Collapsible layered cushion

• US 9,492,018 B2
• Filed: 02/13/2015
• Issued: 11/15/2016
• 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 Maurice, Manney, Thomas Christopher, Metzer, Collin, Buchen, Gerald Michael, Danis, John Marcell
• Primary Examiner(s): POLITO, NICHOLAS F
• Application Number:
  US14/622,642
• Publication Number:
  US 20150157135A1
• Time in Patent Office: 641 Days
• Field of Search: 563/0, 563/2, 563/6, 564/4, 542/0, 570/1, 570/6, 570/9, 571/0, 572/4, 572/7, 572/8, 572/9, 565/2, 565/21, 565/3, 565/4, 565/53, 565/59, 590/1, 267/117, 267/142, 267/145, 297/452.24, 297/452.42, 29745245-45248, 297/452.55, 297/452.57, 297/452.65, 428/72, 428/73, 428/116, 428/178
• 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 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 second matrix of void cells formed exclusively in a second sheet of resiliently deflectable material, the second matrix 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;

a plurality of drainage holes providing one or more fluid-permeable channels through the first sheet of resiliently deflectable material and the second sheet of resiliently deflectable material;

a foam layer; and

a removable cover configured to envelop the first matrix of void cells, the second matrix of void cells, and the foam layer, wherein the foam layer is removable from the cover, the first matrix of void cells, and the second matrix of void cells.

2. The layered cushion of claim 1 wherein each of the plurality of drainage holes is positioned at an interface between an axially aligned void cell of the first matrix and a void cell of the second matrix.

3. The layered cushion of claim 1 wherein each of the plurality of drainage holes facilitates fluid transport through a pair of void cells.

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

5. The layered cushion of claim 1, wherein each void cell of the first matrix is aligned with a corresponding void cell of the second matrix along an axis normal to the foam layer.

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

7. The layered cushion of claim 1 further comprising:

a separation layer configured to be oriented between the foam layer and the first sheet of resiliently deflectable material.

8. The layered cushion of claim 7 wherein the separation layer adjoins the cover.

9. A washable layered mattress comprising:

a foam layer;

a void cell layer including a first matrix of void cells formed exclusively in a first sheet of resiliently deflectable material and a second matrix of void cells formed exclusively in a second sheet of resiliently deflectable material, wherein the first matrix includes at least two rows and two columns of void cells and the second matrix includes 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, the separation layer substantially preventing the foam layer from collapsing into the void cell layer;

a plurality of drainage holes providing one or more fluid-permeable channels through the first sheet of resiliently deflectable material and the second sheet of resiliently deflectable material of the void cell layer; and

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

10. The washable layered mattress of claim 9 wherein each of the plurality of drainage holes is positioned at an interface between a void cell of the first matrix and a void cell of the second matrix.

11. The washable layered mattress of claim 9 wherein each of the plurality of drainage holes facilitates fluid transport through an axially aligned pair of void cells of the void cell layer.

12. The washable layered mattress of claim 9 wherein each of the plurality of drainage holes facilitates fluid transport in a direction parallel to the normal axis of the foam layer.

13. The washable layered mattress of claim 9 wherein the cover constrains the foam layer in a selected position and orientation relative to void cell layer when enveloping the foam layer.

14. The washable layered mattress of claim 9 wherein the foam layer, the void cell layer, and the removable cover are each fluid-permeable.

15. The washable layered mattress of claim 9 wherein the separation layer is formed continuously with the removable cover.

16. The washable layered mattress of claim 9 wherein the separation layer adjoins the cover.

17. A method of assembling a layered cushion comprising:

positioning a foam layer adjacent to a void cell layer on opposite sides of a separation layer, wherein the separation layer contacts the first matrix of void cells and substantially prevents the foam layer from collapsing into the void cell layer, the void cell layer including a first matrix of void cells formed exclusively in a first sheet of resiliently deflectable material and a second matrix of void cells formed exclusively in a second sheet of resiliently deflectable material, wherein each void cell of the first matrix is aligned with a corresponding void cell of the second matrix and includes a drainage hole that facilitates fluid transport through the first sheet of resiliently deflectable material and the second sheet of resiliently deflectable material, and wherein the first matrix includes at least two rows and two columns of void cells and the second matrix includes at least two rows and two columns of void cells;

positioning the foam layer and the void cell layer within a cover; and

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

18. The method of claim 17, 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 the second matrix of void cells.

19. The method of claim 17 wherein each drainage hole facilitates fluid transport through an axially aligned pair of void cells.

20. The method of claim 17 wherein the cover constrains the first matrix of void cells in a fixed position relative to the second matrix of void cells when enveloping the first matrix of void cells and the second matrix of void cells.

21. A washable layered mattress comprising:

a foam layer;

a void cell layer including a first matrix of void cells formed exclusively in a first sheet of resiliently deflectable material and a second matrix of void cells formed exclusively in a second sheet of resiliently deflectable material, wherein the first matrix includes at least two rows and two columns of void cells and the second matrix includes at least two rows and two columns of void cells, wherein each of the void cells in the first matrix and in the second matrix is maintained at atmospheric pressure independent from a state of compression of the void cell layer;

a separation layer configured to be oriented between the foam layer and the void cell layer, wherein the separation layer substantially prevents the foam layer from collapsing into the void cell layer; and

a removable cover configured to envelop the foam layer and the void cell layer wherein the foam layer is removable from the cover, the first matrix of void cells, and the second matrix of void cells.