Composite Cushioning System

Embodiments of the disclosure relate generally to cushioning apparatuses. Specific embodiments relate to spring-coil and elastomeric foam mattresses with cushioning fabrics.

Cushioning systems may serve as a utilitarian means for promoting health by providing structural support while enhancing a user's comfort. Cushioning technology has evolved over time to include coiled springs, foam, and elastomeric components. Such synthetic materials reduce the need for animal cushioning products like goose down or similar fill material thereby providing environmentally conscious alternative products to consumers.

Coiled spring cushioning systems may be comprised of any number of metallics or plastics. Despite providing strong structural support coiled cushioning systems have drawbacks. Coils may be uncomfortable when in close contact to a user's skin. Coils observable through an outer covering may be unsightly. Coils may be heavy therefore difficult for some users to reposition.

Foam cushioning systems provide users with a soft means for structural support. Foam has special durability due to its quality of returning to a decompressed state after a user provided pressure is removed. However, lightweight foam may provide insufficient support to a user. Strongly supportive foam is heavy and shares drawbacks with spring coils.

Elastomeric materials, also known as “gel elastomers,” or “gels” are one way to bridge the gap between coils and foam. Rigid gels provide strong support much like coil springs. Other malleable gels share the benefits and drawbacks of foam. Such gels can be made from various polymer materials as might be known now or in the future.

Composite cushioning systems comprised of spring coils, foam, and gel materials may provide a user with aesthetically pleasing support in a user-friendly package. However, such composite systems may be expensive to manufacture due to complicated designs and costly materials making them inaccessible to much of the market. A need exists for user friendly yet cost effective composite cushioning systems.

Accordingly, there is a need for composite cushioning systems that combine the benefits of individual coil spring, foam, and/or gel cushion systems. When combined as described herein, such composite cushioning systems use the benefits of single material systems to resolve drawbacks, improve performance, and present a cost-effective solution. The present invention fulfills these needs and provides other related advantages.

The present invention is directed to an apparatus satisfying the need for cost effective eco and user-friendly cushioning systems. A composite cushioning system having features of the present invention generally includes a base, a lower foam layer supporting the base, and an upper foam layer above said base on which a topper is disposed. The topper may have different configurations across various embodiments. A cover encloses the base, foam layers, and topper, with such cover preferably having a padded cushioning quality, as in quilted or knitted layers enclosing cushioning material.

The present invention is directed to a composite cushioning system, which includes a spring coil base layer, a topper layer, and an outer cover. The spring base layer has an array of coil springs surrounded by a border of cushioning foam and covered by an upper foam layer. The topper layer is disposed on the upper foam layer and coextensive with the spring base layer, said topper layer having an elastomeric layer coupled to a foam layer. The outer cover encloses both the spring base layer and the topper layer.

In one embodiment, the foam layer of the topper layer may include an inferior cushioning layer, the elastomeric layer may include a median elastomeric layer disposed on the inferior cushioning layer, and the topper layer may further include a superior fabric layer disposed on the median elastomeric layer. The topper layer may further include a plurality of buttons connecting the superior fabric layer to the inferior cushioning layer through the median elastomeric layer, creating a tufted look and feel. The outer cover may include a padded cushioning material, such as a quilted fabric or a formed unitary fabric enclosing a cushioning material.

In another embodiment, the elastomeric layer of the topper layer may include a median elastomeric layer disposed on the upper foam layer, the median elastomeric layer covering an area that is less than an area of the spring base layer. Stated another way, the median elastomeric layer is configured having a surface area that is less than a surface area of the spring base layer. In this embodiment, the foam layer of the topper layer includes a border cushion layer and a superior cushion layer. The border cushion layer surrounds the median elastomeric layer so as to have edges coterminous with edges of the upper foam layer. The superior cushion layer is disposed on the median elastomeric layer and the border cushion layer having edges coterminous with edges of the superior cushion layer. The topper layer further includes a fabric layer disposed between and fixed to the median elastomeric layer and the superior cushion layer, with the fabric layer is fixed to the superior cushion layer by an adhesive. The fabric layer may also be fixed to the median elastomeric layer by the adhesive, or preferably by melting, either with the fabric layer being in the mold during the injection molding process or by applying heat to the elastomeric layer when in contact with the fabric layer.

In yet another embodiment, the elastomeric layer of the topper layer may include an elastomeric cushion enclosed within a fabric cover, which is preferably resilient, but not necessarily stretchy. The fabric cover is preferably fixed to the upper foam layer by an adhesive. In an alternate embodiment, the topper layer may include a foam layer possibly designated as an inferior cushion layer, where both the elastomeric cushion and inferior cushion layer are coextensive with the upper foam layer of the coil spring layer. In this alternate embodiment, the fabric cover is preferably fixed to the inferior cushion layer by an adhesive.

In a further embodiment, the elastomeric layer of the topper layer may be an elastomeric cushion substantially co-extensive with the upper foam layer of the spring base layer. The topper layer may further comprise a supplemental cushion layer, with the elastomeric cushion and the supplemental cushion layer integrally formed at a melting interface. The elastomeric layer may further include an edge support structure around a perimeter of the melting interface. The supplemental cushion layer is preferably co-extensive with said upper foam layer of the spring base layer.

In a still further embodiment, the elastomeric layer of the topper layer may include a first elastomeric cushion disposed over a second elastomeric cushion, with a positioning fabric disposed and fixed therebetween. The first elastomeric cushion and the second elastomeric cushion are preferably co-extensive with each other, but both have a surface area that is less than the surface area of the upper foam layer of the spring base layer.

The elastomeric layer may further include a first foam border surrounding the first elastomeric cushion and a second foam border surrounding the second elastomeric cushion. The positioning fabric is disposed and fixed between the first foam border and the second foam board such that the topper layer is coextensive with the upper foam layer of the spring base layer. The first foam border and first elastomeric layer each have a uniform first thickness, and the second foam border and second elastomeric layer each have a uniform second thickness. The second thickness is preferably greater than the first thickness.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present there between. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section.

As used herein, the singular forms “a,” “an,” and “the,” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” “includes” and/or “including,” and “have” and/or “having,” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

Furthermore, relative terms, such as “lower” or “bottom,” and “upper” or “top,” and “inner” or “outer,” may be used herein to describe one element's relationship to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures.

Unless otherwise defined, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Exemplary embodiments of the present invention are described herein with reference to idealized embodiments of the present invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the present invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

The present invention is directed to a composite cushioning system, in particular a cushion or mattress, generally referred to by reference numeralin. At a minimum, composite cushioning systemincludes a base layerand a topper layer. Other cushioning materials can be added to the topper layer, either in one or more layers, consisting of soft polyurethane foam, foamed latex, or padding placed in a fabric sleeve. The padding in the fabric sleeve can be selected from buckwheat hulls, cotton, wool, down, foam particles, or segmented polyethylene tubes. The fabric sleeve can be a single cavity or the sleeve can be sewn together using yarn to form multiple cavities filled with filling material. While the detailed description is based upon the following description and drawings depicting an illustrated size and shape, the inventive composite cushion systemmay be provided in any size and shape, including but not limited to twin, full, queen, or king size mattresses, or cushions, pads, or mattresses of any desired size.

As shown ina composite cushioning systemcomprises a basehousing a plurality of coil springs, a lower foam layerand an upper foam layeroppositely disposed about said baseand a toppercoextensive with and supported by said base. The plurality of coil springstake different forms, including link springs, one-wire steel springs, independent cartridge springs, partitioned springs. A linked spring is a coil of thicker wire diameter springs that are fixed with a steel wire link. A wire spring is a continuous stream of steel wire that is wrapped around each part of the mattress from the end of the bed to the end of the bed and then linked in parallel. The independent cartridge spring is a steel spring in a separate shell, which is a separate bag made of non-woven fabric or cloth that is ultrasonically bonded or glued together.

Independent cartridge springs can be laid out in many forms, either in parallel pairs or in a honeycomb layout to provide different contact areas. A zoned spring is an improvement on the independent cartridge spring, adjusting the spring's elasticity according to the different support needed for different areas on the entire mattress. A coil spring mattress may be divided into multiple zone, preferably 5-7 zones. The implementation solution can be to use a spring with high support in the hip, back area where the weight is higher and a spring with low support in the head of the legs. Separate designs are also made according to the different support requirements at the edges and in the middle. It is also possible to change the coil diameter of the spring to adjust the number of springs used per unit area, preferably using a smaller coil diameter spring at the edge of the mattress and a larger coil diameter spring in the middle area.

The spring layercan also use an airbag as an alternative. The airbag can be adjusted by an air pump to adjust the amount of air pressure in the airbag to achieve the adjustment of the support force. Multiple airbags can be used to accommodate the need for different support forces in different zones. In addition, the air pressure in the airbag can be controlled to change at different times according to the needs of use. The spring layercan also use air fibers as an alternative. Air fibers are a polyolefin elastomer extruded by melting in a porous die, injected into cooling water, cooled, and formed into an interlaced web of fibers with high elasticity, breathability, and washability. The spring layercan also use as an alternative a palm mat, which is made using plant fibers such as mountain palm silk or coconut silk. The spring layercan also use polyurethane foam as an alternative. The polyurethane foam can be shaped and processed to change the local material density of the polyurethane foam by cutting or molding it to change the support force and stress-strain curve according to the functional requirements.

As shown insaid toppercomprises an inferior cushioning layersupporting a median elastomeric layersupporting a superior fabric layer. A plurality of buttonsconnects said inferior cushioning layerto said superior fabric layerthrough said median elastomeric layer. While illustrated with a particular number and spacing, the buttonsmay be distributed across the topperin any frequency and spacing. For example, larger toppersas found on mattresses of different sizes might have buttonsless frequently (i.e., every ten grids on the elastomer layer) or more frequently (i.e., every grid or every other grid).

As shown inan outer coverencloses said baseand said topper. Said outer covermay comprise a cushioning materialas shown in. Said outer coverpreferably has a top fabric, a side fabric and a bottom fabric. The three parts of the fabric can be the same material or different materials. One combination scheme has the junction of the top fabric and the side fabric generally on the side, which can be in the form of zipper or stitched. The combination of the side fabric and the bottom fabric is generally on the bottom. Another combination scheme is to have only a top fabric and a bottom fabric, with the top fabric being made to wrap around the top and sides, and the bottom fabric being made to wrap around the bottom and sides, with the top and bottom fabrics being joined either on the bottom or the sides, by a zipper or stitching. The top fabric, side fabric and bottom fabric can be one or more of knitted, woven or quilted fabrics.

Knitted fabric is formed by the process of yarn sequence bending into loops, while the loops are set in series with each other and form the fabric, while the yarn forms the loops. Knitted fabric organizations are weft knitting flat knitting, ribbed organization, double reverse organization, warp knitting chain organization, warp flat organization, warp satin organization, etc. Such knitted fabric can also use the fabric described in patent GB1577399, a knitted fabric to provide a set of loops, the top surface knitted fabric and the bottom surface knitted fabric by stacking needles or loops (tuck stitches or loops) between said knitted fabric together, the spacing between said stitches positioned to define the free space between said top surface fabric and bottom surface fabric to fill the yarn, can be textured synthetic long yarns. The disclosure of foreign patent GB1577399 is hereby incorporated by reference.

Woven fabric is a fabric made of two or more sets of mutually perpendicular yarns, interwoven at an angle of 90 degrees for warp and weft. Woven fabrics are divided into plain weave, twill weave, and satin weave. It is also possible to use double-woven fabric that has warp yarns of two systems of surface warp, and inner warp, and can adopt a variety of structural methods to interlace the weft yarns of two systems of surface weft inner weft. It is also possible to use a multi-layer fabric where each layer of warp yarn is interlaced with its weft yarn respectively, and the layers are connected by warp yarn to form a whole. Quilted fabrics are interlayered textiles sewn with long needles, said textiles can be knitted fabrics, woven fabrics, or non-woven fabrics, and said interlayers can be filament yarns, cotton fibers, wool fibers, hemp fibers, etc. The interlayer can also be knitted fabric, woven fabric, polymer film, polyurethane foam, latex foam, etc.

The covercan also be provided with a window for the consumer to view the internal structure of the mattress, the window can be square, L-shaped, monogram. Inside the outer sleeve can also be provided with an inner sleeve, the inner sleeve can be one or more of knitted fabric, woven fabric or quilted fabric. The inner sleeve can use functional fabrics, such as flame-retardant fabrics, waterproof fabrics, blackout fabrics, etc.

Said elastomeric layer(in this and across other embodiments described herein) can be any thermoplastic rubber, which is formed using a plastic injection molding machine, i.e., heated, melted, injected into the mold, and formed after cooling. Said thermoplastic rubber can be one or more of styrene (SBS, SIS, SEBS, SEPS), olefin (TPO, TPV), diene (TPB, TPI), vinyl chloride (TPVC, TCPE), ammonia ester (TPU), ester (TPEE), amide (TPAE), organofluorine (TPF), silicone, and ethylene, etc.

An adhesivemay fix foam to fabric, foam to foam, and foam to elastomeric material. Said adhesivemay fix said lower foam layerto said baseand to said plurality of springs. Another adhesivemay fix said upper foam layerto the opposite side of said baseand to the opposite side of said plurality of springs. In some embodiments, such adhesivemay fix the inferior cushioning layerto the median elastomeric layerand the median elastomeric layerto the superior fabric layer. In a preferred embodiment, as described below, the inferior cushioning layeris fixed by each buttonto the median elastomeric layer, with each buttonalso being fixed to the superior fabric layer, which superior fabric layeris preferably fixed to the median elastomeric layerby melting.

In many embodiments, polymer foam material, particularly open cell foams, may comprise said lower foam layer, said upper foam layer, and said inferior cushioning layer. Such open-cell, polymer foam material has a reduced density compared to other materials, which reduces the overall weight of the cushioning system while providing sufficient structural support. Such foam materials may also serve as a surface for adhesive between layers of the system. In other embodiments, such foam may serve as a site for heat fixation between layers.

Such foam material preferably surrounds said plurality of coil springsas shown in. The presence of such foam material as described insulates a user from the sight and feel of said plurality of coil springs. This insulation is provided inferiorly by said lower foam layer, superiorly by said upper foam layer, and at the sides in part by said baseand a cover foam. Said cover foammay be of the same composition of said base. The lower foam layer, the upper foam layer, and the cover foamin the base layercan be one or more of polyurethane foam, foam latex, 3D spacer fabric, and air fiber. The cushioning layercan be one or more of polyurethane foam, foam latex, and 3D spacer fabric. The 3D spacer fabric or 3d mesh fabric refers to a high elasticity and high density three-dimensional hollow structure, preferably having upper and lower mesh six-sided shapes, which are preferably breathable. The middle is preferably made of functional polyester fiber material, which is X-90° a soft material for support.

As shown in, said plurality of springsprovides structural support to the composite cushioning system. Said plurality of springsare preferably disposed in adjacent cylindrical fashion within optional fabric sheathes. Their vertical orientation maximally resists pressure applied by a user along a vertical axis of the apparatus perpendicular to said lower foam layeras shown in.

As shown in, said plurality of buttonsis comprised of a buttonin series. Each buttonmechanically connects said inferior cushioning layerto said superior fabric layerthrough the median elastomeric layeras shown in. The median elastomeric layermay bend and compress in response to the pressure supplied by a button, as shown increating an overall tufting configuration about the topperacross the plurality of buttons. Similarly, the median elastomeric layermay also bend and compress in response to pressure supplied by a user thereby providing a cushioning quality to the topperin the overall composite cushioning system.

As shown in, another embodiment of the present invention comprises a second embodiment of toppercombined with said base, upper foam layer, lower foam layer,, plurality of springsand cover foamconfigured as shown in.

As shown in, said second toppercomprises a superior cushioning layercoextensive with said basethat is disposed over an elastomeric layerpreferably having an area less extensive than said base. Said elastomeric layeris surrounded by a lateral foam layerabout the border forming an elastomeric-foam junction() adjoined to the upper foam layerand superior cushioning layerby adhesive. As shown in, an intermediate fabric layeris preferably disposed between said superior cushioning layerand said elastomeric layer, affixed by adhesiveor similar securing structure. The superior cushioning layercan be one or more of polyurethane foam, foam latex, and 3D spacer fabric. Preferably, the fabric layeris affixed to the elastomeric layerby melting, either with the fabric layerbeing in the mold during the injection molding process or by applying heat to the elastomeric layerwhen in contact with the fabric layer.

Elastomeric materials comprise a substantial part of the weight of the type of composite cushioning systems described herein. As shown in, said elastomeric layerhaving a smaller surface area than the base, provides users with a lighter weight system than other systems incorporating an elastomeric layer coextensive with the base.

As shown in, another embodiment of the composite cushioning system may include a third topperenclosed by a fabric coveras shown in. Said third embodiment of topperincludes an elastomeric matcoextensive with said baseresting upon said upper foam layerand base-all enclosed by an outer coveras shown in. Said fabric coverand enclosed elastomeric matis fixed to said upper foam layerby an adhesiveas shown in. The fabric coveris also preferably attached to the elastomeric matby one of either injection molding with the fabric in the mold or by melting adherence. The fabric coveris readily connected to the upper foam layerby the adhesive. The adhesivemay also join the upper foam layerto the tops of the coil springs, preferably including an intervening fabric layer (not shown). Said base, upper foam layer, lower foam layer, plurality of springsand cover foamare configured as shown in.

Foam may be absent from said third topperotherwise comprised of said elastomeric matenclosed in fabric cover. While an elastomeric mathaving a surface area co-extensive with the baseincreases the overall weight of the system, it also maximizes flexibility and thus comfort for a user. This comfort is due to the flexible bending and support qualities of elastomeric materials defined by elastomeric grid wallsthroughout a given topper.

show another embodiment of the composite cushioning systemincluding a fourth embodiment of topperdisposed directly upon said base. Said fourth topperincludes an elastomeric padsubstantially coextensive with said baseand a supplemental foam layer. The supplemental foam layermay be attached to the upper foam layerof the baseby an adhesive. Said supplemental foam layermay optionally have a higher melting point than said elastomeric pad. Said supplemental foam layerand elastomeric padintersect at a melting interfacewhere heat may be applied to facilitate adhesion. In a particularly preferred embodiment, the elastomeric padmay be formed with the supplemental foam layerpositioned in a form mold, such as during a process of injection molding the elastomeric pad. As shown in, the edge borders of the melting interfaceof the elastomeric padand supplemental foam layermay include a quarter-round pieceor similar edge support structure to provide increased support and securing surface to the edge borders of the melting interface. The edges of the elastomeric padmay also curve toward the quarter-round pieceso as to provide a more comfortable transition (as opposed to a corner edge) for a user when in contact with the edge. This edge support structurecan be provided in other shapes as may fit the needs of the user.

illustrate yet another embodiment of the composite cushioning system including a fifth embodiment of topperwith said base, upper foam layer, lower foam layer, plurality of springsand cover foamconfigured as shown in. As shown in, said fifth topperincludes a first foam borderas a perimeter around a first elastomeric layerdisposed over a positioning fabric. The positioning fabricis preferably coextensive with the base, whereas the first elastomeric layerhas a smaller surface area. Said positioning fabricis disposed on top of a second elastomeric layerand a second foam border. Said second elastomeric layerand second foam bordermay optionally be of greater thickness than said first elastomeric layerand first foam border.

The first elastomeric layer, second elastomeric layer, and intervening positioning fabricare preferably formed integrally as with the positioning fabricbeing included in a form mold during a process of forming the elastomeric layers,by injection molding. In this way, the elastomer material from the elastomeric layers,may melt or ooze through the fabric. As shown in, since the positioning fabricis co-extensive with the base, but the elastomeric layers,are not, the portion of the positioning fabricextending beyond is contained between the first foam borderand second foam border. By using adhesiveor similar securing methods, the elastomeric layers,, positioning fabric, and foam borders,may ultimately be formed as a unitary piece, separable only by destructive means. This fifth topperpreferably rests directly on the upper foam layer. Due to their respective textures and friction coefficients, the second foam borderand second elastomeric layeron top of the upper foam layermay tend to remain as positioned, particularly when enclosed in an outer cover. An adhesivemay be used between the upper foam layerand second foam bordersto more securely maintain this positioning.

In any of the foregoing embodiments, the polyurethane foam is preferably flexible and selected according to mattress design features such as super soft foam, normal foam, high resilience foam, high load bearing soft foam, slow spring-back foam sponge (slow spring-back sponge), and polyurethane foam with added gel particles. Polyurethane foam can be processed in shape, and the local material density of polyurethane foam can be changed by cutting or molding according to the functional requirements. The support force and stress-strain curve can also be altered. Wave undulations, pyramid undulations, wedge undulations, etc. can be formed on the surface of polyurethane foam. It is also possible to cut the part in the middle between the top and the bottom to optimize the stress-strain curve of the polyurethane foam.

Foamed latex is formed by foaming the latex of the ingredients into latex foam, and then injected into the mold, gelled, vulcanized, removed from the mold, washed and dried. It can be prepared by using natural latex or synthetic latex as raw material, with high elasticity. It has the characteristics of shock absorption, compression fatigue resistance, good load-bearing capacity, comfort and durable characteristics.

The mattressmay comprise one, two or more of the topper layers,,,, anddescribed above. The topper layers,,,, andcan be made into any size mattress, with the length and width of the topper layers,,,, andbeing the length and width of the mattress. The mattressmay also consist of two topper layers,,,, and, which may be separately constructed with different properties, such as firmness, elasticity, ventilation capacity, etc., according to user needs. The two topper layers,,,, andcan be provided with linking devices on the coverto connect the pad systems to each other.

The mattressmay further comprise a plurality of topper layers,,,, and, and the plurality of the same may be set differently according to the different mechanical response of different areas of the body to the topper layers,,,, and. For example, the weight of the waist-hip can increase the support force, and the weight of the legs can be reduced by the small weight of the support force. The plurality of topper layers,,,, andcan be provided with linking devices on the outer coverto connect the plurality of topper layers,,,, andto each other.