Collapsible Layered Cushion

• US 20170027336A1
• Filed: 10/18/2016
• Published: 02/02/2017
• Est. Priority Date: 06/07/2011
• Status: Active Grant

• Current Assignee: Skydex Technologies Incorporated
• Original Assignee: Skydex Technologies Incorporated
• Inventors: Buchen, Gerald Micheal, Wyman, Ethan Thomas, Feighery, Daniel Antonio, Sugano, Eric William, Foley, Peter Maurice, Manney, Thomas Christopher, Metzer, Collin, Danis, John Marcell
• Granted Patent: US 10,638,854 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A42B 3/127 with removable or adjustable pads
• CPC Class Codes: A47C 27/001 with several cushions, mattresses or the like, to be put together in one cover
• CPC Class Codes: A47C 27/007 permeable to liquid or air in a special way A47C27/006 takes precedence
• CPC Class Codes: A47C 27/053 with only one layer of foamed material
• CPC Class Codes: A47C 27/065 of special shape
• CPC Class Codes: A47C 27/148 of different resilience
• CPC Class Codes: A47C 27/15 consisting of two or more layers A47C27/16 takes precedence
• CPC Class Codes: A47C 31/105 for mattresses
• CPC Class Codes: B29D 99/0092 Producing upholstery articles, e.g. cushions, seats B29C63/025 takes precedence
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: Y10T 29/481 Method
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/234 including elements cooperating to form cells

Abstract

A layered cushion that may be fully disassembled for easy cleaning is disclosed herein. The sleep system is durable and fire retardant. The layered cushion may include a foam layer, a layer of void cells, and a cover. The foam permits fluids to move freely there through and contours to a user'"'"'s body to maximize comfort and reduce interface pressure. The reticulated foam layer resists compression set and thermosetting. The layer of void cells also permits fluids to move freely there through and provide additional support to the user'"'"'s body. The individual void cells of the void cell layer are perforated to allow the transmission of fluids there through. The cover couples the other layers together to form the layered cushion and prevents the layers from deteriorating. The cover is removable to permit cleaning each of the layers independently.

Claims

1. A layered cushion comprising:

a void cell layer including at least a first matrix of void cells formed exclusively in a single sheet of resiliently deflectable material;

a foam layer;

a separation layer interleaved between the foam layer and the void cell layer and in contact with the first matrix of void cells, the separation layer substantially preventing the foam layer from collapsing into the void cell layer; and

a cover configured to envelop the void cell layer, the foam layer, and the separation layer.

2. The layered cushion of claim 1, wherein the first matrix includes at least two rows and two columns of void cells.

3. The layered cushion of claim 1, wherein the void cell layer further includes a second matrix of void cells including at least two rows and two columns of void cells, wherein each void cell of the first matrix is axially aligned with a corresponding void cell of the second matrix.

4. The layered cushion of claim 1, wherein the cover constrains the first matrix of void cells in a fixed position relative to the foam layer when enveloping the first matrix of void cells and the foam layer.

5. The layered cushion of claim 1, wherein the foam layer substantially collapses at a lower pressure than the void cell layer.

6. The layered cushion of claim 1, wherein the void cell layer includes a plurality of drainage holes providing one or more fluid-permeable channels through the single sheet of resiliently deflectable material.

7. The layered cushion of claim 1, wherein each drainage hole is positioned at an interface between a void cell of the first matrix of void cells and a void cell of a second matrix of void cells of the void cell layer.

8. The layered cushion of claim 1, wherein the foam layer and the cover are fluid-permeable.

9. The layered cushion of claim 1, wherein the separation layer adjoins the cover.

10. The layered cushion of claim 1, wherein at least one void cell of the void cell layer opens to the separation layer.

11. A method of assembling a layered cushion comprising:

positioning a foam layer and a void cell layer on opposite sides of a separation layer such that the separation layer contacts a first matrix of void cells of the void cell layer and substantially prevents the foam layer from collapsing into the void cell layer, wherein the first matrix of void cells is formed exclusively in a single sheet of resiliently deflectable material; and

placing the positioned foam layer, separation layer, and the void cell layer within a cover; and

closing the cover to envelop the foam layer, the separation layer, and the void cell layer.

12. The method of claim 11, wherein the foam layer, the void cell layer, and the cover are removable from one another.

13. The method of claim 11, wherein at least one void cell of the void cell layer opens to the separation layer.

14. The method of claim 11, wherein the void cell layer further includes a second matrix of void cells and wherein each void cell of the first matrix is aligned with a corresponding void cell of the second matrix.

15. The method of claim 11, wherein the separation layer is formed continuously with the cover.

16. The method of claim 11, wherein the cover constrains the foam layer in a selected position and orientation relative to void cell layer when enveloping the foam layer.

17. A washable layered mattress comprising:

a foam layer;

a void cell layer including at least a first matrix of void cells formed exclusively in a first sheet of resiliently deflectable material, the first matrix including at least two rows and two columns of void cells;

a separation layer interleaved between the foam layer and the void cell layer and in contact with the first matrix of void cells, wherein the separation layer substantially prevents the foam layer from collapsing into the void cell layer; and

a cover configured to envelop the void cell layer, the foam layer, and the separation layer.

18. The washable layered mattress of claim 17, wherein the separation layer is formed continuously with the cover.

19. The washable layered mattress of claim 17, wherein the cover constrains the foam layer in a selected position and orientation relative to void cell layer when enveloping the foam layer.

20. The washable layered mattress of claim 17, wherein the foam layer, the void cell layer, and the cover are each fluid-permeable.

21. The washable layered mattress of claim 17, wherein the separation layer adjoins the cover.

22. The washable layered mattress of claim 17, further comprising a plurality of drainage holes providing one or more fluid-permeable channels through the first sheet of resiliently deflectable material.

23. The washable layered mattress of claim 17, wherein each of the void cells of the first matrix open to the separation layer and