U.S. patent application number 12/893265 was filed with the patent office on 2011-03-31 for foam cushion having reduced cross-section area foam profiles forming hollow portion(s) for deformation.
This patent application is currently assigned to NOMACO INC.. Invention is credited to Bangshu Cao, Edouard Lauer.
Application Number | 20110072587 12/893265 |
Document ID | / |
Family ID | 43778669 |
Filed Date | 2011-03-31 |
United States Patent
Application |
20110072587 |
Kind Code |
A1 |
Cao; Bangshu ; et
al. |
March 31, 2011 |
FOAM CUSHION HAVING REDUCED CROSS-SECTION AREA FOAM PROFILES
FORMING HOLLOW PORTION(S) FOR DEFORMATION
Abstract
Cushions are disclosed herein. In one embodiment, a cushion is
comprised of a plurality of foam profiles each having a top surface
and a bottom surface, and a geometry of reduced cross-section area
from the top surface to the bottom surface in a vertical
projection. The plurality of foam profiles are arranged such that
the top surfaces of the plurality of foam profiles are disposed in
or substantially in a first plane. In this manner, hollow portions
can be formed between adjacent foam profiles. At least one sheet of
material is affixed to at least one of the top surface and the
bottom surface of the plurality of foam profiles. When a
compression force is imposed on the cushion, the hollow portions
allow the foam profiles to adapt to deformation. Further, by
providing the hollow portions, the cushion can more easily be
rolled or wrapped for transport or storage.
Inventors: |
Cao; Bangshu; (Raleigh,
NC) ; Lauer; Edouard; (Zebulon, NC) |
Assignee: |
NOMACO INC.
Zebulon
NC
|
Family ID: |
43778669 |
Appl. No.: |
12/893265 |
Filed: |
September 29, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61246772 |
Sep 29, 2009 |
|
|
|
61293289 |
Jan 8, 2010 |
|
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Current U.S.
Class: |
5/655.9 |
Current CPC
Class: |
A47C 27/144 20130101;
A47C 17/70 20130101; A47C 27/15 20130101; A47C 27/146 20130101 |
Class at
Publication: |
5/655.9 |
International
Class: |
A47C 20/02 20060101
A47C020/02 |
Claims
1. A cushion, comprising: a plurality of foam profiles each having
a top surface and a bottom surface, and a geometry of reduced
cross-section area from the top surface to the bottom surface in a
vertical projection; wherein the plurality of foam profiles are
arranged such that the top surfaces of the plurality of foam
profiles are disposed in or substantially in a first plane, and the
bottom surfaces of the plurality of foam profiles are disposed in
or substantially in a second plane parallel or substantially
parallel to the first plane; and at least one sheet of material
affixed to at least one of the top surface and the bottom surface
of the plurality of foam profiles.
2. The cushion of claim 1, wherein the plurality of foam profiles
are comprised of foamed material comprised from the group
consisting of polypropylene, polypropylene copolymer, polystyrene,
polyethylene, ethylene vinyl acetate (EVA), polyolefin, including
metallocene catalyzed low density polyethylene, thermoplastic
olefin (TPO), thermoplastic polyester, thermoplastic vulcanizates
(TPVs), polyvinyl chlorides (PVCs), chlorinated polyethylene,
styrene block copolymers, ethylene methyl acrylates (EMAs),
ethylene butyl acrylates (EBAs), polyurethane, natural rubber,
synthetic rubber, latex, silicone, ethylene propylene diene Monomer
(M-class) rubber (EPDM), isoprene, chloroprene, neoprene,
melamine-formaldehyde, and polyester.
3. The cushion of claim 1, wherein the plurality of foam profiles
are comprised of foamed material comprised from the group
consisting of cross-linked polyolefin, rubber, or other polymers
which have a glass transition temperature below 25 degrees C., and
non-cross-linked polyolefin, rubber, or other polymers which have a
glass transition temperature below 25 degrees C.
4. The cushion of claim 1, wherein at least one of the plurality of
foam profiles has a different density from at least one other of
the plurality of foam profiles to produce at least two zones of
firmness.
5. The cushion of claim 1, wherein the plurality of foam profiles
have a density in a range of 8 kg/m.sup.3 to 100 kg/m.sup.3.
6. The cushion of claim 1, wherein the plurality of foam profiles
have a foam cell size in a range of 0.01 mm to 10 mm.
7. The cushion of claim 1, wherein the plurality of foam profiles
contain at least one of a flame retardant, a smoke suppressant, an
antimicrobial agent, a fragrance, a color, or an additive.
8. The cushion of claim 1, wherein the plurality of foam profiles
are comprised of open cell foam, close cell foam, or open and close
cell foam.
9. The cushion of claim 1, wherein the plurality of foam profiles
have a close cell content greater than 80%.
10. The cushion of claim 1, wherein the at least one sheet of
material is comprised of either a woven or non-woven sheet of
material.
11. The cushion of claim 1, wherein the at least one sheet of
material is affixed to the plurality of foam profiles using an
affixation means comprised from the group consisting of thermal
welding and ultrasonic welding.
12. The cushion of claim 1, further comprising at least one void
disposed between the top surfaces of adjacent foam profiles among
the plurality of foam profiles.
13. The cushion of claim 1, wherein at least one of the plurality
of foam profiles has a cross-section shape in the form of a circle,
an ellipse, a triangle, a square, a rectangle, a trapezoid, a
polygon having more than four sides, a profile having a concave
surface, and a profile having a convex surface.
14. The cushion of claim 1, wherein at least one of the plurality
of foam profiles has a cross-section shape that includes an
opening.
15. The cushion of claim 1, wherein a ratio of a width of the top
surfaces of the plurality of foam profiles to a width of the bottom
surfaces of the plurality of foam profiles is greater than 1.5.
16. The cushion of claim 1, further comprising at least one end
foam profile disposed on an end of the plurality of foam
profiles.
17. The cushion of claim 16, wherein the at least one end foam
profile is comprised of a first end foam profile disposed on a
first end of the plurality of foam profiles and a second end foam
profile disposed on a second end of the plurality of foam profiles
opposite the first end.
18. The cushion of claim 1, further comprising at least one hollow
section disposed in at least one of the plurality of foam
profiles.
19. The cushion of claim 18, further comprising a filler material
disposed in the at least one hollow section.
20. The cushion of claim 19, wherein the filter material is
comprised from the group consisting of a bicellular material, a
thermoset material, and a thermoplastic material.
21. The cushion of claim 19, further comprising a vacuum disposed
in the at least one hollow section.
22. The cushion of claim 1, wherein the plurality of foam profiles
are at least partially melted down on their top surfaces to form a
pattern such as islands and grooves.
23. The cushion of claim 1, further comprising an open cell foam
layer disposed on the top surface of the plurality of foam
profiles.
24. The cushion of claim 1, further comprising two or more strips
of re-closable fasteners disposed on at least a portion of the at
least one sheet of material.
25. The cushion of claim 1, further comprising at least one cut
disposed between ends of at least one of the plurality of foam
profiles.
26. The cushion of claim 1, wherein at least one of the plurality
of foam profiles provides at least two different zones of
firmness.
27. The cushion of claim 1 providing in an apparatus comprised from
the group consisting of a mattress, a bed, a seat, furniture, a
mat, a beach mat, a camping mat, an athletic mat, padding, and a
protection pad.
28. A method of providing a cushion, comprising: providing a
plurality of foam profiles each having a top surface and a bottom
surface, and a geometry of reduced cross-section area from the top
surface to the bottom surface in a vertical projection; arranging
the plurality of foam profiles such that the top surfaces of the
plurality of foam profiles are disposed in or substantially in a
first plane, and the bottom of the plurality of foam profiles are
disposed in or substantially in a second plane parallel or
substantially parallel to the first plane; and affixing at least
one sheet of material to at least one of the top surface and the
bottom surface of the plurality of foam profiles.
29. The method of claim 28, wherein providing the plurality of foam
profiles comprises providing at least one first foam profile among
the plurality of foam profiles of a first density and at least one
second foam profile among the plurality of foam profiles of a
second density different from the first density.
30. The method of claim 28, wherein affixing the at least one sheet
of material is comprised of welding the at least one sheet of
material to the at least one of the top surface and the bottom
surface of the plurality of foam profiles.
31. The method of claim 28, further comprising at least one void
disposed between the top surfaces of adjacent foam profiles among
the plurality of foam profiles.
32. The method of claim 28, wherein providing the plurality of foam
profiles further comprises providing at least one of the plurality
of foam profiles having a cross-section shape that includes an
opening.
33. The method of claim 28, further comprising disposing at least
one end foam profile on an end of the plurality of foam
profiles.
34. The method of claim 28, further comprising disposing at least
one hollow section in at least one of the plurality of foam
profiles.
35. The method of claim 34, further comprising disposing a filler
material in the at least one hollow section.
36. The method of claim 28, further comprising at least partially
melting the plurality of foam profiles down on their top surfaces
to form a pattern such as islands and grooves.
37. The method of claim 28, further comprising providing two or
more strips of re-closable fasteners disposed on at least a portion
of the at least one sheet of material.
38. The method of claim 28, further comprising disposing at least
one cut between ends of at least one of the plurality of foam
profiles.
39. The method of claim 28, further comprising providing at least
two different zones of firmness in the plurality of foam profiles.
Description
PRIORITY CLAIMS
[0001] The present application claims priority to U.S. Provisional
Patent Application Ser. No. 61/246,772, filed Sep. 29, 2009, titled
"CLOSE CELL FOAM CUSHION," which is incorporated herein by
reference in its entirety.
[0002] The present application also claims priority to U.S.
Provisional Patent Application Ser. No. 61/293,289, filed Jan. 8,
2010, titled "CLOSE CELL FOAM CUSHION," which is incorporated
herein by reference in its entirety.
BACKGROUND
[0003] 1. Field of the Disclosure
[0004] The technology of the disclosure relates to cushioning,
which may be used, for example, in cushioning applications such as
mattresses, seats, foot support, back support, and protection
pads.
[0005] 2. Technical Background
[0006] Cushions and materials providing cushioning are used in
numerous environments and applications, for example, in the home,
hotels, transportation, hospitals, sport facilities, etc. In terms
of cushion material and structure, metal spring and open cell
polyurethane foam planks have been popularly employed. Convoluted
open cell polyurethane foam, latex foam, and inversely convoluted
foam cushion have also been employed in lieu of using metal
springs. In comparison with open cell foam, close cell foam at the
same density can show higher compression modulus. In other words,
one may use much lighter weight close cell foam to reach similar
firmness of open cell foam. This can reduce carbon release of a
cushioning product, providing environmental protection and energy
savings.
[0007] Open channel crossing a foam cushion has been widely used to
improve cushioning performance. Cushion surfaces may have different
indentation patterns for better touch, feel and appearance. In
addition, a cushion can be made from various types of repeating
units, such as half moon shapes and big bubbles as examples.
However, in these examples, the cushion does not easy bend or curl
for transportation or storage. One could provide a cushion pad that
is more easily bent or curled by providing a thin cushion pad in
which a foam pad is indented with spanned folding lines to provide
bend lines for easier bending and curling of the pad. However, it
may be desirable to provide a thicker cushion that can be easily
bent or folded for transportation while still retaining the
cushioning performance provided by the indentation patterns
provided in the cushioning surface.
SUMMARY OF THE DETAILED DESCRIPTION
[0008] Embodiments disclosed in the detailed description include
cushions, which may be used in mattresses, bedding, seats, and mats
as non-limiting examples. Non-limiting features of these cushions
are to effectively support a compression force with much less usage
of material, to adapt to large deformations without bottoming out
as seen for some spring coils, to curl up for easy shipping and
storage, and/or to have light weight and good buoyancy.
[0009] In this regard, in one embodiment, a cushion is comprised of
a plurality of foam profiles. Each of the plurality of foam
profiles has a top surface and a bottom surface, and a geometry of
reduced cross-section area from the top surface to the bottom
surface in a vertical projection. The plurality of foam profiles
are arranged such that the top surfaces of the plurality of foam
profiles are disposed in or substantially in a first plane, and the
bottom surfaces of the plurality of foam profiles are disposed in
or substantially in a second plane parallel or substantially
parallel to the first plane. In this manner, hollow portions can be
formed between adjacent foam profiles. At least one sheet of
material is affixed to at least one of the top surface and the
bottom surface of the plurality of foam profiles. The sheet of
material assists to maintain the integrity of the cushion and to
distribute an imposed force to the plurality of foam profiles. When
a compression force is imposed on the cushion, the hollow portions
allow the plurality of foam profiles to change their shapes to
adapt to the deformation. As the compression force is removed, the
plurality of foam profiles can return to their original shapes.
Further, by providing the hollow portions, the cushion can more
easily be rolled or wrapped for transport or storage.
[0010] In another embodiment, a method of providing a cushion is
provided. The method comprises providing a plurality of foam
profiles each having a top surface and a bottom surface, and a
geometry of reduced cross-section area from the top surface to the
bottom surface in a vertical projection. The method also comprises
arranging the plurality of foam profiles such that the top surfaces
of the plurality of foam profiles are disposed in or substantially
in a first plane, and the bottom of the plurality of foam profiles
are disposed in or substantially in a second plane parallel or
substantially parallel to the first plane. The method also
comprises affixing at least one sheet of material to at least one
of the top surface and the bottom surface of the plurality of foam
profiles.
[0011] Additional features and advantages will be set forth in the
detailed description which follows, and in part will be readily
apparent to those skilled in the art from that description or
recognized by practicing the embodiments as described herein,
including the detailed description that follows, the claims, as
well as the appended drawings.
[0012] For example, wherein the plurality of foam profiles can be
comprised of foamed material comprised from the group consisting of
polypropylene, polypropylene copolymer, polystyrene, polyethylene,
ethylene vinyl acetate (EVA), polyolefin, metallocene catalyzed low
density polyethylene, thermoplastic olefin (TPO), thermoplastic
polyester, thermoplastic vulcanizates (TPVs), polyvinyl chlorides
(PVCs), chlorinated polyethylene, styrene block copolymers,
ethylene methyl acrylates (EMAs), ethylene butyl acrylates (EBAs),
polyurethane, natural rubber, synthetic rubber, latex, silicone,
ethylene propylene diene Monomer (M-class) rubber (EPDM), isoprene,
chloroprene, neoprene, melamine-formaldehyde, and polyester. The
foam can include closed cells, open cells, or a combination of
both. Any density of the foam profiles is possible. Different zones
of firmness can be provided in the cushion. The sheet of material
can be comprised of either a woven or non-woven sheet of material.
The cross-section shape of the plurality of foam profiles can be
provided in a variety of shapes. Edges pieces can be disposed on
ends of the plurality of foam profiles for the cushion. The
plurality of foam profiles can include hollow sections that may or
may not include filler material. The cushion can be used in any
application desired, including but not limited to a mattress, a
bed, a seat, furniture, a mat, a beach mat, a camping mat, an
athletic mat, padding, and a protection pad.
[0013] It is to be understood that both the foregoing general
description and the following detailed description present
embodiments, and are intended to provide an overview or framework
for understanding the nature and character of the disclosure. The
accompanying drawings are included to provide a further
understanding, and are incorporated into and constitute a part of
this specification. The drawings illustrate various embodiments,
and together with the description serve to explain the principles
and operation of the concepts disclosed.
BRIEF DESCRIPTION OF THE FIGURES
[0014] FIG. 1 illustrates a side perspective view of an exemplary
cushion comprised of a plurality of adjacent exemplary foam
profiles having a geometry of reduced cross-section area from top
to bottom in a vertical projection, with sheets affixed to the foam
profiles;
[0015] FIG. 2A illustrates a side view of an exemplary foam profile
in FIG. 1 in an uncompressed state;
[0016] FIG. 2B illustrates a side view of an exemplary foam profile
in FIG. 1 in a compressed state;
[0017] FIGS. 3A-3F illustrate side views of exemplary alternative
foam profiles that can be employed in a cushion, including the
cushion in FIG. 1 as an example, and according to the embodiments
disclosed herein;
[0018] FIGS. 4A-4C illustrate side views of exemplary foam profiles
for building up the edge portion of a cushion, including the
cushion in FIG. 1 as an example, and according to the embodiments
disclosed herein;
[0019] FIG. 5 illustrates a side view of the cushion of FIG. 1
partially rolled up;
[0020] FIGS. 6A-6C illustrate exemplary filler material disposed in
a hollow portion of the foam profile in the cushion of FIG. 1;
[0021] FIGS. 6D-6F illustrate side views of exemplary filler
material disposed in a hollow portion of an alternative foam
profile that may be provided in a cushion, including the cushion of
FIG. 1 as an example;
[0022] FIG. 7 illustrates a top view of a cushion comprised of a
plurality of adjacent exemplary foam profiles having a geometry of
reduced cross-section area from top to bottom in a vertical
projection, with sheets affixed to the foam profiles, which also
employs end foam profiles on ends to provide intensified firmness
at edge portions of the cushion;
[0023] FIG. 8 illustrates a side perspective view of a cushion
comprised of a plurality of adjacent exemplary foam profiles having
a geometry of reduced cross-section area from top to bottom in a
vertical projection, with sheets affixed to the foam profiles,
wherein the foam profiles are melted down on a top surface before a
sheet is applied thereto to create pattern of islands and grooves
in the cushion;
[0024] FIG. 9 illustrates a side perspective view of a cushion
comprised of a plurality of adjacent exemplary foam profiles having
a geometry of reduced cross-section area from top to bottom in a
vertical projection, and further comprising an open cell layer
disposed on top of the foam profiles with strips of re-closable
fastener disposed on the bottom of the foam profiles;
[0025] FIG. 10 illustrates a side perspective view of a cushion
comprised of a plurality of adjacent exemplary foam profiles
comprised of multiple pieces of long and specially shaped close
cell foam profiles having a geometry of reduced cross-section area
from top to bottom in a vertical projection;
[0026] FIG. 11 illustrates a side view of the foam profile provided
in the cushion of FIG. 10; and
[0027] FIGS. 12A and 12B illustrate perspective and side views,
respectively, of the foam profile provided in the cushion of FIG.
10 with optional cuts disposed in the foam profile.
DETAILED DESCRIPTION
[0028] The embodiments set forth below represent the necessary
information to enable those skilled in the art to practice the
embodiments and illustrate the best mode of practicing the
embodiments. Upon reading the following description in light of the
accompanying drawing figures, those skilled in the art will
understand the concepts of the embodiments and will recognize
applications of these concepts not particularly addressed herein.
It should be understood that these concepts and applications fall
within the scope of the disclosure and the accompanying claims.
[0029] Embodiments disclosed in the detailed description include
cushions, which may be used in mattresses, bedding, seats, and mats
as non-limiting examples. Non-limiting features of these cushions
are to effectively support a compression force with much less usage
of material, to adapt to large deformations without bottoming out
as seen for some spring coils, to curl up for easy shipping and
storage, and/or to have light weight and good buoyancy.
[0030] In this regard, in one embodiment, a cushion is comprised of
a plurality of foam profiles. Each of the plurality of foam
profiles has a top surface and a bottom surface, and a geometry of
reduced cross-section area from the top surface to the bottom
surface in a vertical projection. The plurality of foam profiles
are arranged such that the top surfaces of the plurality of foam
profiles are disposed in or substantially in a first plane, and the
bottom surfaces of the plurality of foam profiles are disposed in
or substantially in a second plane parallel or substantially
parallel to the first plane. In this manner, hollow portions can be
formed between adjacent foam profiles. At least one sheet of
material is affixed to at least one of the top surface and the
bottom surface of the plurality of foam profiles. The sheet of
material assists to maintain the integrity of the cushion and to
distribute an imposed force to the plurality of foam profiles. When
a compression force is imposed on the cushion, the hollow portions
allow the plurality of foam profiles to change their shapes to
adapt to the deformation. As the compression force is removed, the
plurality of foam profiles can return to their original shapes.
Further, by providing the hollow portions, the cushion can more
easily be rolled or wrapped for transport or storage.
[0031] FIG. 1 illustrates a side perspective view of an exemplary
cushion 11 comprised of a plurality of adjacent exemplary foam
profiles 12 having a geometry of reduced cross-section area from
top to bottom in a vertical projection, with sheets 13 affixed to
the plurality of foam profiles 12. As examples only, the cushion 11
may be used in any application desired, including but not limited
to a mattress, a bed, a seat, furniture, a mat, a beach mat, a
camping mat, an athletic mat, padding, and a protection pad. In
this example, the plurality of foam profiles 12 includes multiple
pieces of hollow, long, and specially shaped close cell foam.
However, the plurality of foam profiles 12 could also be open cell,
or a combination of both open and close cells.
[0032] In this embodiment, the plurality of foam profiles 12 each
have a top surface 14 and a bottom surface or edge 15, and a
geometry of reduced cross-section area from the top surface 14 to
the bottom surface 15 in a vertical projection. In this example,
the cross-section outskirt of plurality of foam profiles 12 is a
triangle, which may be an isosceles triangle, but other geometries
are possible that provide this reduced cross-section area feature.
Non-limiting examples include circles, ellipses, other triangles,
rectangles, trapezoids, and other polygons that have more than four
(4) sides. In this example, each of the plurality of foam profiles
12 also contains a hollow portion 17 to allow for deformation when
a force is imparted thereon, as described below in more detail.
[0033] In this embodiment, the plurality of foam profiles 12 are
disposed between two sheets 13. The sheets 13 can serve to maintain
the integrity of the cushion 11 when a force is imparted on the
cushion 11. The sheets 13 are comprised of a material or materials.
The plurality of foam profiles 12 are arranged such that the top
surfaces 14 are disposed in or substantially in a first plane
P.sub.1, and the bottom surfaces 15 are disposed in or
substantially in a second plane P.sub.2 parallel or substantially
parallel to the first plane P.sub.1. The sheets 13 are affixed to
the plurality of foam profiles 12 from its top surface 14 and
bottom surface 15. In this manner, as discussed in more detail
below, voids V are created between adjacent foam profiles 12 at the
top surfaces 15 of the plurality of foam profiles 12 due to the
reduced cross-section area disposed in the plurality of foam
profiles 12 to allow for easy bending and rolling of the cushion
11.
[0034] The sheets 13 may be made from any material desired, and may
be woven or non-woven. The sheets 13 may be affixed to the
plurality of foam profiles 12 using an affixation means comprised
from the group consisting of thermal welding and ultrasonic
welding. Multiple levels, such as three (3) or more layers of
sheets enclosing two (2) or more layers of foam profiles 12, may be
provided. The sheets 13 could be pieced together instead of
providing the sheets 13 as one single piece of material. The sheets
13 could be made of materials that are flexible or materials that
do not stretch.
[0035] An edge piece 16 is a long rectangular piece of foam used to
build an edge portion of cushion 11, and it is also bonded to
non-woven sheets 13. There is a much larger bonding area between
the plurality of foam profiles 12 and the non-woven sheet 13 on a
top surface of the cushion 11 than that on a bottom surface of the
cushion 11. Because of strong bonding of the plurality of foam
profiles 12 as well as the edge pieces 16 with the non-woven sheets
13, the cushion 11 has good integrity.
[0036] As examples, the plurality of foam profiles 12 can be
comprised of foamed material comprised from the group consisting of
polypropylene, polypropylene copolymer, polystyrene, polyethylene,
ethylene vinyl acetate (EVA), polyolefin, metallocene catalyzed low
density polyethylene, thermoplastic olefin (TPO), thermoplastic
polyester, thermoplastic vulcanizates (TPVs), polyvinyl chlorides
(PVCs), chlorinated polyethylene, styrene block copolymers,
ethylene methyl acrylates (EMAs), ethylene butyl acrylates (EBAs),
polyurethane, natural rubber, synthetic rubber, latex, silicone,
ethylene propylene diene Monomer (M-class) rubber (EPDM), isoprene,
chloroprene, neoprene, melamine-formaldehyde, and polyester. The
plurality of foam profiles 12 can include closed cells, open cells,
or a combination of both. Any density of the plurality of foam
profiles 12 is possible. The plurality of foam profiles 12 could be
separated along the extrusion direction like blocks to provide
independent movement in the extrusion direction.
[0037] The plurality of foam profiles 12 can be made of various
foam materials such as cross-linked or non-cross-linked polyolefin,
rubber, or other polymers which have a glass transition temperature
below room temperature around 25 degrees C., as examples. The
plurality of foam profiles 12 may have a density, for example, in a
range of 8 kg/m.sup.3 to 100 kg/m.sup.3, preferably 16 kg/m.sup.3
to 48 kg/m.sup.3. The plurality of foam profiles 12 may have a cell
size in a range of 0.01 mm to 10 mm, preferably 0.3 mm to 3 mm, as
examples. The plurality of foam profiles 12 may have a close cell
content of more than 80% as an example. The plurality of foam
profiles 12 may also contain various additives such as a flame
retardant, a smoke suppressant, an antimicrobial agent, a
fragrance, a color, etc., as examples.
[0038] Also, because the sheet 13 is attached to the bottom surface
15 of the plurality of foam profiles 12, when a compression force
is imposed on the cushion 11, the plurality of foam profiles 12 are
deformed while the integrity of the cushion 11 is maintained. The
sheet 13 also plays a role in keeping each individual foam profile
12 maintained into a proper position in the cushion 11. In this
regard, FIG. 2A illustrates a side view of a foam profile 12 in
FIG. 1 in an uncompressed state. FIG. 2B illustrates a side view of
a foam profile 12 in FIG. 1 in a compressed state. More
particularly, FIGS. 2A and 2B show schematically a change in
cross-section of the plurality of foam profiles 12 before and after
compression (e.g., 50% compression). Because the hollow portion 17
is disposed in the foam profile 12, the foam profile 12 is also
capable of adapting to large deformation. Once a compression force
is removed, the foam profile 12 can return to its original
shape.
[0039] There could be many alternative shapes for the plurality of
foam profiles 12. In this regard, FIGS. 3A-3F illustrate side views
of exemplary alternative foam profiles 12 that can be employed in a
cushion, including the cushion 11 in FIG. 1 as an example. As shown
in FIGS. 3A and 3B, hollow foam profiles 10 and 18 can have concave
and convex side surfaces. A hollow foam profile 19 can have an
outskirt of isosceles trapezoid and inner elliptical channel as
shown in FIG. 3C. A hollow foam profile 20 can represent an
isosceles trapezoid with arc bottom as shown in FIG. 3D. The
cross-section of a hollow foam profile 22 can have grooves on its
top surface, as shown in FIG. 3E, to have better air convection on
the profile surface. In order to speed up air flow in and out of a
hollow foam profile, holes 21 can be drilled through the hollow
foam profile wall, as shown in FIG. 3F.
[0040] FIGS. 4A-4C illustrate side views of exemplary foam profiles
for building up the edge portion of a cushion, including the
cushion 11 in FIG. 1 as an example. The cushion 11 can have the
rectangular edge piece 16, as shown in FIGS. 1 and 4A as an
example. As alternatives, a solid right angle trapezoid foam
profile 23 and a hollow right angle trapezoid foam profile 24 can
be used as shown in FIGS. 4B and 4C, as another example.
[0041] FIG. 5 illustrates a side view of the cushion 11 of FIG. 1
partially rolled up. Since the sheet 13 is soft and flexible, the
cushion 11 can be bent as shown in FIG. 5. Also, the plurality of
foam profiles 12 in this example are arranged in parallel and
distanced from each other with a space or void V between them,
which allows easy bending and curling of the cushion 11 as well.
When the cushion 11 is bent or curled, the voids V formed in the
cushion 11 between adjacent foam profiles 12 provide for the
ability for the cushion 11 to be easily bent or curled. The voids V
between the foam profiles 12 in the cushion 11 are reduced and
eventually closed if the adjacent foam profiles 12 are brought
together during bending or curling of the cushion 11. The greater
the void V between adjacent foam profiles 12, the more the cushion
11 can be rolled with less radius.
[0042] It may also be desired to have greater firmness for the edge
portion of the cushion 11 than the middle portion of the cushion
11. For example, in a mattress application, this may assist in
preventing a person from falling off the mattress. Firmness in the
edge portion can be intensified by inserting a short piece of solid
foam into the end of a corresponding hollow foam profile. In this
regard, FIG. 6A illustrates the foam profile 12 with the hollow
portion 17 disposed therein. FIGS. 6B and 6C illustrate exemplary
filler material 25 disposed in the hollow portion 17 of the foam
profile 12 in the cushion 11 of FIG. 1. FIGS. 6D-6F illustrate side
views of exemplary filler material 27 disposed in a hollow portion
40 of the hollow foam profile 19 that may be provided in a cushion,
including the cushion 11 of FIG. 1 as an example. For example, as
illustrated in FIGS. 6A-6C, the filter material 25 may be a
triangle-shaped foam insert that can be put in the end of the
hollow portion 17 of the foam profile 12 to form a combined profile
26. As another example, as illustrated in FIGS. 6D-6F, the filler
material 27 in the form of an elliptical-shaped foam insert can be
put in the end of the hollow foam profile 19 to form a combined
profile 28.
[0043] FIG. 7 illustrates a top view of the cushion 11 of FIG. 1
which employs solid right angle trapezoid foam profiles 23 on ends
of the cushion 11 to provide intensified firmness at edge portions
of the cushion 11. FIG. 8 illustrates a side perspective view of
the cushion 11 of FIG. 1 comprised of the plurality of adjacent
exemplary foam profiles 12 melting down on the top surface 14 in a
desired pattern, such as having islands 29 and grooves 30. The
resulting cushion 11 may have a more rugged feel and
appearance.
[0044] FIG. 9 illustrates a side perspective view of the cushion 11
of FIG. 1, modified by adding an open cell foam layer 31 on the top
of the cushion 11. On the bottom surface of the cushion 11, strips
of re-closable plastic fasteners can be used along the edge of the
cushion 11 to lock the position of the bottom non-woven sheet 13 to
a supporting surface, specifically using a pair of fasteners 32,
which may be re-closeable, in a lateral direction and a pair of
fasteners 33 in a longitudinal direction, as shown in FIG. 9.
Matching parts of the pairs of fasteners 32, 33 on the supporting
surface underneath the cushion 11 are not shown in FIG. 9.
[0045] FIG. 10 illustrates a side perspective view of a cushion 34
composed of multiple pieces of long and specially shaped close cell
foam profiles 35 between two non-woven sheets 13. Each of the foam
profiles 35 has geometry of reduced cross-section area from top to
bottom in terms of its vertical projection, as shown in FIG. 11. In
this embodiment, the foam profile 35 contains an opening 41. The
non-woven sheets 13 are affixed to the foam profile 35 to cover the
top and bottom of the foam profiles 35. All of the pieces of the
foam profiles 35 are in parallel and distanced from each other with
a small space. Because of the strong bonding of the foam profiles
35 with the non-woven sheets 13, the cushion 34 has good integrity.
Since the non-woven sheets 13 are soft and flexible, the cushion 34
can be bent. When a compression force is imposed on the cushion 34,
the foam profile 35 changes its shape to adapt to a large
deformation. The non-woven sheets 13 play a role of keeping each
individual foam profile 35 locked in a proper position in the
cushion 34. Once a compression force is removed, the foam profiles
35 return to their original shapes.
[0046] FIGS. 12A and 12B illustrate perspective and side views,
respectively, of a foam profile 35 employed in the cushion 34 of
FIG. 10 with optional cuts 42 disposed therein. Providing the
optional cuts 42 may serve to provide a desired cushioning effect
and may also reduce the weight of the cushion 34. With the optional
multiple cuts 42 cut from the bottom to trim out a portion of the
foam profile 35, the foam profile 35 becomes foam profile 36, as
shown in FIGS. 12A and 12B.
[0047] Many modifications and other embodiments of the embodiments
set forth herein will come to mind to one skilled in the art to
which the embodiments pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the description
and claims are not to be limited to the specific embodiments
disclosed and that modifications and other embodiments are intended
to be included within the scope of the appended claims. It is
intended that the embodiments cover the modifications and
variations of the embodiments provided they come within the scope
of the appended claims and their equivalents. Although specific
terms are employed herein, they are used in a generic and
descriptive sense only and not for purposes of limitation.
* * * * *