Collapsible layered cushion

• US 8,990,987 B2
• Filed: 04/01/2013
• Issued: 03/31/2015
• Est. Priority Date: 06/07/2011
• Status: Active Grant

• Current Assignee: Skydex Technologies Incorporated
• Original Assignee: Skydex Technologies Incorporated
• Inventors: Wyman, Ethan Thomas, Feighery, Daniel Antonio, Sugano, Eric William, Foley, Peter, Manney, Thomas, Metzer, Collin, Buchen, Gerald Michael, Danis, John Marcel
• Primary Examiner(s): POLITO, NICHOLAS F
• Application Number:
  US13/854,869
• Publication Number:
  US 20130326819A1
• Time in Patent Office: 729 Days
• Field of Search: 563/0, 563/2, 563/6, 564/4, 542/0, 570/1, 570/6, 570/9, 571/0, 572/7, 572/8, 572/9, 565/2, 565/3, 565/4, 565/53, 565/59, 590/1, 565/21, 572/4, 267/117, 267/142, 267/145, 297/452.21, 297/452.24, 297/452.42, 297/452.45, 297/452.46, 297/452.48, 297/452.55, 297/452.57, 297/452.65, 428/72, 428/73, 428/116, 428/178
• US Class Current: 5/727
• 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 foam layer;

a fluid permeable void cell layer including;

a first matrix of void cells formed in a first surface;

a second matrix of void cells formed in a second surface, wherein the first surface, the second surface, and the foam layer each share a common normal axis;

at least one drainage hole at an interface between two adjacent void cells in the void cell layer, wherein the foam layer substantially collapses at a lower pressure than the fluid permeable void cell layer;

a separation layer configured to be oriented between the foam layer and the fluid permeable void cell layer, wherein at least one void cell of the fluid permeable void cell layer opens to the separation layer;

a rigid layer oriented adjacent to the fluid permeable void cell layer; and

a cover configured to envelop the foam layer and the void cell layer, wherein the cover constrains the foam layer and the fluid permeable void cell layer in a selected position and orientation when enveloping the foam layer and the fluid permeable void cell layer, and wherein the foam layer, the fluid permeable void cell layer, and the cover are removable from one another.

2. The layered cushion of claim 1,

wherein the cover is further configured to envelop the rigid layer;

the cover further constrains the rigid layer in a selected position and orientation when enveloping the foam layer, the fluid permeable void cell layer, and the rigid layer; and

the rigid layer is removable from the foam layer, the fluid permeable void cell layer, and the cover.

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

4. The layered cushion of claim 1, wherein the foam layer, the void cell layer, and the cover are fluid permeable.

5. The layered cushion of claim 1, wherein a combination of the foam layer and the fluid permeable void cell layer provides a substantially monotonic pressure-deflection curve.

6. The layered cushion of claim 1, wherein the fluid permeable void cell layer includes four or more void cells arranged in a matrix.

7. The layered cushion of claim 1, wherein the cover includes one or more selectively detachable fasteners oriented along at least one side of the cover.

8. The layered cushion of claim 1, wherein openings in the void cells permit fluid transmission through opposing surfaces of the void cell layer.

9. The layered cushion of claim 1, wherein the void cell layer includes at least two stacked cells, the at least two stacked cells including a first upper cell with an upper open surface and a second lower cell with a lower open surface.

10. A method of assembling a layered cushion comprising:

positioning a foam layer adjacent a first surface of a separation layer and within a cover;

positioning a fluid permeable void cell layer adjacent a second surface of the separation layer and within the cover, the fluid permeable void cell layer including a matrix of void cells formed in a first surface sharing a common normal axis with the foam layer, wherein the matrix of void cells includes at least one cell that opens to the separation layer and at least one cell that has a drainage hole, and wherein the foam layer substantially collapses at a lower pressure than the fluid permeable void cell layer;

positioning a rigid layer adjacent to the fluid permeable void cell layer; and

closing the cover to envelop the foam layer and the fluid permeable void cell layer, wherein the foam layer, the fluid permeable void cell layer, and the cover are removable from one another.

11. The method of claim 10,

wherein the closing operation further envelops the rigid layer and the rigid layer is removable from the foam layer, the fluid permeable void cell layer, and the cover.

12. The method of claim 10, wherein the separation layer adjoins the cover.

13. The method of claim 10, wherein the foam layer and the cover are fluid permeable.

14. The method of claim 10, wherein a combination of the foam layer and the fluid permeable void cell layer provides a substantially monotonic pressure-deflection curve.

15. The method of claim 10, wherein the fluid permeable void cell layer includes four or more void cells arranged in a matrix.

16. The method of claim 10, wherein the fluid permeable void cell layer includes two layers of void cells in an opposing or interdigitated arrangement.

17. The method of claim 10, wherein the cover includes one or more selectively detachable fasteners oriented along at least one side of the cover.

18. A washable layered mattress comprising:

a fluid permeable foam layer;

a fluid permeable void cell layer including;

a first matrix of void cells formed in a first surface; and

a second matrix of void cells formed in a second surface, wherein the first surface, the second surface, and the foam layer each share a common normal axis;

a separation layer oriented between the foam layer and the fluid permeable void cell layer, wherein at least one void cell in the fluid permeable void cell layer opens to the separation layer;

a rigid layer configured to be oriented adjacent the fluid permeable void cell layer; and

a cover that envelops and constrains the foam layer and the fluid permeable void cell layer in a selected position and orientation, wherein the foam layer, the fluid permeable void cell layer, and the cover are removable from one another, and wherein at least one cell in the fluid permeable void cell layer includes a drainage hole.

19. The washable layered mattress of claim 18, wherein the foam layer substantially collapses at a lower pressure than the void cell layer.