacturing system 810. For example, the user interface 830 may be instantiated as an app on a computer or smartphone; a webpage accessible via a browser; a kiosk deployed at a point-of-sale location and comprising a touchscreen and/or physical buttons for user input and a display, such as a graphical display, for presenting options and instructions to the user; etc.

In one embodiment, the user interface 830 may be further configured to receive a second user preference between at least the first firmness and the second firmness.

In one embodiment, the manufacturing system 810 may be configured to form a support layer of a body support structure.

In one embodiment, the manufacturing system 810 may be further configured to form from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has the first firmness and a second portion in proximity to the second surface that has the second firmness;

Alternatively or in addition, the manufacturing system 810 may be further configured to form from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, a plurality of first gel bodies embedded in the first material, and a plurality of second gel bodies embedded in the first material, wherein each first gel body has a first firmness and is closer than any second gel body to the first surface, and each second gel body has a second firmness and is closer than any first gel body to the second surface.

The manufacturing system 810 may also be configured to affix the at least one topper layer to the body support structure above the support layer, such that (a) the first surface is in proximity to the support layer if the first user preference is for the second firmness or (b) the second surface is in proximity to the support layer if the first user preference is for the first firmness.

In embodiments wherein the user interface 830 receives user firmness preference input from a second user, the manufacturing system 810 may be further configured to form a first topper layer and a second topper layer, and affix the first topper layer and the second topper layer to the body support structure such that one side of the first topper layer is adjacent to one side of the second topper layer, including affixing the second topper layer to the body support structure above the support layer, such that (a) the first surface of the second topper layer is in proximity to the support layer if the second user preference is for the second firmness or (b) the second surface of the second topper layer is in proximity to the support layer if the second user preference is for the first firmness.

The manufacturing system 810 may be further configured to form at least one layer of the body support structure below the support layer and/or to form at least one layer of the body support structure between the support layer and the at least one topper layer.

Further, generally, any structures shown and described in one embodiment of the present disclosure may be incorporated into any other embodiment of the present disclosure, regardless of whether such structures are explicitly described as being components of that other embodiment.

A body support structure of any disclosed embodiment may be positioned on any appropriate foundation disposed thereunder. For example, if the body support structure is a mattress, the foundation may be selected from, but is not limited to, box springs; metal frames; and adjustable supports, including electromechanically adjustable supports; among others.

The particular embodiments disclosed above are illustrative only, as the disclosure may be modified and practiced in different, but equivalent manners, apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the disclosure. Accordingly, the protection sought herein is as set forth in the claims below.

Claims

1. A body support structure, comprising: a support layer; andat least one topper layer above the support layer and comprising a first material, a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has a first firmness and a second portion in proximity to the second surface that has a second firmness.

2. The body support structure of claim 1, wherein: the body support structure comprises a first topper layer and a second topper layer, wherein one side of the first topper layer is adjacent to one side of the second topper layer.

3. The body support structure of claim 2, wherein the first firmness of the first portions of the gel bodies of the first topper layer is substantially the same as the first firmness of the first portions of the gel bodies of the second topper layer, the second firmness of the second portions of the gel bodies of the first topper layer is substantially the same as the second firmness of the second portions of the gel bodies of the second topper layer, the first surface of the first topper layer is closer than the second surface of the first topper layer to the support layer, and the second surface of the second topper layer is closer than the first surface of the second topper layer to the support layer.

4. The body support structure of claim 1, further comprising: at least one layer below the support layer.

5. The body support structure of claim 1, further comprising: at least one layer between the support layer and the at least one topper layer.

6. The body support structure of claim 1, wherein each gel body has a shape in top view selected from the group consisting of squares, rectangles, diamonds, parallelograms, other quadrilaterals, triangles, polygons with other than four sides, circles, ellipses, raindrops, and other curved shapes.

7. The body support structure of claim 1, wherein each gel body comprises an inner gel portion and an outer, non-gel portion.

8. The body support structure of claim 7, wherein the inner gel portion comprises by weight: Styrene block copolymer 2-80%, plasticized oil 10-90%, thermoplastic polystyrene—polybutadiene-polystyrene block copolymer 5-80%, and essential oil additive 0.01%-3%.

9. The body support structure of claim 8, wherein the essential oil additive is green tea oil at 0.3%.

10. A method, comprising: forming a support layer of a body support structure;forming from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has a first firmness and a second portion in proximity to the second surface that has a second firmness; andaffixing the at least one topper layer to the body support structure above the support layer.

11. The method of claim 10, wherein: forming the at least one topper layer comprises forming a first topper layer and a second topper layer, wherein one side of the first topper layer is adjacent to one side of the second topper layer.

12. The method of claim 11, wherein the first firmness of the first portions of the gel bodies of the first topper layer is substantially the same as the first firmness of the first portions of the gel bodies of the second topper layer, the second firmness of the second portions of the gel bodies of the first topper layer is substantially the same as the second firmness of the second portions of the gel bodies of the second topper layer, and the affixing comprises affixing the first surface of the first topper layer in proximity to the support layer, and affixing the second surface of the second topper layer in proximity to the support layer.

13. The method of claim 10, further comprising: forming at least one layer of the body support structure below the support layer.

14. The method of claim 10, further comprising: forming at least one layer of the body support structure between the support layer and the at least one topper layer.

15. The method of claim 10, wherein forming the at least one topper layer comprises forming each gel body to have a shape selected from the group consisting of squares, rectangles, diamonds, parallelograms, other quadrilaterals, triangles, polygons with other than four sides, circles, ellipses, raindrops, and other curved shapes.

16. The method of claim 10, wherein forming the at least one topper layer comprises forming each gel body to comprise an inner gel portion and an outer, non-gel portion.

17. The method of claim 16, wherein forming the at least one topper layer comprises forming the inner gel portion of each gel body to comprise by weight: Styrene block copolymer 2-80%, plasticized oil 10-90%, thermoplastic polystyrene—polybutadiene-polystyrene block copolymer 5-80%, and essential oil additive 0.01%-3%.

18. The method of claim 17, wherein the essential oil additive is green tea oil at 0.3%.

19. A system, comprising: a user interface configured to receive a first user preference between at least a first firmness and a second firmness;a manufacturing system configured to: form a support layer of a body support structure;form from a first material at least one topper layer, wherein the at least one topper layer comprises a first surface, a second surface, and a plurality of gel bodies embedded in the first material, wherein each gel body has a first portion in proximity to the first surface that has the first firmness and a second portion in proximity to the second surface that has the second firmness; andaffix the at least one topper layer to the body support structure above the support layer, such that (a) the first surface is in proximity to the support layer if the first user preference is for the second firmness or (b) the second surface is in proximity to the support layer if the first user preference is for the first firmness.

20. The system of claim 19, wherein: the user interface is further configured to receive a second user preference between at least the first firmness and the second firmness; andthe manufacturing system is further configured to:form a first topper layer and a second topper layer, andaffix the first topper layer and the second topper layer to the body support structure such that one side of the first topper layer is adjacent to one side of the second topper layer.

21. The system of claim 20, wherein the manufacturing system is further configured to affix the second topper layer to the body support structure above the support layer, such that (a) the first surface of the second topper layer is in proximity to the support layer if the second user preference is for the second firmness or (b) the second surface of the second topper layer is in proximity to the support layer if the second user preference is for the first firmness.

22. The system of claim 19, wherein the manufacturing system is further configured to form at least one layer of the body support structure below the support layer.

23. The system of claim 19, wherein the manufacturing system is further configured to form at least one layer of the body support structure between the support layer and the at least one topper layer.

24. The system of claim 19, wherein the manufacturing system is further configured to form each gel body to have a shape selected from the group consisting of squares, rectangles, diamonds, parallelograms, other quadrilaterals, triangles, polygons with other than four sides, circles, ellipses, raindrops, and other curved shapes.

25. The system of claim 19, wherein the manufacturing system is further configured to form the at least one topper layer by forming each gel body to comprise an inner gel portion and an outer, non-gel portion.

26. The system of claim 25, wherein the manufacturing system is further configured to form the at least one topper layer by forming the inner gel portion of each gel body to comprise by weight: Styrene block copolymer 2-80%, plasticized oil 10-90%, thermoplastic polystyrene—polybutadiene-polystyrene block copolymer 5-80%, toner 0.03-3%, and essential oil additive.

27. The system of claim 26, wherein the essential oil additive is green tea oil.