Patent Grant
11229298
Embodiments of the disclosure relate generally to elastomeric cushioning elements for compressible cushions, including mattresses, mattress toppers, seat cushions, etc., including reinforcing elements, and to methods of forming cushions including reinforcing elements.
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.
U.S. Pat. No. 7,730,566, “Multi-Walled Gelastic Material,” issued Jun. 8, 2010, the disclosure of which is incorporated herein in its entirety by this reference, describes cushion structures having interconnected walls that buckle. A first wall buckles when a threshold force is applied. Buckling of the first wall may cause buckling of a second wall, which may decrease the chance that the first wall will “bottom out.” Bottoming out would increase pressure on the portion of the cushioned object over the buckled portion of the cushion. One side of the cushion has walls spaced relatively close together, and the opposite side has walls spaced farther apart. That is, some walls of the cushion extend only partially through the cushion. The wider-spaced portions of the walls may buckle more easily than the closer-spaced portions of the walls when an irregularly shaped object presses against the walls.
U.S. Pat. No. 8,919,750, “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014, the disclosure of which is incorporated herein in its entirety by this reference, describes a cushioning element having a top cushioning surface and a bottom base surface, and which includes an elastomeric material and a stabilizing material. Interconnected buckling walls formed of the elastomeric material are connected to the stabilizing material.
In some embodiments, a cushion includes a cushioning element. The cushioning element may comprise an elastomeric material forming a plurality of intersecting buckling walls defining a plurality of voids in an expanded form. The elastomeric material may comprise an elastomeric polymer and a plasticizer. The cushioning element may also comprise a reinforced corner including a stiffening feature. The stiffening feature may comprise a characteristic of at least one of the intersecting buckling walls in the reinforced corner or an element disposed in at least one void in the reinforced corner.
In some embodiments, a compressed cushion includes a cushioning element comprising an elastomeric material and at least one corner that comprises a reinforced portion. The elastomeric material may comprise an elastomeric polymer and a plasticizer. The reinforced portion exhibiting at least one of a higher stiffness or a higher elasticity relative to central portions of the cushioning element
Methods of forming a cushion are also disclosed. The method includes forming a cushioning element comprising an elastomeric material. The cushioning element comprises a plurality of intersecting buckling walls defining a plurality of hollow columns in an expanded form. The method includes reinforcing at least one corner of the cushioning element such that the at least one corner exhibits relatively higher stiffness relative to central portions of the cushioning element.
While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:
The illustrations presented herein are not meant to be actual views of any particular cushion, cushioning element, reinforcing element, or component thereof, but are merely idealized representations employed to describe illustrative embodiments. The drawings are not necessarily to scale. Elements common between figures may retain the same numerical designation.
As used herein, the term “cushioning element” means and includes any deformable device intended for use in cushioning one body relative to another. As a non-limiting example, cushioning elements (e.g., mattresses, seat cushions, etc.) include materials intended for use in cushioning a person, animal, or object relative to another object (e.g., a bed frame, chair seat, etc.) that might otherwise abut against the person, animal, or object.
As used herein, the term “elastomeric polymer” means and includes a polymer capable of recovering its original size and shape after deformation. In other words, an elastomeric polymer is a polymer having elastic or viscoelastic properties. Elastomeric polymers may also be referred to as “elastomers” in the art. Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).
As used herein, the term “elastomeric block copolymer” means and includes an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B).
As used herein, the term “plasticizer” means and includes a substance added to another material (e.g., an elastomeric polymer) to increase a workability of the material. For example, a plasticizer may increase the flexibility, softness, or extensibility of the material. Plasticizers include, without limitation, hydrocarbon fluids, such as mineral oils. Hydrocarbon plasticizers may be aromatic or aliphatic.
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 “elastomer gels,” “gelatinous elastomers,” or simply “gels.”
As used herein, any relational term, such as “first,” “second,” “top,” “bottom,” etc., is used for clarity 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.
As used herein, the term “and/or” means and 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 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.
Applicant has found that cushioning elements may deform when pressure is applied laterally upon the cushioning element. A lateral force may be applied by an elastic cover (e.g., mattress cover, fitted sheet, mattress protector, seat cover, etc.) causing the cushioning element to deform. Deformation due to an elastic cover may cause the cushioning element to assume an undesirable shape. The undesirable shape may cause fitment problems with a support base (e.g., box spring, bed frame, seat, etc.) in or on which the cushioning element may be placed and/or secured.
The present disclosure describes a cushion that may be roll-packed, folded, or otherwise compressed for display, storage, and/or shipping to a customer. For example, the cushion may be roll-packed into a cylindrical shape. The roll-packed cushion may be provided in a cylindrical bag. Cylindrical bags for shipping roll-packed cushions are described in, for example, U.S. Pat. No. 9,796,522, “A Bag for Shipping a Cushion and Related Methods,” filed Mar. 7, 2016, assigned to the assignee of the present application, the entire disclosure of which is hereby incorporated herein by this reference. Cushions compressed and disposed in cylindrical bags may be easier to handle than cushions, such as mattresses that are traditionally packaged, shipped, and sold in a flat configuration.
In some embodiments, the top layer 104 and the bottom layer 106 may comprise a foam material. In other embodiments, the top layer 104 may comprise a stretchable material secured to or integral with the elastomeric cushioning element 102. Such a stretchable material is described in U.S. patent application Ser. No. 15/062,621, “Mattresses and Mattress Toppers Including Knitted Fabric, and Related Methods,” filed Mar. 7, 2016, assigned to the assignee of the present application, the entire disclosure of which is incorporated herein by this reference. In yet other embodiments, the cushion 100 may comprise additional layers.
The buckling walls 108 may be formed of an elastomeric material. Elastomeric materials are described in, for example, U.S. Pat. No. 5,994,450, “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom,” issued Nov. 30, 1999; U.S. Pat. No. 7,964,664, “Gel with Wide Distribution of MW in Mid-Block” issued Jun. 21, 2011; U.S. Pat. No. 4,369,284, “Thermoplastic Elastomer Gelatinous Compositions” issued Jan. 18, 1983; U.S. Pat. No. 8,919,750, “Cushioning Elements Comprising Buckling Walls and Methods of Forming Such Cushioning Elements,” issued Dec. 30, 2014; the entire disclosures of each of which are incorporated herein by this reference. The elastomeric material may include an elastomeric polymer and a plasticizer. The elastomeric material may be a gelatinous elastomer (also referred to in the art as gel, elastomer gel, or elastomeric gel), a thermoplastic elastomer, a natural rubber, a synthetic elastomer, a blend of natural and synthetic elastomers, etc.
The elastomeric polymer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). For example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc., of Houston, Tex., under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, Tex., under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651. In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene/propylene or ethylene/butylene or ethylene/ethylene/propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The elastomeric material may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers.
The elastomeric material may include one or more plasticizers, such as hydrocarbon fluids. For example, elastomeric materials may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, N.J., under the trade names BLANDOL® and CARNATION®.
In some embodiments, the elastomeric material may have a plasticizer-to-polymer ratio from about 0.1:1 to about 50:1 by weight. For example, elastomeric materials may have plasticizer-to-polymer ratios from about 1:1 to about 30:1 by weight, or even from about 1.5:1 to about 10:1 by weight. In further embodiments, elastomeric materials may have plasticizer-to-polymer ratios of about 4:1 by weight.
The elastomeric material may have one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. For example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer. As another example, metal particles (e.g., aluminum, copper, etc.) may increase the thermal conductivity of the resulting elastomeric material because such particles may have greater thermal conductivity than the plasticizer or polymer. Microspheres filled with wax or another phase-change material (i.e., a material formulated to undergo a phase change near a temperature at which a cushioning element may be used) may provide temperature stability at or near the phase-change temperature of the wax or other phase-change material within the microspheres (i.e., due to the heat of fusion of the phase change). The phase-change material may have a melting point from about 20° C. to about 45° C.
The elastomeric material may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate), commercially available as IRGANOX® 1010, from BASF Corp., of Iselin, N.J. or as EVERNOX®-10, from Everspring Corp. USA, of Los Angeles, Calif.; octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, commercially available as IRGANOX® 1076, from BASF Corp. or as EVERNOX® 76, from Everspring Chemical; and tris(2,4-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® 168, from BASF Corp. or as EVERFOS® 168, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of elastomeric material. The use of antioxidants in mixtures of plasticizers and polymers is described in columns 25 and 26 of U.S. Pat. No. 5,994,450, previously incorporated by reference. The elastomeric material may include up to about 5 wt % antioxidants. For instance, the elastomeric material may include from about 0.10 wt % to about 1.0 wt % antioxidants.
In some embodiments, the elastomeric material may include a resin. The resin may be selected to modify the elastomeric material to slow a rebound of the elastomeric cushioning element 102 after deformation. The resin, if present, may include a hydrogenated pure monomer hydrocarbon resin, such as those commercially available from Eastman Chemical Company, of Kingsport, Tenn., under the trade name REGALREZ®. The resin, if present, may function as a tackifier, increasing the stickiness of a surface of the elastomeric material.
In some embodiments, the elastomeric material may include a pigment or a combination of pigments. Pigments may be aesthetic and/or functional. That is, pigments may provide the elastomeric cushioning element 102 with an appearance appealing to consumers. In addition, an elastomeric cushioning element 102 having a dark color may absorb radiation differently than an elastomeric cushioning element 102 having a light color.
The elastomeric material may include any type of gelatinous elastomer. For example, the elastomeric material may include a melt-blend of one part by weight of a styrene-ethylene-ethylene-propylene-styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® 4055) with four parts by weight of a 70-weight straight-cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and/or other additives.
The elastomeric material may include a material that may return to its original shape after deformation, and that may be elastically stretched. The elastomeric material may be rubbery in feel, but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials, and may have a durometer hardness lower than conventional rubber materials. For example, the elastomeric material may have a hardness on the Shore A scale of less than about 50, from about 0.1 to about 50, or less than about 5.
In some embodiments, the elastomeric cushioning element 102 may be compressed. For example, the elastomeric cushioning element 102 may be roll-packed into a cylindrical shape. Methods of roll-packing a mattress are described in, for example, U.S. Pat. No. 8,046,973, “Machine for Packaging Mattresses,” issued Nov. 1, 2011; U.S. Patent Publication No. 2003/0074863, “Method for Roll Packing Foam Cores,” published Apr. 24, 2003; U.S. Patent Publication No. 2015/0203221, “System and Method for Packaging a Foam Product,” published Jul. 23, 2015; and U.S. Pat. No. 9,796,522, “A Bag for Shipping a Cushion and Related Methods,” filed Mar. 7, 2016, assigned to the assignee of the present application; the entire disclosures of each of which are incorporated herein by this reference.
In some embodiments, the roll-packing machine may apply a load sufficient to transform the elastomeric cushioning element 102 to a compressed form. As used herein, the term “compressed form” means and includes a state in which the elastomeric cushioning element 102 has a size and shape different from its original size and shape, wherein adjacent buckling walls 108 are substantially pressed together and may be collapsed such that voids 110 may be minimized or may not substantially exist. As described in U.S. Pat. No. 9,796,522, previously incorporated herein, the cushion 100 including the elastomeric cushioning element 102 in compressed form may be packaged, such as in a cylindrical bag, and shipped to a customer. To use the cushion 100, the customer may remove the cushion 100 from the packaging and allow the cushion 100 and the elastomeric cushioning element 102 to return to its original size and shape.
It has been observed that the elastomeric material, according to embodiments of the present disclosure, may be sufficiently sticky such that the elastomeric cushioning element 102 may not return to the expanded form after the cushion 100 is removed from the bag. That is, the buckling walls 108 may stick to one another or remain stuck to one another after the cushion 100 is removed from the bag. In some embodiments, the elastomeric cushioning element 102 may not return to the expanded form within a reasonable amount of time (e.g., less than approximately eight hours). In other embodiments, the elastomeric cushioning element 102 may not return to the expanded form without manually or mechanically manipulating (e.g., pulling on) the elastomeric cushioning element 102 to separate the buckling walls 108. However, when the elastomeric cushioning element 102 is formed as part of the cushion 100, the layers 104 or 106 may inhibit direct access to the elastomeric cushioning element 102 and may hinder manipulation of the elastomeric cushioning element 102 in order to separate the buckling walls 108. This sticking together of polymeric materials is referred to in the art as “blocking.” To enable the elastomeric cushioning element 102 to return to the expanded form from the compressed form, a surface of the elastomeric cushioning element 102 may have a coating material (e.g., anti-tack material, anti-stick material) on surfaces of the buckling walls 108. Coating materials may include a thin film covering all portions of the buckling walls 108 as described in U.S. patent application Ser. No. 15/654,948, “Cushions Including a Coated Elastomeric Cushioning Element and Related Methods,” filed Jul. 20, 2017, assigned to the assignee of the present application, the entire disclosure of which is hereby incorporated herein by this reference. Coating materials may also include powders as described in U.S. patent application Ser. No. 15/062,674, “Cushions Including a Coated Elastomeric Cushioning Element and Related Methods,” filed Mar. 7, 2017, assigned to the assignee of the present application, the entire disclosure of which is hereby incorporated herein by this reference.
In some embodiments, the elastomeric cushioning element 102 may have an elastic cover (e.g., mattress topper, fitted sheet, seat cover, mattress protector, and mattress cover) provided with the cushion 100 or added by an end user. The tension of the elastic cover may cause portions of the buckling walls 108 near the edges of the elastomeric cushioning element 102 to deform and/or collapse into the voids 110 between the buckling walls 108. The deformation of the buckling walls 108 may cause the elastomeric cushioning element 102 to deform. The deformation of the elastomeric cushioning element 102 may create fitment issues with a securing element (e.g., frame, chassis, or base) used to secure the elastomeric cushioning element 102 to a bed, or chair.
In some embodiments, the elastomeric cushioning element 102 may have a shape (e.g., square, rectangle, triangle, pentagon, etc.), which has one or more corners 112.
For example, in the embodiment of
In some embodiments, the additional buckling walls 206 may be oriented at an angle from the reinforced buckling walls 202. For example, the additional buckling walls 206 may be oriented such that they extend between corners 210 of the reinforced columns 204 formed by the reinforced buckling walls 202. In some embodiments, the additional buckling walls 206 may extend between each corner 210 of the reinforced columns 204 intersecting in the middle in order to form an “X” shape. In other embodiments, a plurality of additional buckling walls 206 may extend at a common angle relative to the reinforced buckling walls 202 with each additional buckling wall 206 parallel to the other additional buckling walls 206. For example, one of the additional buckling walls 206 may extend between two of the corners 210 of the reinforced column 204, with other additional buckling walls 206 running parallel to the first additional buckling wall 206 offset on each side of the first additional buckling wall 206 within the reinforced column 204.
Some embodiments may combine the numbers and orientations set forth above with different reinforced columns 204 having different numbers and orientations of additional buckling walls 206. The different combinations may exhibit different qualities that may be desirable in different areas of the elastomeric cushioning element 102 (
In some embodiments, the additional buckling walls 206 may be formed from the same elastomeric material as the other portions of the elastomeric cushioning element 102 (
In some embodiments, the reinforced columns 204 may be filled with material other than an elastomer material (e.g., foam).
Referring to the reinforced corners demonstrated in the embodiments of
In some embodiments, a material with a different density may be used to form at least one of the features in the reinforced corner 200a-200d. By way of example but not limitation, a higher density material may be used to form the additional buckling walls 206, or a lower density material may be used to fill in the voids 110 in the reinforced corners 200c, 200d. In some embodiments, a higher density material may be used to form the reinforced buckling walls 202 in the reinforced corners 200a-200d.
In some embodiments, the protrusions 302 may protrude substantially the same distance from the base 304 as the thickness of the elastomeric cushioning element 102, such that the protrusions 302 extend completely through the elastomeric cushioning element 102 when the base 304 is in contact with the top surface 103 or bottom surface 105 of the elastomeric cushioning element 102. In other embodiments, the protrusions 302 may protrude from the base 304 a distance less than or greater than the thickness of the elastomeric cushioning element 102. For example, the protrusions 302 may extend a distance from the base 304, which is ½ the thickness of the elastomeric cushioning element 102, ⅓ the thickness of the elastomeric cushioning element 102, or ¾ the thickness of the elastomeric cushioning element 102.
The elastomeric cushioning element 102 may have any selected dimensions based on the intended use. For example, if the cushion 100 is a mattress for a king size bed, the elastomeric cushioning element 102 may be approximately 76 inches (193 cm) by about 80 inches (203 cm), with a thickness of approximately 2 inches (5.08 cm). If the cushion 100 is a mattress for a queen size bed, the elastomeric cushioning element 102 may be approximately 60 inches (152 cm) by 80 inches (203 cm), with a thickness of approximately 2 inches (5.08 cm). If the cushion 100 is a mattress for an extra-long twin size bed, the elastomeric cushioning element 102 may be approximately 38 inches (96.5 cm) by 80 inches (203 cm), with a thickness of approximately 2 inches (5.08 cm). In some embodiments, the elastomeric cushioning element 102 may have any other selected thickness, such as approximately 3 inches (7.62 cm), approximately 1 inch (2.54 cm), or approximately 4 inches (10.16 cm).
In some embodiments, the protrusions 302 may be solid (e.g., not hollow, full, or unitary). In other embodiments, the protrusions 302 may be hollow. In some embodiments, the hollow protrusions 302 may have an exterior wall 308 with a thickness greater than the thickness of the buckling walls 108 (e.g., in a manner similar to the embodiment shown and described with reference to
In some embodiments, the hollow protrusions 302 may include additional walls 312. The additional walls 312 may be oriented parallel, transverse, and/or perpendicular to one or more the exterior walls 308. The additional walls 312 may be positioned in a middle portion of the exterior walls 308 (e.g., may bisect the exterior walls 308) and extend perpendicularly from the exterior wall 308 to the opposite exterior wall 308 within the cavity 310 of the protrusion 302. In another embodiment, a plurality of additional walls 312 may be formed perpendicularly with equal spacing along the exterior walls 308. In other embodiments, the spacing between the additional walls 312 may not be equal. In some embodiments, a plurality of additional walls 312 may be positioned perpendicular to each other within the cavity 310 of the protrusions 302. In other embodiments, the plurality of additional walls 312 may be positioned parallel to each other within the cavity 310 of the protrusions 302.
In some embodiments, the additional walls 312 may be oriented at an angle from the exterior walls 302. For example, the additional walls 312 may be oriented such that they extend between corners 314 of the cavity 310 formed by the exterior walls 308. In some embodiments, the additional walls 312 may extend between each corner 314 of the cavity 310 intersecting in the middle forming an “X” shape. In other embodiments, a plurality of additional walls 312 may extend at a common angle relative to the exterior walls 308 with each additional wall 312 parallel to the other additional walls 312. For example, one of the additional walls 312 may extend between two of the corners 314 of the cavity 310, with other additional walls 312 running parallel to the first additional wall 312 offset on each side of the first additional wall 312 within the cavity 310.
In some embodiments, the reinforcing plug 300 may comprise protrusions 302 without a base 304. The protrusions 302 may be complimentary to the voids 110 in the cushioning element 102. The protrusions 302 may be independently inserted into the voids 110 allowing reinforcing plug 300 to be inserted over larger or smaller areas and in different geometric patterns depending on the requirements of each cushioning element 102. Each individual protrusion 302 may be attached to the cushioning element 102 using adhesives, thermal boding, or mechanical fasteners. For example, the protrusions 302 may be secured to the voids 110 or the top surface 103 (
The reinforcing plug 300 may have a coating material (e.g., anti-tack material, anti-stick material) on surfaces of the exterior walls 302 and/or the additional walls 312. Coating materials may include a thin film or a powder as described in U.S. patent application Ser. No. 15/654,948, and U.S. patent application Ser. No. 15/062,674, both of which are assigned to the assignee of the present application, and previously incorporated by reference herein.
In some embodiments, the reinforcing plug 300 may be formed from a different elastomeric material than the elastomeric material used for the elastomeric cushioning element 102. The different elastomeric material may be formulated to have a higher elasticity (e.g., stiffness, young's modulus) than the elastomeric material used to form the other portions of the elastomeric cushioning element 102. In other embodiments, the reinforcing plug 300 may be formed from a non-elastomeric material (e.g., metal, wood, hard plastic).
Referring to
Referring to
In some embodiments, the reinforcing plug 300 may be inserted into the elastomeric cushioning element 102 before the top layer 104 and bottom layer 106 are attached to the elastomeric cushioning element 102. When inserted into the elastomeric cushioning element 102, the base 304 of the reinforcing plug 300 may act to stop the reinforcing plug 300 from passing completely through the elastomeric cushioning element 102. In some embodiments, the reinforcing plug 300 may be inserted into the elastomeric cushioning element 102 from the top surface 103 with the base 304 of the reinforcing plug 300 resting against the top surface 103 of the elastomeric cushioning element 102. In other embodiments, the reinforcing plug 300 may be inserted from the bottom surface 105 of the elastomeric cushioning element 102 with the base 304 of the reinforcing plug 300 resting against the bottom surface 105.
In some embodiments, a stabilizing material (e.g., scrim material) may be used to attach (e.g., adhere, glue, secure, etc.) the elastomeric cushioning element 102 to surrounding materials such as, for example, the reinforcing plug 300, the top layer 104, or the bottom layer 106. The stabilizing material is described in U.S. patent application Ser. No. 15/662,934, “Mattresses Including Spacer Fabric and Related Methods,” filed Jul. 28, 2017, assigned to the assignee of the present application, the entire disclosure of which is hereby incorporated herein by this reference. The stabilizing material may be placed over the elastomeric cushioning element 102 with the previously inserted reinforcing plug 300. In some embodiments, the stabilizing material may be placed on the elastomeric cushioning element 102 opposite the base 304 of the reinforcing plug 300. The stabilizing material may attach the ends of the protrusions 302 opposite the base 304 to the elastomeric cushioning element 102 such that the reinforcing plug 300 may be secured by the base 304 on one end and the stabilizing material on the other. Once the elastomeric cushioning element 102 is assembled the cushion 100 may be assembled in the methods previously set forth. The cushion 100 may then be roll packed for shipping as set forth above.
In some embodiments, the reinforcing plug 300 may be shipped separate from the compressed cushion 100 (e.g., not inserted into the elastomeric cushioning element 102 before compression). The reinforcing plug 300 may be inserted into the elastomeric cushioning element 102 after the elastomeric cushioning element 102 expands to its expanded form.
The embodiments of the cushion described herein may improve the cushion's ability to retain its shape when a lateral force is applied to the cushion (e.g., to edge and/or corner portions of the cushion). In particular, embodiments of the disclosure may improve the ability of the cushion to retain its shape when an elastic cover is placed thereon. Such deformation of the cushion could cause fitment problems when placing the cushion in a securing base. Therefore, maintaining the shape of the cushion is a desirable feature when integrating the cushion with the frames and bases inherent with such cushions.
While the present disclosure has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the disclosure as hereinafter claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the disclosure as contemplated by the inventor.
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