Cushions comprising deformable members and related methods

• US 8,932,692 B2
• Filed: 05/20/2010
• Issued: 01/13/2015
• 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.
• Primary Examiner(s): Pierce, Jeremy R
• Application Number:
  US12/784,247
• Publication Number:
  US 20100227091A1
• Time in Patent Office: 1,699 Days
• Field of Search: 428/35.7, 428/36.1, 428/36.2, 428/36.9, 156/242, 156/244.12, 156/244.13, 156/245, 571/6, 571/9, 572/0
• US Class Current: 428/36.1
• CPC Class Codes: A47C 27/056 with different layers of foamed material
• 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 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2437/02 Gloves, shoes
• CPC Class Codes: B32B 2479/00 Furniture upholstery B32B2601/00
• CPC Class Codes: B32B 25/045 of foam
• CPC Class Codes: B32B 25/08 of synthetic resin
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/22 using plasticisers
• CPC Class Codes: B32B 27/283 : comprising polysiloxanes
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1362 : Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/1366 : Textile, fabric, cloth, or pile is sandwiched between two distinct layers of material unlike the textile, fabric, cloth, or pile layer
• CPC Class Codes: Y10T 428/139 : Open-ended, self-supporting conduit, cylinder, or tube-type article

Abstract

Cushions include a plurality of pockets formed from a support material and a deformable member comprising a deformable polymer material disposed in each pocket of the plurality of pockets. The support material may comprise at least one of a fabric and a film. Each of the deformable members may be configured as a column having a column axis. Methods of forming cushions include forming a plurality of deformable members, forming a plurality of pockets from a support material, and disposing each of the deformable members of the plurality of deformable members in each of the pockets of the plurality of pockets. The deformable members may be configured so that each of the deformable members is isolated from the other deformable members by the support material.

Claims

1. A mattress cushion comprising:

a support material having a plurality of connected pockets formed therein, the support material comprising at least one of a fabric and a film; and

a plurality of laterally isolated deformable members, at least one deformable member of the plurality of laterally isolated deformable members disposed within at least one of the connected pockets of the plurality of connected pockets, the plurality of deformable members comprising a deformable polymer material;

wherein the support material is configured to maintain the laterally isolated deformable members within the connected pockets when the laterally isolated deformable members are not under load without the laterally isolated deformable members being attached to any other material.

2. The mattress cushion of claim 1, wherein the plurality of laterally isolated deformable members comprises a plurality of hollow tubes.

3. The mattress cushion of claim 1, wherein the deformable members of the plurality of laterally isolated deformable members are configured to buckle when compressed generally parallel to column axes of the deformable members of the plurality of laterally isolated deformable members to a pressure beyond a threshold pressure level.

4. The mattress cushion of claim 1, wherein the at least one deformable member of the plurality of laterally isolated deformable members exhibits a non-linear stress-strain curve in compression.

5. The mattress cushion of claim 1, wherein the deformable polymer material comprises gel.

6. The mattress cushion of claim 1, wherein the support material comprises a stretchable material.

7. The mattress cushion of claim 6, wherein the stretchable material comprises at least one of polyurethane film and polyvinyl chloride film.

8. The mattress cushion of claim 1, wherein the deformable members of the plurality of laterally isolated deformable members are oriented generally parallel to one another, and column axes of the deformable members of the plurality of laterally isolated deformable members are oriented generally perpendicular to a cushioning surface of the cushion.

9. The mattress cushion of claim 1, wherein at least one of top ends and bottom ends of the deformable members of the plurality of laterally isolated deformable members are interconnected by at least one of a fabric and a skin layer.

10. The mattress cushion of claim 1, wherein the support material of at least one of the connected pockets of the plurality of connected pockets is sealed at least around at least one of a top end and a bottom end of the deformable member of the plurality of laterally isolated deformable members disposed within the at least one of the connected pockets.

11. The mattress cushion of claim 1, wherein another cushion is connected to at least one of the support material and the deformable members.

12. The mattress cushion of claim 1, further comprising a cushion cover connected to or at least partially surrounding at least one of the support material and deformable members.

13. A cushion, comprising:

a plurality of laterally isolated deformable members, each deformable member of the plurality of laterally isolated deformable members comprising a gel material, each deformable member of the plurality of deformable members configured as a column having a column axis; and

a support material at least partially surrounding each deformable member of the plurality of laterally isolated deformable members, the support material having a plurality of pockets formed therefrom, each deformable member of the plurality of laterally isolated deformable members disposed respectively within a pocket of the plurality of pockets;

wherein at least one deformable member of the plurality of laterally isolated deformable members is configured to buckle within a pocket of the plurality of pockets when compressed along the column axis of the deformable member to a pressure beyond a threshold pressure level without causing displacement or deformation of the adjacent deformable members; and

wherein the support material is configured to maintain the laterally isolated deformable members within the connected pockets when the laterally isolated deformable members are not under load without the laterally isolated deformable members being attached to any other material.

14. The cushion of claim 13, wherein each deformable member of the plurality of laterally isolated deformable members is isolated along the length thereof parallel to its column axis from each of the other deformable members of the plurality of deformable members by the support material.

15. The cushion of claim 13, wherein the deformable members of the plurality of laterally isolated deformable members are oriented generally parallel to one another, and the column axes of the deformable members of the plurality of laterally isolated deformable members are oriented generally perpendicular to a cushioning surface of the cushion.

16. The cushion of claim 13, wherein the support material is sealed at least one of above the deformable members of the plurality of laterally isolated deformable members or below the deformable members of the plurality of laterally isolated deformable members.

17. The cushion of claim 16, wherein the support material is configured to stretch as a deformable member of the plurality of laterally isolated deformable members buckles.

18. A method of forming a mattress cushion, comprising:

forming a plurality of laterally isolated deformable members, each of the deformable members of the plurality of laterally isolated deformable members comprising a deformable polymer material, configured as a column having a column axis;

forming a plurality of connected pockets within a support material comprising at least one of a fabric material and a film;

disposing at least one of the deformable members of the plurality of deformable members in at least one connected pocket of the plurality of connected pockets; and

at least substantially laterally isolating each deformable member of the plurality of deformable members from other deformable members of the plurality of deformable members by the support material, such that the support material is configured to maintain the laterally isolated deformable members within the connected pockets when the laterally isolated deformable members are not under load without the laterally isolated deformable members being attached to any other material.

19. The method of claim 18, further comprising configuring at least one deformable member of the plurality of deformable members to buckle when compressed along a column axis of the deformable members to a pressure beyond a threshold-buckling pressure level.

20. The method of claim 19, further comprising selecting the support material to stretch as a deformable member of the plurality of deformable members buckles.

21. The method of claim 18, further comprising selecting the deformable polymer material to comprise gel.

22. The method of claim 18, further comprising selecting the support material to comprise a stretchable material.

23. The method of claim 18, further comprising:

orienting the column axes of the deformable members of the plurality of laterally isolated deformable members generally parallel to one another; and

orienting the column axes of the deformable members of the plurality of laterally isolated deformable members perpendicular to a cushioning surface of the cushion.

24. The method of claim 18, further comprising interconnecting at least one of top ends and bottom ends of the deformable members of the plurality of laterally isolated deformable members using at least one of fabric and a skin layer.

25. The method of claim 18, further comprising sealing at least one of a top portion and a bottom portion of the support material of each interconnected pocket of the plurality of interconnected pockets around each of the deformable members of the plurality of laterally isolated deformable members in each interconnected pocket.

26. The method of claim 25, further comprising securing a connecting layer over the sealed at least one of a top portion and a bottom portion of the support material.

27. A mattress cushion comprising:

a fabric defining a plurality of connected pockets; and

a plurality of laterally isolated foam members, at least one foam member of the plurality of laterally isolated foam members disposed within at least one of the connected pockets of the plurality of connected pockets;

wherein the fabric is configured to maintain the laterally isolated foam members within the connected pockets when the laterally isolated foam members are not under load without the laterally isolated foam members being directly attached to any other material.

28. The mattress cushion of claim 27, wherein each foam member of the plurality of laterally isolated foam members comprises at least one of a thermoset material and a thermoplastic material.

29. The mattress cushion of claim 27, wherein each foam member of the plurality of laterally isolated foam members comprises polyurethane.