CUSHIONING ASSEMBLIES WITH THERMOPLASTIC ELEMENTS ENCAPSULATED IN THERMOSET PROVIDING CUSTOMIZABLE SUPPORT AND AIRFLOW, AND RELATED METHODS

• US 20140317856A1
• Filed: 04/24/2014
• Published: 10/30/2014
• Est. Priority Date: 04/26/2013
• Status: Active Grant

• Current Assignee: Noel Group, LLC
• Original Assignee: Noel Group, LLC
• Granted Patent: US 10,045,633 B2
• Time in Patent Office: Days
• US Class Current: 5/724
• CPC Class Codes: A47C 27/065 of special shape
• CPC Class Codes: A47C 27/144 inside the mattress or cushion
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: B29C 70/70 Completely encapsulating inserts B29C70/86 takes precedence
• CPC Class Codes: B29L 2031/751 Mattresses, cushions upholstery B29L2031/58

Abstract

Embodiments disclosed herein include cushioning assemblies with thermoplastic elements encapsulated in thermoset providing customizable support and airflow. A cushioning assembly for a cushion provides cushioning and support for a user. Thermoplastic elements are encapsulated within a thermoset matrix to provide additional support at specific sections of the cushion. The shape and location of the thermoplastic elements may be configured to provide the support and cushioning characteristics desired by a user. The thermoplastic elements may include air passageways in communication with the outside. In this manner, support is provided precisely where needed for the user, the weight and expense of the cushion is reduced by eliminating expensive redundant support, and the heat and humidity that can cause user discomfort is reduced.

Claims

1. A method of creating a cushioning assembly, comprising:

extruding at least one thermoplastic profile;

disposing the at least one thermoplastic profile within an enclosure by suspending the at least one thermoplastic profile with at least one removable elongated member; and

dispensing thermoset material within the enclosure to encapsulate the at least one thermoplastic profile to form a thermoset matrix as part of a cushioning core,

wherein the cushioning core comprises the thermoset matrix encapsulating the at least one thermoplastic profile.

2. The method of claim 1, wherein cushioning core is comprised of a mattress core.

3. The method of claim 1, wherein the extruding the at least one thermoplastic profile comprises forming a longitudinal passageway through each of the at least one thermoplastic profile.

4. The method of claim 3, wherein the dispensing the thermoset material comprises forming a top planar surface opposite a bottom planar surface, and the top planar surface and the bottom planar surface are parallel or substantially parallel.

5. The method of claim 4, wherein the dispensing the thermoset material further comprises disposing the at least one thermoplastic profile between the top planar surface and the bottom planar surface.

6. The method of claim 1, wherein the dispensing the thermoset material further comprises dispensing polyurethane or latex or other suitable multi part formulated cushioning material.

7. The method of claim 1, further comprising providing the enclosure as a mattress enclosure comprising a foam base and at least one side support that is supported by the foam base, the at least one side support and the foam base are arranged to enclose an inner volume configured to hold the cushioning core.

8. The method of claim 7, further comprising cutting the at least one side support to a length to abut against opposite side supports of the at least one side supports, wherein a seal is created by the abutments.

9. The method of claim 7, wherein the disposing the at least one thermoplastic profile comprises making at least one opening in opposite side supports of the at least one side support and supporting the at least one removable elongated member with the at least one opening in the opposite side supports.

10. The method of claim 9, wherein the at least one removable elongated member is a rigid support configured to interface with an internal surface of the at least one thermoplastic profile.

11. The method of claim 7, wherein the at least one side support comprises thermoplastic.

12. The method of claim 6, wherein the foam base comprises thermoplastic.

13. A cushioning assembly, comprising:

a cushioning core comprising at least one thermoplastic profile encapsulated within a thermoset matrix by an attachment disposed around a longitudinal exterior surface of each of the at least one thermoplastic profile,

wherein the thermoset matrix is configured to transfer to, and receive from, the at least one thermoplastic profile, a weight of the user.

15. The cushioning assembly of claim 13, further comprising a foam base supporting the mattress cushioning core disposed adjacent to a top side of the foam base.

16. The cushioning assembly of claim 13, further comprising at least one foam side support member configured to be disposed adjacent a periphery portion of the mattress core to provide side support for the mattress core, the at least one side support is supported by the foam base.

19. The cushioning assembly of claim 13, wherein each of the at least one thermoplastic profile comprises polyethylene.

20. The cushioning assembly of claim 13, wherein the thermoset matrix comprises polyurethane.

14. The cushioning assembly comprised of a mattress assembly, wherein the cushioning core is comprised of a mattress core comprising the at least one thermoplastic profile encapsulated within the thermoset matrix by the attachment disposed completely around the longitudinal exterior surface of each of the at least one thermoplastic profile.

17. The cushioning assembly of claim 14, wherein each of the at least one thermoplastic profile includes at least one longitudinal passageway extending therethrough.

18. The cushioning assembly of claim 17, wherein the each of the at least one longitudinal passageway contains air in communication with the atmosphere via at least one opening through the at least one foam side support member.

21. The cushioning assembly of claim 14, wherein the thermoset matrix comprises a top planar surface and a bottom planar surface opposite the top planar surface, the top planar surface and the bottom planar surface are parallel or substantially parallel.

22. The cushioning assembly of claim 21, wherein the at least one thermoplastic profile is disposed between the top planar surface and the bottom planar surface.

23. The cushioning assembly of claim 14, wherein the thermoset matrix comprises a plurality of core segments.

24. The cushioning assembly of claim 14, wherein the thermoset matrix is formed from a slow-reacting formula.

25. The cushioning assembly of claim 14, wherein the mattress core comprises either a plurality of core segments or a singular core segment.

26. The cushioning assembly of claim 14, wherein the thermoset matrix is formed from multi part formulation with a reaction process suitable to complete the entire dispense prior to a foaming action occurring.