Cushions comprising gel springs

• US 8,434,748 B1
• Filed: 10/03/2008
• Issued: 05/07/2013
• Est. Priority Date: 10/03/2007
• Status: Active Grant

• Current Assignee: Purple Innovation LLC (Global Partner Acquisition Corp.)
• Original Assignee: Edizone LC (Edizone)
• Inventors: Pearce, Tony M., Pearce, Terry V.
• Primary Examiner(s): SCHWARTZ, CHRISTOPHER P
• Application Number:
  US12/287,047
• Time in Patent Office: 1,677 Days
• Field of Search: 267142-146, 267/152, 267/153, 248634-638, 556/4, 565/55
• US Class Current: 267/142
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: B68G 5/00 Resilient upholstery pads finished upholstery B68G11/00 ; making upholstery from plastics B29D99/0092

Abstract

Various gel springs can be constructed for cushioning purposes.

Claims

1. A gel springs cushion comprising:

a plurality of individual gel spring members, each gel spring member having a top surface, a bottom surface, and a side wall, each gel spring member being bucklable in a loading direction generally parallel to the side wall, wherein the top surface may move laterally relative to the bottom surface;

a layer of non-stretchable material bonded directly to the bottom surface of each individual gel spring member; and

a layer of stretchable material bonded directly to the top surface of each individual gel spring member;

wherein the side wall of each gel spring member is unsupported between the layer of non-stretchable material and the layer of stretchable material.

2. The gel springs cushion of claim 1, wherein the layer of stretchable material comprises a first fabric.

3. The gel springs cushion of claim 2, wherein the layer of non-stretchable material comprises a second fabric.

4. The gel springs cushion of claim 3, wherein at least a portion of material of the plurality of individual gel spring members is disposed within at least one of the first fabric and the second fabric.

5. The gel springs cushion of claim 3, further comprising a foam material bonded to the first fabric or the second fabric.

6. The gel springs cushion of claim 3, further comprising an innerspring assembly secured to the first fabric or the second fabric.

7. The gel springs cushion of claim 3, wherein each gel spring member of the plurality is heat-fused to the first fabric and the second fabric.

8. The gel springs cushion of claim 1, wherein at least one of the non-stretchable material and stretchable material comprises a sheet of gel.

9. The gel springs cushion of claim 1, wherein a first cross section of at least one gel spring member of the plurality is different from a second cross section of the at least one gel spring member of the plurality, the first and second cross sections taken transverse to the sidewall.

10. The gel springs cushion of claim 1, wherein at least one gel spring member of the plurality is hollow.

11. The gel springs cushion of claim 1, wherein at least one gel spring member of the plurality is solid.

12. The gel springs cushion of claim 1, wherein at least one gel spring member of the plurality comprises a slow rebound gel that includes a material selected from the group consisting of resin and rosin.

13. The gel springs cushion of claim 1, wherein buckling of at least one gel spring member of the plurality causes a deviation from the elastic line in a plot of load as a function of deflection for the at least one buckled gel spring member.

14. The gel springs cushion of claim 1, wherein at least one gel spring member of the plurality is at least partially constructed from an elastomeric gel.

15. The gel springs cushion of claim 1, wherein the side walls of each gel spring member are generally parallel;

the top surfaces of each gel spring member are within a common top plane; and

the bottom surfaces of each gel spring member are within a common bottom plane.

16. The gel springs cushion of claim 1, wherein at least one gel spring member of the plurality is hollow and at least one gel spring member of the plurality is solid.

17. The gel springs cushion of claim 1, wherein at least one gel spring member of the plurality of individual gel spring members is connected to an adjacent gel spring member of the plurality of individual gel spring members at a first end and at a second, opposing end of the at least one gel spring member.

18. A gel springs cushion comprising:

a non-stretchable first fabric;

a stretchable second fabric; and

a plurality of individual gel spring members bonded directly to the first fabric and the second fabric, each individual gel spring member comprising an elastomeric gel, wherein;

at least one of the plurality of individual gel spring members is bucklable in a direction generally perpendicular to a plane of the first fabric or a plane of the second fabric; and

a top surface of at least one of the plurality of individual gel spring members may move laterally relative to a bottom surface of the at least one of the plurality of individual gel spring members.

19. The gel springs cushion of claim 18, wherein at least one of the plurality of individual gel spring members is heat-fused directly to the first fabric and the second fabric.

20. The gel springs cushion of claim 18, wherein a first cross section of at least one gel spring member of the plurality is different from a second cross section of the at least one gel spring member of the plurality, the first and second cross sections taken parallel to the plane of the first fabric or the plane of the second fabric.

21. The gel springs cushion of claim 18, wherein at least one gel spring member of the plurality defines at least one hollow.

22. The gel springs cushion of claim 18, wherein at least one gel spring member of the plurality is solid.

23. The gel springs cushion of claim 18, wherein at least one gel spring member of the plurality comprises a slow rebound gel that includes a material selected from the group consisting of resin and rosin.

24. The gel springs cushion of claim 18, wherein buckling of an individual gel spring member of the plurality causes a deviation from the elastic line in a plot of load as a function of deflection for the buckled gel spring member.

25. The gel springs cushion of claim 18, wherein at least two gel springs members of the plurality are hollow and in contact with each other along their peripheries.

26. The gel springs cushion of claim 18, wherein the non-stretchable first fabric is affixed to a non-gel springs cushioning element, the non-gel springs cushioning element having a structure selected from the group consisting of foam and an innerspring assembly.

27. The gel springs cushion of claim 18, wherein at least one gel spring member of the plurality defines at least one hollow and at least one gel spring member of the plurality is solid.