This disclosure relates generally to cushions with different zones that cushion in different ways, including cushions with flat surfaces that have the feel of a contoured mattress (i.e., virtually contoured mattresses). Such virtual surface contouring may be accomplished in cushions in which a plurality walls are interconnected to define hollow columns by including one or more stiffeners and/or one or more voids in the walls that define the hollow columns of a particular area or zone of a cushioning surface to impart that area or zone of the cushioning surface with a desired cushioning characteristic. Methods for designing a cushion with interconnected walls that define hollow columns to impart the cushion with virtual surface contouring are also disclosed.
A cushion of this disclosure includes a plurality of interconnected walls that define a plurality of cells, with the walls that define each cell comprising a hollow column. Walls of the plurality of interconnected walls may be formed from an elastomeric material, such as a so-called “gel.” The walls may be arranged in such a way as to define a grid (e.g., a square grid, a rectangular grid, a triangular grid, a hexagonal grid, etc.), with the hollow columns defining the cells or spaces of the grid. Such an arrangement may be referred to as a “patterned gel layer.” The hollow columns and the cells they define may be arranged in an array. For example, the walls may be arranged to create a square grid with each hollow column being substantially square. In some embodiments, the walls may be arranged to create a hexagonal grid with each hollow column being substantially hexagonal (i.e., a “honeycomb” arrangement). In some embodiments, the walls are arranged such that some regions of the cushion have a grid of one shape (e.g., square, hexagonal, triangular, diamond, etc.) and some regions have a grid of another shape (e.g., square, hexagonal, triangular, diamond, etc.).
The hollow columns and the cells they define may extend completely through a thickness of the cushion, substantially through the thickness of the cushion, or partially through the thickness of the cushion. A thin layer or film of a material (e.g., the material from which the interconnected walls are formed, etc.) may extend transversely across an end or an intermediate location of a hollow column and its cell that extend substantially through the thickness of the cushion. Such a thin layer or film may have a thickness that is about 5% or less of the thickness of the portion of the cushion through which the hollow column and its cell extend. A hollow column that extends partially through the cushion may include one section or a plurality of sections that, in combination, extend through less than 95% of the thickness of the portion of the cushion through which the hollow column and its cell extend.
The cushion may have a configuration that imparts it with virtual contouring. Stated another way, the cushion may have a flat surface with different areas or zones that have different cushioning characteristics or that support a cushioned object differently than other areas or zones of the cushioning surface.
The walls and/or hollow columns of each zone of such a cushion may include features that enable that zone of the cushion to have predetermined cushioning characteristics (e.g., stiffness (or firmness), deformability (e.g., the area of the surface of the cushion that deforms under a load, the extent (e.g., depth, etc.) to which the cushion deforms under the load, etc.), etc.) and, thus, to cushion an object (e.g., an individual, etc.) or a portion of the object in a predetermined manner. In this regard, the walls and/or hollow columns of a cushion according to this disclosure may have configurations (e.g., stiffeners, voids in the walls that define the hollow columns, etc.) that impart each zone of the cushion with a predetermined stiffness (i.e., softness and/or stiffness) and/or deformability.
The elastomeric material that forms the plurality of interconnected walls may comprise any suitable material that will readily deform when placed under a load and resiliently rebound (i.e., return to its original shape) upon removal of the load. In various embodiments, the elastomeric material may comprise a gel or a gel-like material. In a specific, but non-limiting example, the gel or gel-like material may comprise a block copolymer that has been extended with a plasticizer. A non-limiting example of a block copolymer is a triblock copolymer, such as a so-called A-B-A triblock copolymer. A nonlimiting example of a plasticizer is mineral oil. Other so-called “synthetic rubber” materials and other materials that may be used to form the walls include, without limitation, rubber, foams (e.g., polyurethane foams, etc.), and other materials that deform when placed under a load and resilient rebound (e.g., to their original shape, etc.) upon removing the load.
Optionally, adjacent zones of the cushion may be integrally formed, or formed during the same process step (e.g., molded together, etc.).
In some embodiments, one or more zones of the cushion may include stiffeners, or stiffeners. A stiffener, or stiffener, may be defined by the material (e.g., the elastomeric material, etc.) that defines the plurality of interconnected walls. Without limitation, a stiffener, or stiffener, may comprise an enlarged junction between interconnected walls at a corner of a hollow column, or cell, of the cushion. An enlarged junction may include one or more filleted (i.e., radiused) interior corners within the interior of a hollow column (i.e., a “filleted junction”) or any other suitable enlarged shape (e.g., a round cross-section, such as a circle, oval, ellipse, etc.; a polygonal cross-section, such as a diamond, square, etc.); etc.). Each dimension across each end of such an enlarged junction (e.g., in-line with the interconnected walls, diagonals, etc.) may exceed a thickness of each wall of the walls joined at the enlarged junction.
An arrangement of stiffeners across a zone of the cushion may at least partially define cushioning characteristics of each zone of the cushion and provide different zones of the cushion with different cushioning characteristics at different locations, or areas or zones, over a cushioning surface of the cushion. As an example, locations of the cushioning surface that are intended to be relatively firm may include a firm arrangement of stiffeners (e.g., more stiffeners, larger stiffeners, etc.), while locations of the cushion that are intended to be relatively soft may include a soft arrangement of stiffeners (e.g., fewer stiffeners, smaller stiffeners, etc.).
A hollow column may include an enlarged junction (e.g., a filleted junction, etc.) at one corner. A hollow column may include enlarged junctions (e.g., filleted junctions, etc.) at a plurality of corners (e.g., opposite corners of the hollow column, etc.). Each corner of a hollow column may include an enlarged junction (e.g., a filleted junction, etc.) (i.e., all of the corners of the hollow column may include enlarged junctions).
All of the hollow columns of the cushion may include at least one stiffener. Alternatively, only selected hollow columns of the cushion (e.g., hollow columns at corners of the cushion, hollow columns at outer edges of the cushion, hollow columns at locations of the cushion that are expected to receive the greatest load (e.g., midway between the head and foot of a mattress etc.), etc.) may include at least one stiffener.
For example, each hollow column of the cushion of a mattress disposed in regions (i.e., zones) that correspond to locations where an individual will place their shoulders can include stiffeners in only selected (i.e., not all) hollow columns and/or fewer stiffeners in at least some hollow columns to make the shoulder areas of the cushion relatively soft. Similarly, regions (i.e., zones) of the cushion located where an individual would rest their hips can include stiffeners in only selected (i.e., not all) hollow columns and/or fewer stiffeners in at least some hollow columns to make the hip areas of the cushion relatively soft. Conversely, areas of the cushion that receive an individual's head, back, and legs may include stiffeners in more hollow columns and/or more stiffeners in at least some hollow columns to make these zones stiffer and, thus, firmer than the shoulder and hip zones of the cushion. The features of the walls of the buckling columns of the shoulder zone(s) and hip zone(s) may also be tailored to provide these zones with different stiffnesses or firmnesses. The features of the walls of the buckling columns of the head zone(s), back zone(s), and leg zone(s) may also be tailored to provide these zones with different stiffnesses and/or firmnesses.
In some embodiments, hollow columns including at least one stiffener are arranged throughout the cushion in a gradient, giving rise to regions of the cushion with greater stiffness or firmness and regions of the cushion with less stiffness or firmness.
Each hollow column of a cushion that includes at least one stiffener (e.g., one or more enlarged junctions, etc.) may be stiffened in the same manner (e.g., it may have the same number of enlarged junctions, etc.) as every other hollow column that includes at least one stiffener. As another option, the manner and extent to which each hollow column is stiffened (e.g., the type, number, and arrangement of stiffeners, such as enlarged junctions of the hollow column, etc.) may correspond to a location of the hollow column on the cushion. In some embodiments, the incorporation of stiffeners into a cushion with interconnected walls that define hollow columns may facilitate a reduction in the wall-to-wall distance or spacing (i.e., distance across each cell), height or thickness of the cushion.
In some embodiments, the cushion may include softeners. As a nonlimiting example, such a softener may comprise a void in at least one wall that defines at least one hollow column. Such a void may comprise a feature that excludes material from the plurality of interconnected walls. In some embodiments, the void may comprise an opening in a wall of the plurality of interconnected walls. Such an opening may include a recess, or a notch, in an edge of the wall. Such an opening may include a window in the wall. In other embodiments, a void may comprise a recess, or thinned region (e.g., a dimple, etc.) in one or both surfaces of the wall. Each void may have a size and shape that enables it to eliminate material from the wall, thereby reducing the weight of the wall and the weight and density of the cushion of which the wall is a part, without reducing the cushioning characteristics of the cushion. In some embodiments, the incorporation of voids into the walls of a cushion with interconnected walls that define hollow columns may facilitate a minimization in the wall-to-wall distance or spacing (i.e., distance across each cell) and/or the height or thickness of the cushion, or a reduction in the wall-to-wall distance or spacing and/or the height or thickness of the cushion relative to a conventional cushion that comprises a plurality of interconnected walls formed from an elastomeric material and defining a grid.
Variations in voids from one hollow column to another or from one region of a cushion to another may be employed in a manner that imparts a cushioning surface of the cushion with one or more gradients in stiffness and/or deformability. Such a gradient may be provided across a length and/or a width of the cushion, provide a transition between zones that have stiffnesses and/or deformabilities that differ from each other, or for any other purpose.
In some embodiments, the incorporation of voids into the interconnected walls that define hollow columns of a cushion may facilitate an increase in breathability of the cushion. Conventional cushions constructed from elastomeric materials generally do not permit air to flow through the elastomeric material and, thus, laterally through the cushion. This blocked air flow can trap heat, such as body heat, within the hollow columns of the cushion. By including voids within the walls, air and heat can pass laterally through at least portions of the cushion to unblocked hollow columns and/or a periphery of the cushion. Thus, the air and heat can pass more readily out of the cushion, creating a cooler and more comfortable experience for the user.
An arrangement of voids or other softeners in the walls across the cushion may at least partially define one or more cushioning characteristics of the cushion at different locations or regions over a cushioning surface thereof. As an example, voids or other softeners may be arranged evenly across the cushion to impart the cushion with the same cushioning characteristics across an entirety of the cushioning surface or substantially across the cushioning surface (e.g., with the possible exception of edges of the cushion, etc.). As another example, locations of the cushioning surface that are intended to be relatively firm may include a firm arrangement of voids (e.g., fewer voids, smaller voids, differently shaped voids (i.e., void geometry), etc.) or other softeners, while locations of the cushion that are intended to be relatively soft may include a soft arrangement of voids (e.g., more voids, larger voids, differently shaped voids (i.e., void geometry) etc.) or other softeners. Locations of the cushion that are intended to be relatively soft may correspond to a head, shoulder, and/or hip area of a user. Locations of the cushion that are intended to be relatively firm may correspond to a neck, back, leg, and/or arm area of a user.
In some embodiments, the particular stiffness and/or deformability of a particular zone of a cushion may be achieved by providing an elastomeric gel layer, or a patterned gel layer, with a hollow column geometry (e.g., shape, size, wall thickness, etc.) that provides the desired stiffness and deformability in that zone. By way of example, the stiffness and/or deformability of a patterned gel layer with interconnected walls that define cuboid cells may differ from the stiffness/softness and/or deformability of a patterned gel layer in which the interconnected walls define hollow columns with similarly sized hexagonal or triangular cross-sections taken transverse to the heights of the hollow columns, or to the height or thickness of the patterned gel layer. As another example, a patterned gel layer with interconnected walls that define cells of a particular shape (e.g., cuboid, hexagonal prisms, triangular prisms, etc.) having a relatively large size may be less stiff (i.e., softer) and/or more deformable than a patterned gel layer with interconnected walls that define cross-sectionally smaller cells of the same shape. Thus, patterned gel layers with different geometries may be included in different zones of a cushion to impart the different zones with stiffnesses and/or deformabilities that differ from each other.
Variabilty in stiffness and/or deformability from one zone of a cushion to another zone of a cushion may also be accomplished by using elastomeric gel materials that have different hardnesses (or softnesses) to define different zones of the cushion.
Differences in stiffness and/or deformability from one zone of a cushion to another may also be achieved by layering. For example, one or more zones of a cushion may include a single patterned gel layer. One or more other zones of the cushion may include two or more superimposed layers, the interconnected walls and cells of which are at least partially offset from each other. The superimposed layers may have the same or different geometries from each other. Such an offset arrangement can provide greater support to a user compared to other embodiments of cushions. In embodiments where the superimposed layers are made from the same material, the stiffness and/or deformability of a zone with superimposed layers may differ from (e.g., be stiffer than, be less deformable than, etc.) the stiffness and/or deformability of a zone with a single layer. Likewise, the stiffness and/or deformability of a zone with three superimposed layers may differ from the stiffness and/or deformability of a zone with two superimposed layers.
Any combination of stiffeners, wall voids, hollow column geometries, materials, layering, etc., may be used to provide a zone of a cushion with a desired stiffness and/or deformability and to provide for variability in the stiffness and/or deformability of a cushion from one zone to another and, thus, may provide virtual contouring of the cushion and its cushioning surface.
A method for designing a cushion with a plurality of interconnected walls that define hollow columns may include determining one or more cushioning characteristics (e.g., stiffness and/or deformability) for different zones of the cushion and optimizing (e.g., minimizing, etc.) each zone of the cushion to achieve the one or more cushioning characteristics. Such a method may include one or more of incorporating features into each zone of the cushion that optimize the cushioning characteristics of the cushion, using patterned gel layers with different geometries in different zones of the cushion, using different layering of patterned gel layers in different zones of the cushion, using materials with different mechanical properties (e.g., hardness, elasticity, etc.) in different zones of the cushion, etc.
Other aspects of this disclosure, as well as features and advantages of various aspects of the disclosed subject matter, should be apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.
In the drawings:
The walls 20 of the cushion 10 may be formed from any suitable material including, but not limited to, an elastomeric material. The elastomeric material may comprise a gel, which may be referred to as an “elastomeric gel” or as a “gel elastomer.” Examples of elastomeric materials that comprise gels include, but are not limited to, plasticizer-extended block copolymers (e.g., plasticizer-extended diblock copolymers, plasticizer-extended triblock copolymers, etc.). U.S. Pat. Nos. 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein, disclose various embodiments of A-B-A triblock copolymers that may be used to form the walls 20 of the cushion 10. Purple Innovation, LLC's Hyper-Elastic Polymer 4.0 mix, which comprises a mineral oil-extended A-B-A triblock copolymer, is a specific example of a gel that may be used to define the walls 20 of the cushion 10. In embodiments where the walls 20 are formed from a gel, the cushion 10 may comprise a patterned gel layer.
When the cushion 10 is placed under a load, the hollow columns 30 may buckle, as described in U.S. Pat. Nos. 7,730,566 and 8,919,750, the entire disclosures of which are hereby incorporated herein, or bulge, as described in U.S. Patent Application Publication US 2019/0075884 A1, the entire disclosure of which are hereby incorporated herein.
As illustrated by
In addition,
Referring now to
The topology study was simulated on the embodiment of cushion 10 shown in
The various results illustrated in
For example, with returned reference to
Additionally, and/or alternatively, with returned reference to
In some embodiments, the virtual contouring of the cushion 10, 10′ arises out of the manner in which enlarged junctions 22 (
Returning reference again to
In addition to imparting a cushion 10′ (
Although this disclosure provides many specifics, these should not be construed as limiting the scope of any of the claims that follow, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, and of their elements and features, may be devised which do not depart from the spirit or scope of any of the claims. Features from different embodiments may be employed in combination. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.
A claim for priority to the Jan. 27, 2023 filing date of U.S. Provisional Patent Application No. 63/441,581, titled CUSHIONING ELEMENTS WITH VIRTUAL SURFACE CONTOURING (“the '581 Provisional Application”), is hereby made. The entire disclosure of the '581 Provisional Application is hereby incorporated herein.
Number | Date | Country | |
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63441581 | Jan 2023 | US |