Cushions comprising core structures and related methods

• US 8,628,067 B2
• Filed: 05/20/2010
• Issued: 01/14/2014
• Est. Priority Date: 10/03/2008
• Status: Active Grant

• Current Assignee: Purple Innovation LLC (Global Partner Acquisition Corp.)
• Original Assignee: Edizone LC (Edizone)
• Inventors: Pearce, Tony M., Nilson, Joseph T.
• Primary Examiner(s): SCHWARTZ, CHRISTOPHER P
• Application Number:
  US12/784,346
• Publication Number:
  US 20100229308A1
• Time in Patent Office: 1,335 Days
• Field of Search: 267/103, 267/110, 267/142, 267/145, 267/146, 565/4, 56552-6555, 573/9, 428/36.1, 428/35.7, 428/99
• US Class Current: 267/142
• CPC Class Codes: A47C 27/144 inside the mattress or cushion
• 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 27/16 reinforced with sheet-like or rigid elements, e.g. profiled
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Cushions include a plurality of core structures and a support material at least partially surrounding each core structure of the plurality of core structures. The core structures and support material comprise different deformable polymer materials. Each of the core structures may be configured as a column having a column axis. Methods of forming cushions include forming a plurality of core structures, and at least partially surrounding each core structure of the plurality of core structures with a support material comprising a second, different deformable polymer material. The core structures may be configured such that each core structure is integrally interconnected along a length thereof to no more than two other core structures of the plurality of core structures.

Claims

1. A cushion, comprising:

a plurality of core structures, each core structure of the plurality of core structures comprising a first deformable polymer material, each core structure of the plurality of core structures configured as a column having a column axis; and

a support material at least partially surrounding each core structure of the plurality of core structures, the support material comprising a second deformable polymer material differing in composition from the first deformable polymer material of the plurality of core structures;

wherein each core structure of the plurality of core structures is integrally interconnected along a length thereof to no more than two other core structures of the plurality of core structures; and

wherein the support material comprises a unitary body of support material having a plurality of recesses therein, each core structure of the plurality of core structures disposed respectively within a recess of the plurality of recesses in the unitary body of support material.

2. The cushion of claim 1, wherein each core structure of the plurality of core structures is isolated along the length thereof from each of the other core structures of the plurality of core structures by the support material.

3. The cushion of claim 1, wherein each core structure of the plurality of core structures is configured to buckle when compressed along the column axis of the core structure to a pressure beyond a threshold pressure level.

4. The cushion of claim 1, wherein the first deformable polymer material comprises gel.

5. The cushion of claim 1, wherein the second deformable polymer material comprises foam.

6. The cushion of claim 1, wherein at least two core structures of the plurality of core structures are interconnected by a rib member extending along a length of each of the at least two core structures and integrally formed with the at least two core structures.

7. The cushion of claim 6, wherein the plurality of core structures comprises a plurality of lines of interconnected core structures, the core structures in each line of interconnected core structures being interconnected to at least one other core structure in the line of interconnected core structures by an integral rib member.

8. The cushion of claim 1, wherein the column axis of the core structures of the plurality of core structures are oriented generally parallel to one another, and the column axis of the core structures of the plurality of core structures are oriented perpendicular to a cushioning surface of the cushion.

9. The cushion of claim 1, wherein at least one of top ends and bottom ends of the core structures of the plurality of core structures are interconnected by at least one of fabric and a skin layer.

10. A cushion, comprising:

a plurality of core structures, each core structure of the plurality of core structures comprising a gel material, each core structure of the plurality of core structures configured as a column having a column axis, each core structure of the plurality of core structures being interconnected along a length thereof to no more than two other core structures of the plurality of core structures; and

a support material at least partially surrounding each core structure of the plurality of core structures, the support material comprising a unitary body of deformable polymer foam having a plurality of recesses therein, each core structure of the plurality of core structures disposed respectively within a recess of the plurality of recesses in the unitary body of support material;

wherein each core structure of the plurality of core structures is configured to buckle within a recess of the plurality of recesses in the unitary body of deformable polymer foam when compressed along the column axis of the core structure to a pressure beyond a threshold pressure level.

11. The cushion of claim 10, wherein each core structure of the plurality of core structures is isolated along the length thereof from each of the other core structures of the plurality of core structures by the support material.

12. The cushion of claim 10, wherein at least two core structures of the plurality of core structures are interconnected by a rib member extending along the length of the at least two core structures and integrally formed with each core structure of the at least two core structures.

13. The cushion of claim 10, wherein the plurality of core structures comprises a plurality of lines of interconnected core structures, the core structures in each line of interconnected core structures being interconnected to at least one other core structure in the line of interconnected core structures by an integral rib member.

14. The cushion of claim 10, wherein the column axis of the core structures of the plurality of core structures are oriented generally parallel to one another, and the column axis of the core structures of the plurality of core structures are oriented perpendicular to a cushioning surface of the cushion.

15. The cushion of claim 10, wherein at least one of top ends and bottom ends of the core structures of the plurality of core structures are interconnected by at least one of fabric and a skin layer.

16. A method of forming a cushion, comprising:

forming a plurality of core structures each comprising a first deformable polymer material and configured as a column having a column axis;

disposing each core structure of the plurality of core structures respectively within a recess of a plurality of recesses in a unitary body of support material to at least partially surround each core structure of the plurality of core structures with the support material, the support material comprising a second deformable polymer material differing in composition from the first deformable polymer material; and

configuring each core structure of the plurality of core structures to be integrally interconnected along a length thereof to no more than two other core structures of the plurality of core structures.

17. The method of claim 16, wherein configuring each core structure of the plurality of core structures to be integrally interconnected along a length thereof to no more than two other core structures of the plurality of core structures comprises configuring each core structure of the plurality of core structures to be integrally interconnected along a length thereof to no other core structures of the plurality of core structures.

18. The method of claim 16, further comprising at least substantially laterally isolating each core structure of the plurality of core structures from all other core structures of the plurality of core structures by the support material.

19. The method of claim 16, further comprising configuring each core structure of the plurality of core structures to buckle when compressed along a column axis of the core structure to a pressure beyond a threshold pressure level.

20. The method of claim 16, further comprising selecting the first deformable polymer material to comprise gel.

21. The method of claim 16, further comprising selecting the second deformable polymer material to comprise foam.

22. The method of claim 16, further comprising interconnecting at least two core structures of the plurality of core structures with a rib member extending along a length of each of the at least two core structures and integrally formed with the at least two core structures.

23. The method of claim 22, further comprising forming the plurality of core structures to comprise a plurality of lines of interconnected core structures by interconnecting the core structures in each line of interconnected core structures to at least one other core structure in the line of interconnected core structures with an integral rib member.

24. The method of claim 16, further comprising:

orienting the core structures of the plurality of core structures generally parallel to one another; and

orienting the column axis of the core structures of the plurality of core structures perpendicular to a cushioning surface of the cushion.

25. The method of claim 16, further comprising interconnecting at least one of top ends and bottom ends of the core structures of the plurality of core structures using at least one of fabric and a skin layer.