U.S. patent application number 13/630435 was filed with the patent office on 2013-04-04 for cellular mattress assemblies and related methods.
This patent application is currently assigned to NOMACO INC.. The applicant listed for this patent is Nomaco Inc.. Invention is credited to Michael Allman, Matthias Breidsprecher, Bangshu Cao, Edouard Lauer, Ivan Sobran, Julian Thomas Young.
Application Number | 20130081209 13/630435 |
Document ID | / |
Family ID | 47991254 |
Filed Date | 2013-04-04 |
United States Patent
Application |
20130081209 |
Kind Code |
A1 |
Young; Julian Thomas ; et
al. |
April 4, 2013 |
CELLULAR MATTRESS ASSEMBLIES AND RELATED METHODS
Abstract
Embodiments disclosed herein include cellular mattress
assemblies and related methods. The cellular mattresses assemblies
may comprise thermoplastic material and/or thermoset material to
achieve appropriate comfort and support characteristics. The
cellular mattress assemblies may also comprise one or more
components including a cellular thermoplastic foam profile to
achieve appropriate comfort and support characteristics. The
cellular mattress may include a support layer, a comfort layer, and
a transition layer between the support layer and the comfort
layer.
Inventors: |
Young; Julian Thomas;
(Zebulon, NC) ; Allman; Michael; (Wilson, NC)
; Breidsprecher; Matthias; (Raleigh, NC) ; Cao;
Bangshu; (Raleigh, NC) ; Lauer; Edouard;
(Zebulon, NC) ; Sobran; Ivan; (Raleigh,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nomaco Inc.; |
Zebulon |
NC |
US |
|
|
Assignee: |
NOMACO INC.
Zebulon
NC
|
Family ID: |
47991254 |
Appl. No.: |
13/630435 |
Filed: |
September 28, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61541434 |
Sep 30, 2011 |
|
|
|
Current U.S.
Class: |
5/739 ;
5/740 |
Current CPC
Class: |
A47C 27/15 20130101;
A47C 27/065 20130101; A47C 27/063 20130101 |
Class at
Publication: |
5/739 ;
5/740 |
International
Class: |
A47C 27/15 20060101
A47C027/15 |
Claims
1. A mattress assembly for bedding or seating placed under a load,
comprising: at least one comfort layer providing cushioning
characteristics; at least one support layer providing support
characteristics; and at least one transition layer including at
least one mattress member disposed between the at least one comfort
layer and the at least one support layer, the at least one mattress
member comprising a unitary composite cushioning structure, the
unitary composite cushioning structure comprising: at least one
cellular thermoplastic material providing support characteristics
and cushioning characteristics, at least one cellular thermoset
material providing a resilient structure with cushioning
characteristics, and a stratum disposed between at least a portion
of the cellular thermoplastic material and at least a portion of
the cellular thermoset material to secure the at least a portion of
the cellular thermoset material to the at least a portion of the
cellular thermoplastic material to form the unitary composite
cushioning structure exhibiting a combination of the support
characteristics and the cushioning characteristics and the
resilient structure with cushioning characteristics when the
unitary composite cushioning structure is placed under the
load.
2. The mattress assembly of claim 1, further comprising at least
one second comfort layer disposed between the at least one mattress
member and the at least one support layer, and the second comfort
layer comprises the cellular thermoset material.
3. The mattress assembly of claim 1, wherein the stratum is
configured to be formed by disposing a non-solid phase of the
cellular thermoset material on a cellular thermoplastic foam
profile, and the cellular thermoset material undergoes a transition
into a solid phase to form a bond with the cellular thermoplastic
material.
4. The mattress assembly of claim 1, wherein the at least one
mattress member includes a first layer and a second layer, the
first layer configured to provide support, and the second layer
configured to provide cushioning and support.
5. The mattress assembly of claim 4, wherein the second layer
comprises at least two extensions extending orthogonally from a
longitudinal plane of a cellular thermoplastic foam profile.
6. The mattress assembly of claim 5, wherein the second layer is
produced integrally with the first layer.
7. The mattress assembly of claim 5, wherein the second layer
includes an open chamber at least partially formed by the at least
two extensions, and the open chamber is configured to receive the
cellular thermoset material.
8. The mattress assembly of claim 7, wherein each of the at least
two extensions are in a shape of a hollow cylinder including a
center axis parallel to the longitudinal plane of the cellular
thermoplastic foam profile, and each of the at least two extensions
are attached to the first layer at a portion of the extension along
an outer tangential surface of the shape of the hollow
cylinder.
9. The mattress assembly of claim 8, wherein the first layer
includes a plurality of orifices parallel to the longitudinal plane
of the cellular thermoplastic foam profile.
10. The mattress assembly of claim 9, wherein the first layer
further comprises at least one support member, wherein at least one
of the at least one support member is disposed between any two of
the plurality of orifices of the first layer.
11. The mattress assembly of claim 10, wherein each of the at least
one support member includes at least one support surface parallel
to the load.
12. The mattress assembly of claim 11, wherein the first layer of
each of the at least one mattress member transfers the load to the
second layer of each of the at least one mattress member.
13. The mattress assembly of claim 11, wherein the second layer of
each of the at least one mattress member transfers the load to the
first layer of each of the at least one mattress member.
14. The mattress assembly of claim 11, wherein the at least one
mattress member includes at least one cross-cut at least partially
through the second layer, the at least one cross-cut is disposed
orthogonal to the longitudinal axis of the at least one mattress
member, and the at least one cross-cut is configured to improve
motion transfer.
15. The mattress assembly of claim 1, wherein the at least one
comfort layer is at least one-inch thick and at most thirteen
inches thick; the at least one support layer is at least one-inch
thick and at most thirteen inches thick; the at least one mattress
member is at least one-inch thick and at most thirteen inches
thick; and the first layer of the at least one mattress member is
at least a half-inch thick and at most ten inches thick.
16. The mattress assembly of claim 1, further comprising at least
one side support member disposed along a perimeter of the mattress
assembly, and the at least one side support member is configured to
provide a firmer outer edge of the mattress.
17. The mattress assembly of claim 16, wherein the at least one
side support member comprises at least one cellular thermoplastic
side support member including at least one side support orifice
parallel to a longitudinal axis of the at least one cellular
thermoplastic side support member.
18. The mattress assembly of claim 17, wherein a portion of the at
least one cellular thermoplastic side support member is configured
to twist under a moment created by the load.
19. The mattress assembly of claim 18, wherein each of the at least
one elongated side support member further comprises at least one
groove disposed along the longitudinal axis of each of the at least
one elongated side support member, the at least one groove
including an opening in a side surface in each of the at least one
elongated side support member.
20. The mattress assembly of claim 19, wherein the opening of the
at least one groove is at least partially directed orthogonal to
the load, and the at least one groove extends into each of the
elongated side support members a distance from the side surface and
extends beyond the at least one side support orifice.
21. The mattress assembly of claim 20 wherein the portion of the at
least one elongated side support member is disposed between the at
least one groove and the at least one side support orifice.
22. The mattress assembly of claim 21, further comprising at least
one base layer including cellular thermoplastic material; the at
least one support layer and the at least one mattress member are
disposed between the at least one comfort layer and the at least
one base layer; and the at least one side support member
collectively surrounds the at least one support layer and the at
least one mattress member.
23. The mattress assembly of claim 22, wherein the at least one
side support member is disposed between the at least one base layer
and the at least one comfort layer.
24. The mattress assembly of claim 23, wherein the at least one
side support member further comprises at least one cellular
thermoset side support member.
25. The mattress assembly of claim 24, wherein the at least one
cellular thermoset side support member is disposed between the at
least one cellular thermoplastic side support member and the at
least one comfort layer.
26. The mattress assembly of claim 17, wherein the at least one
side support member comprises open-cell thermoplastic material.
27. The mattress assembly of claim 26, wherein the at least one
side support member further comprises at least one closed-cell
thermoplastic side support portion, and the at least one open-cell
thermoplastic support portion is disposed between the at least one
comfort layer and the at least one closed-cell thermoplastic side
support portion.
28. The mattress assembly of claim 10, wherein the at least one
side support member comprises at least one cellular thermoplastic
side support member including at least one side support orifice
disposed parallel to a longitudinal axis of the at least one
cellular thermoplastic side support member, and each of the at
least one side support orifices including at least one orifice
opening on at least one distal end of the at least one cellular
thermoplastic side support member.
29. The mattress assembly of claim 28, wherein the at least one
orifice opening includes an oblong-shaped cross-section elongated
in a direction orthogonal to the load, and the oblong-shaped
cross-section is orthogonal to the longitudinal axis of the at
least one cellular thermoplastic side support.
30. The mattress assembly of claim 28, wherein the at least one
cellular thermoplastic side support member includes at least one
groove parallel to the longitudinal axis of the at least one
cellular thermoplastic side support member; each of the at least
one groove includes an opening along a length of the at least one
cellular thermoplastic side support member, and the opening of each
of the at least one groove at least partially directed orthogonal
to the load.
31. The mattress assembly of claim 30, wherein the at least one
groove includes a first groove and a second groove, the first
groove on an opposite side of the at least one cellular
thermoplastic side support member from a second groove, and each of
the at least one groove includes an opening.
32. The mattress assembly of claim 31, wherein a portion of the
first groove and a portion of the second groove extend between the
at least two side support orifices.
33. The mattress assembly of claim 32, wherein a portion of the at
least one cellular thermoplastic side support member between the
first groove and the at least two side support orifices is
configured to twist under a moment created by the load.
34. The mattress assembly of claim 33, wherein a portion of the at
least one cellular thermoplastic side support member between the
second groove and the at least two side support orifices is
configured to twist under a second moment created by the load.
35. The mattress assembly of claim 34, wherein within a
cross-section orthogonal to the longitudinal axis of the at least
one cellular thermoplastic side support member, a width of the
opening of each of the at least one groove is smaller than a
maximum width of each of the at least one groove.
36. The mattress assembly of claim 35, wherein within the
cross-section orthogonal to the longitudinal axis of the at least
one cellular thermoplastic side support member, a shape of each of
the at least one groove tapers to the portion of each of the at
least one groove extending between the at least two side support
orifices.
37. A mattress assembly for bedding or seating, comprising: a
support layer comprising a cellular thermoplastic material; a
cushioning layer comprising a cellular thermoset material; a
transition layer comprising a cellular thermoplastic material
disposed between the support layer and the cushioning layer, the
transition layer comprising at least two elongated members disposed
within a geometric plane and separated by a gap or abutting each
other; each of the at least two elongated members include a first
end and a second end opposite the first end along a longitudinal
axis, and each of the at least two elongated members include at
least one orifice parallel to the longitudinal axis.
38. The mattress assembly of claim 37, wherein each of the at least
two elongated members comprises at least two orifices parallel to a
longitudinal axis of each of the at least two elongated members,
each of the at least two orifices including two orifice openings on
opposite ends of each of the at least two elongated members, the
two orifice openings including an oblong-shaped cross-section
elongated in a direction orthogonal to the load, the oblong-shaped
cross-section is orthogonal to the longitudinal axis of each of the
at least two elongated members.
39. The mattress assembly of claim 38, wherein each of the at least
two elongated members include at least one groove parallel to the
longitudinal axis of each of the at least two elongated members,
each of the at least one groove including an opening along a length
of each of the at least two elongated members, and the opening of
each of the at least one groove at least partially facing a
direction orthogonal to the load.
40. The mattress assembly of claim 39, wherein the at least one
groove include a first groove on an opposite side of each of the at
least two elongated members from a second groove, and each of the
at least one groove include an opening.
41. The mattress assembly of claim 40, wherein a portion of the
first groove and the second groove extend between the at least two
orifices, a portion of at least one of the at least two elongated
members between the first groove and the at least two orifices is
configured to twist under a moment created by the load, and a
portion of at least one of the at least two elongated members
between the second groove and the at least two orifices is
configured to twist under a second moment created by the load.
42. The mattress assembly of claim 41, wherein within a
cross-section orthogonal to the longitudinal axis of each of the at
least two elongated members, a width of the opening of each of the
at least one groove is less than a maximum width of each of the at
least one groove.
43. The mattress assembly of claim 42, wherein within a
cross-section orthogonal to the longitudinal axis of each of the at
least two elongated members, a shape of each of the at least one
groove tapers to the portion of each of the at least one groove
extending between the at least two orifices.
44. A mattress assembly for sleeping or resting, comprising at
least five percent and at most ninety-five percent cellular
thermoplastic material by weight, and the mattress assembly
comprises at least five percent and at most ninety-five percent
cellular thermoset material by weight.
45. The mattress assembly of claim 44, wherein the cellular
thermoplastic material forms at least one support layer and a
portion of a transition layer, the cellular thermoset material
forms at least one cushioning layer and a second portion of the
transition layer, and the transition layer is disposed between one
of the at least one support layer and one of the at least one
cushioning layer.
46. The mattress assembly of claim 44, wherein the mattress
assembly is fully comprised of the cellular thermoset material and
the cellular thermoplastic material.
47. A mattress assembly for sleeping or resting, comprising at
least five percent and at most ninety-five percent cellular
thermoplastic material by volume, and the mattress assembly
comprises at least five percent and at most ninety-five percent
cellular thermoset material by volume.
48. The mattress assembly of claim 47, wherein the cellular
thermoplastic material forms at least one support layer and a
portion of a transition layer, the cellular thermoset material
forms at least one cushioning layer and a second portion of the
transition layer, and the transition layer is disposed between one
of the at least one support layer and one of the at least one
cushioning layer.
49. A foam mattress assembly for sleeping or resting, comprising:
at least two geometrically-designed thermoplastic foam members
disposed within a geometric plane and separated by a gap or
abutting each other, and the at least two geometrically-designed
thermoplastic foam members include progressive support
characteristics configured to conform and deflect under a load, the
at least two geometrically-designed thermoplastic foam members
configured to distribute the load partially in a horizontal
direction to resist full compression while maintaining comfortable
resistance to said load; wherein a firmness characteristic of the
foam mattress assembly is configured to be provided by geometric
characteristics of the at least two geometrically-designed
thermoplastic foam members and the density of the at least two
geometrically-designed thermoplastic foam members.
50. The foam mattress assembly of claim 49, wherein the geometric
characteristics comprise orifices.
51. The foam mattress assembly of claim 50, wherein the geometric
characteristics comprise grooves including openings.
52. The foam mattress assembly of claim 51, wherein the geometric
characteristics comprise polymers or copolymers.
53. A foam mattress assembly for bedding or seating, comprising: at
least one cellular foam comfort layer providing cushioning
characteristics; at least one cellular foam support layer providing
support characteristics; at least one transition cellular foam
mattress member disposed between the at least one comfort layer and
the at least one support layer and providing a stress-strain
profile exhibiting cushioning and support characteristics; and at
least one side support member surrounding the at least one mattress
member.
54. The mattress assembly of claim 53, wherein the at least one
side support member comprises at least one cellular thermoplastic
side support member including at least one side support orifice
parallel to a longitudinal axis of the at least one cellular
thermoplastic side support member.
55. The mattress assembly of claim 54, wherein a portion of the at
least one cellular thermoplastic side support member is configured
to twist under a moment created by the load.
56. The mattress assembly of claim 55, wherein each of the at least
one elongated side support member further comprises at least one
groove disposed along the longitudinal axis, and the at least one
groove including an opening in a side surface of the at least one
elongated side support member.
57. The mattress assembly of claim 56, wherein the opening of the
at least one groove is at least partially directed orthogonal to
the load, and the at least one groove extends into each of the
elongated side support member a distance from the side surface and
extends beyond the at least one side support orifice.
58. The mattress assembly of claim 57, wherein the portion of the
at least one elongated side support member is disposed between the
at least one groove and the at least one side support orifice.
Description
PRIORITY APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 61/541,434 filed on Sep. 30, 2011, entitled
"Cellular Mattress Assemblies and Related Methods," which is hereby
incorporated by reference in its entirety.
RELATED APPLICATIONS
[0002] This application is related to U.S. patent application Ser.
No. 13/458,239, filed on Apr. 27, 2012, entitled "Unitary
Composite/Hybrid Cushioning Structure(s) And Profile(s) Comprised
Of A Thermoplastic Foam(s) And A Thermoset Material(s) and Related
Methods," which claims priority to U.S. Provisional Patent
Application Ser. No. 61/480,780, filed on Apr. 29, 2011, entitled
"Unitary Composite/Hybrid Cushioning Structure(s) And Profile(s)
Comprised Of A Thermoplastic Foam(s) And A Thermoset Material(s)
and Related Methods," both of which are hereby incorporated herein
by reference in their entireties.
[0003] This application is also related to U.S. patent application
Ser. No. 12/716,804, filed on Mar. 3, 2010, entitled "Unitary
Composite/Hybrid Cushioning Structure(s) and Profile(s) Comprised
of A Thermoplastic Foam(s) and A Thermoset Material(s)," which
claims priority to U.S. Provisional Patent Application No.
61/157,970, filed on Mar. 6, 2009, entitled "Composite/Hybrid
Structures and Formulations of Thermoset Elastomer Foams and
Thermoplastic Engineered Geometry Foam Profiles," both of which are
hereby incorporated herein by reference in their entireties.
[0004] This application is related to U.S. Design patent
application Ser. No. 29/403,050, filed on Sep. 30, 2011, entitled
"Edge Support Cushion," which is hereby incorporated herein by
reference in its entirety.
BACKGROUND
[0005] 1. Field of the Disclosure
[0006] The technology of this disclosure relates generally to
cushioning structures. The cushioning structures can be used for
any cushion applications desired, including but not limited to
mattresses, seats, foot and back support, and upholstery, as
non-limiting examples.
[0007] 2. Technical Background
[0008] Cushioning structures are employed in support applications.
Cushioning structures can be employed in bedding and seating
applications, as examples, to provide cushioning and support.
Cushioning structures may also be employed in devices for safety
applications, such as helmets and automobiles for example.
[0009] The design of a cushioning structure may be required to have
both high and low stiffness. For example, it may be desirable to
provide a cushioning material or device in which a body or object
will easily sink into the cushion a given distance before the
applied weight is supported. As another example, it may be desired
to provide surfaces having low stiffness initially during
application of weight, while the underlying structure needs to have
high stiffness for support. These surfaces may be provided in
safety applications, such as helmets and automobile dashboards as
examples. In this regard, a cushioning structure may be designed
that provides an initial large deflection at a low applied force
with nonlinearly increasing stiffness at increasing deflection.
[0010] To provide a cushioning structure with high and low
stiffness features, cushioning structures can be composed of layers
of varying thicknesses and properties. Each of these components has
different physical properties, and as a result of these properties
and variations in thicknesses and location of the components, the
cushioning structure has a certain complex response to applied
pressure. For example, cushioning structures generally include
components made from various types of foam, cloth, fibers and/or
steel to provide a general response to pressure that is perceived
as comfortable to the individual seeking a place to lie, sit, or
rest either the body as a whole or portions thereof. General foam
plastic materials can also be used as materials of choice for
cushion applications. Foam plastic materials provide a level of
cushionability in and of themselves, unlike a steel spring
structure, or the like. Generally accepted foams fall within two
categories: thermosets and thermoplastics.
[0011] Thermoset materials exhibit the ability to recover after
repeated deformations and provide a generally accepted sleep and/or
cushioning surface. Thermoplastic materials including thermoplastic
foams, and specifically closed cell thermoplastic foams, on the
other hand, while not having the long-term repeatable deformation
capabilities of the thermoset foams, typically provide greater
firmness and support. Further, thermoplastic materials are suitable
to lower density, less weight, and therefore less costly production
while maintaining a more structurally stable aspect to their
construction.
[0012] One example of a cushioning structure employing layers of
varying thicknesses and properties for discussion purposes is
provided in a mattress 10 of FIG. 1. As illustrated therein, a
mattress innerspring 12 (also called "innerspring 12") is provided.
The innerspring 12 is comprised of a plurality of traditional coils
14 arranged in an interconnected matrix to form a flexible core
structure and support surfaces of the mattress 10. The coils 14 are
also connected to each other through interconnection helical wires
16. Upper and lower border wires 18, 20 are attached to upper and
lower end turns of the coils 14 at the perimeter of the array to
create a frame for the innerspring 12. The upper and lower border
wires 18, 20 also create firmness for edge support on the perimeter
of the innerspring 12 where an individual may disproportionally
place force on the innerspring 12, such as during mounting onto and
dismounting from the mattress 10. The innerspring 12 is disposed on
top of a box spring 22 to provide base support.
[0013] The coils 14 located proximate to an edge 23 of the
innerspring 12 are subjected to concentrated loads as opposed to
coils 14 located in an interior 24. To provide further perimeter
structure and edge support for the innerspring 12, support members
25 may be disposed around the coils 14 proximate to the edge 23 of
the innerspring 12 between the box spring 22 and the upper and
lower border wires 18, 20. The support members 25 may be extruded
from polymer-foam as an example.
[0014] To provide a cushioning structure with high and low
stiffness features, various layers of sleeping surface or padding
material 26 can be disposed on top of the innerspring 12. The
padding material 26 provides a cushioning structure for a load
placed on the mattress 10. In this regard, the padding material 26
may be made from various types of foam, cloth, fibers and/or steel
to provide a generally repeatable comfortable feel to the
individual seeking a place to either lie, sit, or rest either the
body as a whole or portions thereof. To provide the cushioning
structure with high and low stiffness features, the padding
material 26 may consist of multiple layers of materials that may
exhibit different physical properties.
[0015] For example, foam plastic materials can be used as materials
of choice for the padding material 26. Foam plastic materials
provide a level of cushionability in and of themselves, unlike a
steel spring structure, or the like. For example, an uppermost
layer 28 may be a soft layer comprised of a thermoset material.
Thus, in the example of FIG. 1, the uppermost layer 28 being
provided as a thermoset material allows a load to sink into the
mattress 10 while exhibiting the ability to recover after repeated
deformations. One or more intermediate layers 30 underneath the
uppermost layer 28 may be provided to have greater stiffness than
the uppermost layer 28 to provide support and pressure spreading
that limits the depth to which a load sinks. For example, the
intermediate layers 30 may also include a thermoset material, such
as latex as an example. A bottom layer 32 may be provided below the
intermediate layers 30 and uppermost layer 28. The uppermost layer
28, the intermediate layers 30, and the bottom layer 32 serve to
provide a combination of desired cushioning characteristics. An
upholstery 34 is placed around the entire padding material 26,
innerspring 12, and box spring 22 to provide a fully assembled
mattress 10.
[0016] The material selection and thicknesses of the uppermost
layer 28, the intermediate layers 30, and the bottom layer 32 of
the mattress 10 can be designed to control and provide the desired
cushioning characteristics, and it may be desired to also provide
support characteristics in the padding material 26. However, the
disposition of layers in the padding material 26 does not easily
allow for providing variations in both cushioning and support
characteristics. For example, a thermoplastic foam could be
included in the padding material 26 to provide greater firmness.
However, compression will occur in the thermoplastic foam over
time. Regardless, further complications that can occur as a result
of including an additional thermoplastic material include the
separate manufacturing and stocking for assembly of the mattress
10, thus adding inventory and storage costs. Further, an increase
in the number of structures provided in the padding material 26
during assembly of the mattress 10 increases labor costs.
SUMMARY OF THE DETAILED DESCRIPTION
[0017] Embodiments disclosed herein include cellular mattress
assemblies and related methods. The cellular mattress assemblies
may comprise thermoplastic material and/or thermoset material to
achieve appropriate comfort and support characteristics. The
cellular mattress assemblies may also comprise one or more
components including a cellular thermoplastic foam profile to
achieve appropriate comfort and support characteristics. The
cellular mattress may include a support layer, a comfort layer, and
a transition layer between the support layer and the comfort
layer.
[0018] Embodiments disclosed herein may include a mattress assembly
employing a unitary composite cushioning structure and related
methods. In this regard in one embodiment, a mattress assembly for
bedding or seating placed under a load is disclosed. The mattress
assembly may include at least one comfort layer providing
cushioning characteristics. The mattress assembly may include at
least one support layer providing support characteristics. The
mattress assembly may include at least one transition layer
including at least one mattress member disposed between the at
least one comfort layer and at least one support layer. The at
least one mattress member may comprise a unitary composite
cushioning structure. The unitary composite cushioning structure
may include at least one cellular thermoplastic material providing
support characteristics and cushioning characteristics. The unitary
composite cushioning structure may include at least one cellular
thermoset material providing a resilient structure with cushioning
characteristics. The unitary composite cushioning structure may
include a stratum disposed between at least a portion of the
cellular thermoplastic material and at least a portion of the
cellular thermoset material. The stratum may secure the at least a
portion of the cellular thermoset material to the at least a
portion of the cellular thermoplastic material to form the unitary
composite cushioning structure. The unitary composite cushioning
structure may exhibit a combination of the support characteristics,
the cushioning characteristics, and the resilient structure with
cushioning characteristics when the unitary composite structure is
placed under a load.
[0019] Embodiments disclosed herein may include a mattress assembly
employing a transition layer comprising a thermoplastic material
and related methods. In this regard in one embodiment, a mattress
assembly for bedding or seating is disclosed. The mattress assembly
may include a support layer comprising thermoplastic material. The
mattress assembly may include a cushioning layer comprising a
thermoset material. The mattress assembly may include a transition
layer comprising a thermoplastic material disposed between the
support layer and the cushioning layer. The transition layer may
include at least two elongated members disposed within a geometric
plane and separated by a gap or abutting each other. Each of the at
least two elongated members may include a first end and a second
end opposite the first end along a longitudinal axis. Each of the
at least two elongated members may include at least one orifice
parallel to the longitudinal axis.
[0020] Embodiments disclosed herein may include a mattress assembly
employing a proportion of thermoplastic material and a proportion
of thermoset material by weight and related methods. In this regard
in one embodiment, a mattress assembly for sleeping or resting is
disclosed. The mattress assembly may comprise at least five (5)
percent and at most ninety-five percent cellular thermoplastic
material by weight. The mattress assembly may also comprising at
least five percent and at most ninety-five (95) percent cellular
thermoset material by weight.
[0021] Embodiments disclosed herein may include a mattress assembly
employing a proportion of thermoplastic material and a proportion
of thermoset material by volume and related methods. In this regard
in one embodiment, a mattress assembly for sleeping or resting is
disclosed. The mattress assembly may comprise at least five (5)
percent and at most ninety-five (95) percent cellular thermoplastic
material by volume. The mattress assembly may also comprising at
least five percent and at most twenty percent cellular thermoset
material by volume.
[0022] Embodiments disclosed herein may include a mattress assembly
employing geometrically-designed thermoplastic foam members and
related methods. In this regard in one embodiment, a foam mattress
assembly for sleeping or resting is disclosed. The foam mattress
assembly may include at least two geometrically-designed
thermoplastic foam members disposed within a geometric plane and
either separated by a gap or abutting each other. The at least two
geometrically-designed thermoplastic foam members may include
progressive support characteristics configured to conform and
deflect under a load. The at least two geometrically-designed
thermoplastic foam members may be configured to distribute the load
partially in a horizontal direction to resist full compression
while maintaining comfortable resistance to said load. A firmness
characteristic of the foam mattress assembly may be configured to
be provided by geometric characteristics of the at least one
geometrically-designed thermoplastic foam profile and the density
of the at least one geometrically-designed thermoplastic foam
profile.
[0023] Embodiments disclosed herein may include a foam mattress
assembly employing a side support member surrounding a mattress
member and related methods. In this regard in one embodiment, a
foam mattress assembly for bedding or seating is disclosed. The
foam mattress assembly may include at least one cellular foam
comfort layer providing cushioning characteristics. The foam
mattress assembly may include at least one cellular foam support
layer providing support characteristics. The foam mattress assembly
may include at least one transition cellular foam mattress member
disposed between the at least one comfort layer and the at least
one support layer and providing a stress-strain profile exhibiting
cushioning and support characteristics. The foam mattress assembly
may include least one side support member surrounding the at least
one mattress member.
[0024] 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.
[0025] 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
[0026] FIG. 1 is an exemplary prior art mattress employing an
innerspring of wire coils;
[0027] FIG. 2 is an exemplary chart of performance curves showing
strain (i.e., deflection) under a given stress (i.e., pressure) for
an exemplary thermoplastic material and thermoset material to
illustrate their individual support characteristics and resiliency
and cushioning characteristics, and the combined support
characteristics of the thermoplastic material and the resilient
structure with cushioning characteristics of the thermoset material
when provided in a unitary composite cushioning structure;
[0028] FIG. 3A is a stress-strain chart for an exemplary mattress
made of thermoset material, illustrating strain on an abscissa axis
and stress on an ordinate axis;
[0029] FIG. 3B is a stress-strain chart for a second exemplary
mattress which is "too hard", and the stress-strain chart includes
strain on an abscissa axis and stress on an ordinate axis;
[0030] FIG. 3C is a stress-strain chart for a third exemplary
mattress which is initially "too soft" and then "too hard", and the
stress-strain chart includes strain on an abscissa axis and stress
on an ordinate axis;
[0031] FIG. 3D is a stress-strain chart for a fourth exemplary
mattress which is initially "slightly harder" than the third
embodiment of the mattress of FIG. 8C, and abruptly "bottoms-out,"
and the stress-strain chart includes strain on an abscissa axis and
stress on an ordinate axis;
[0032] FIG. 3E is a stress-strain chart for a fifth exemplary
mattress which is initially gradually comforting, then supportive
without bottoming out, and the stress-strain chart includes strain
on an abscissa axis and stress on an ordinate axis;
[0033] FIG. 4 is a perspective view of an exemplary mattress
assembly employing a transition layer;
[0034] FIG. 5 is a perspective exploded view of the mattress
assembly of FIG. 4;
[0035] FIG. 6A is a side cutaway exploded partial view of the
mattress assembly of FIG. 4;
[0036] FIG. 6B is a side cutaway partial view of the mattress
assembly of FIG. 4;
[0037] FIG. 6C is a side cutaway view of the mattress assembly of
FIG. 4;
[0038] FIG. 7 is a side cutaway view of a double-sided mattress
assembly;
[0039] FIG. 8 is an exemplary unitary composite cushioning
structure comprised of a thermoset material cohesively or
adhesively bonded to a thermoplastic material with a stratum
disposed therebetween;
[0040] FIG. 9 is an exemplary chart of performance curves showing
strain (i.e., deflection) under a given stress (i.e., pressure) for
different types of thermoplastic foam structures to show the
ability to engineer a cellular thermoplastic foam profile to
provide for manufacturing a unitary composite cushioning
structure;
[0041] FIG. 10 is a side view of a cross-section of another
exemplary cellular thermoset foam profile substantially surrounded
by and cohesively or adhesively bonded to a cellular thermoplastic
foam and a stratum disposed therebetween, to form a unitary
composite cushioning structure;
[0042] FIG. 11 is an exemplary chart illustrating the recovery
characteristics of the unitary composite cushioning structure of
FIG. 10 versus the recovery characteristics of the cellular
thermoplastic foam profile of FIG. 10 over elapsed time to
illustrate the improved compression set characteristics of the
unitary composite cushioning structure over the cellular
thermoplastic foam profile;
[0043] FIG. 12 is a cross-section of an exemplary mattress
illustrating various cushioning layers where a unitary composite
cushioning structure according to exemplary embodiments disclosed
herein may be deployed;
[0044] FIG. 13A is a side lengthwise view of a unitary composite
cushioning structure of the mattress assembly of FIG. 4;
[0045] FIG. 13B is a side lateral view of the unitary composite
cushioning structure of FIG. 13A;
[0046] FIG. 13C is a side lateral view of a second embodiment of
the unitary composite cushioning structure of FIG. 4;
[0047] FIG. 13D is a side lateral view of a third embodiment of the
unitary composite cushioning structure of FIG. 4;
[0048] FIG. 14 is a perspective view of an exemplary sleep or seat
surface comprised of a plurality of the unitary composite
cushioning structures in FIG. 5 comprised of cellular thermoset
foam profiles substantially surrounded by and cohesively or
adhesively bonded to a cellular thermoplastic foam and a stratum
disposed therebetween, to form a unitary composite cushioning
structures;
[0049] FIG. 15 is a perspective view of another exemplary sleep or
seat surface comprised of a plurality of the unitary composite
cushioning structures in FIG. 5 offset from adjacent unitary
composite cushioning structures to provide motion isolation on the
sleep or seat surface;
[0050] FIGS. 16A and 16B are perspective and side views,
respectively, of an exemplary unitary composite cushioning
structure comprised of an extruded thermoplastic foam profile
incorporating chambers with a thermoset material disposed in the
chambers and a stratum provided therebetween to provide zoned
cushioning characteristics in a sleep or seat surface;
[0051] FIG. 17 is a perspective view of the unitary composite
cushioning structure of FIGS. 16A and 16B disposed on top of a
mattress innerspring to provide a padding material for the mattress
innerspring;
[0052] FIG. 18 is a perspective view of another exemplary unitary
composite cushioning structure comprised of a molded thermoplastic
foam profile incorporating chambers with a thermoset material
disposed in the chambers and a stratum provided therebetween, with
a top surface of the thermoset material including convolutions to
provide zoned cushioning characteristics in a sleep or seat
surface;
[0053] FIG. 19 is an exemplary cross-section profile of another
exemplary unitary composite cushioning structure comprised of a
cellular thermoplastic foam profile incorporating chambers with a
thermoset material disposed in the chambers and a stratum provided
therebetween, and that may be employed to provide zoned cushioning
characteristics in a sleep or seat surface;
[0054] FIG. 20 is an exemplary cross-section profile of another
exemplary unitary composite cushioning structure comprised of a
cellular thermoplastic foam profile having extruded closed chambers
with a thermoset material disposed in the chambers and a stratum
provided therebetween that may be employed to provide a cushioning
structure, including but not limited to a sleep or seat surface and
edge or side supports;
[0055] FIGS. 21A and 21B illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0056] FIG. 22 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0057] FIG. 23 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0058] FIG. 24 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0059] FIGS. 25A and 25B illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0060] FIGS. 26A and 26B illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0061] FIGS. 27A-27D illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0062] FIG. 28 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0063] FIGS. 29A and 29B illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0064] FIGS. 30A and 30B illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0065] FIG. 31 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0066] FIG. 32 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0067] FIG. 33 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0068] FIG. 34 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0069] FIGS. 35A-35C illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0070] FIG. 36 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0071] FIG. 37 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0072] FIGS. 38A and 38B illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0073] FIGS. 39A-39D illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0074] FIGS. 40A-40D illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0075] FIGS. 41A and 41B illustrate side view profiles of other
exemplary embodiments of unitary composite cushioning
structure;
[0076] FIG. 42 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0077] FIG. 43 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0078] FIG. 44 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0079] FIG. 45 illustrates a side view profile of another exemplary
embodiment of unitary composite cushioning structure;
[0080] FIG. 46 is a top view of an exemplary unitary composite
cushioning structure comprised of a cellular thermoplastic foam
profile surrounded by a thermoset material;
[0081] FIG. 47 is a top perspective view of exemplary unitary
composite cushioning structure comprised of a coil-shaped cellular
thermoplastic foam profile having an internal chamber with a
thermoset material disposed in the chamber of the cellular
thermoplastic foam profile;
[0082] FIG. 48 is a top perspective view of the unitary composite
cushioning structure in FIG. 47 with an additional filler material
in the form of corc dust mixed with the thermoset material to
provide stability to the thermoset material;
[0083] FIG. 49 is a top view of a plurality of exemplary unitary
composite cushioning structures provided in an array;
[0084] FIG. 50 is a side perspective view of a mattress innerspring
employing exemplary coil-shaped unitary composite cushioning
structures, which may include the composite coil structures of
FIGS. 46-48;
[0085] FIGS. 51A-51M are side perspective views of alternative
cellular thermoplastic foam profiles that can either be
encapsulated or filled with a thermoset material to provide unitary
composite cushioning structures;
[0086] FIGS. 52A-52F are side perspective views of alternative
cellular thermoplastic foam profiles that can either be
encapsulated or filled with a thermoset material to provide unitary
composite cushioning structures;
[0087] FIGS. 53A and 53B are side perspective views of alternative
cellular thermoplastic foam spring arrangements that can provide
unitary composite cushioning structures;
[0088] FIGS. 54A-54C are side perspective views of alternative
cellular thermoplastic foam spring arrangements that can provide
unitary composite cushioning structures;
[0089] FIGS. 55A and 55B illustrate a perspective view of an
exemplary mattress assembly comprised of unitary composite
cushioning structures in the form of foam springs;
[0090] FIG. 56 illustrates another perspective view of an exemplary
mattress assembly comprised of unitary composite cushioning
structures in the form of foam springs;
[0091] FIG. 57 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
polyurethane and certain unitary composite cushioning
structures;
[0092] FIG. 58 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
polyurethane, viscoelastic, and certain unitary composite
cushioning structures;
[0093] FIG. 59 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
certain unitary composite cushioning structures;
[0094] FIG. 60 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
certain unitary composite cushioning structures;
[0095] FIG. 61 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
certain unitary composite cushioning structures;
[0096] FIG. 62 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
certain unitary composite cushioning structures;
[0097] FIG. 63 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
certain unitary composite cushioning structures;
[0098] FIG. 64 illustrates a graph of exemplary stress (i.e.,
pressure) for a given percentage strain (i.e., deflection) for
certain unitary composite cushioning structures;
[0099] FIG. 65 illustrates a bar graph of exemplary support factors
for various cushioning structures, including viscoelastic, latex,
and unitary composite cushioning structures;
[0100] FIG. 66 illustrates a bar graph of exemplary percentage
reduction in height vs. deflection cycles for various cushioning
structures, including polyurethane and unitary composite cushioning
structures;
[0101] FIG. 67 illustrates a bar graph of exemplary percentage
stiffness reduction in height vs. deflection cycles for various
cushioning structures, including polyurethane and unitary composite
cushioning structures;
[0102] FIG. 68 illustrates a graph of exemplary mean reduction in
height vs. deflection cycles for various cushioning structures,
including polyurethane and unitary composite cushioning
structures;
[0103] FIG. 69 illustrates a graph of exemplary mean change in
firmness vs. deflection cycles for various cushioning structures,
including polyurethane and unitary composite cushioning
structures;
[0104] FIG. 70A illustrates an exemplary continuous extrusion
system in an upstream view when looking back towards an extruder
that extrudes the cellular thermoplastic material into a desired
profile onto a conveyor;
[0105] FIG. 70B illustrates the continuous extrusion system in FIG.
70A in a downstream view when away from the extruder that extrudes
the cellular thermoplastic material into a desired profile towards
the conveyor;
[0106] FIG. 71 illustrates a close-up view of the extruder in the
continuous extrusion system in FIGS. 70A and 70B;
[0107] FIG. 72 illustrates the extruder die in the extruder in FIG.
71;
[0108] FIG. 73 illustrates an exemplary cellular thermoplastic
profile extruded by the continuous extrusion system in FIGS. 70A
and 70B;
[0109] FIG. 74 illustrates an exemplary pulling apparatus of the
continuous extrusion system in FIGS. 70A and 70B disposed on the
opposite end of the extruder;
[0110] FIG. 75 illustrates an exemplary conveyor disposed between
the extruder and the pulling apparatus in FIG. 74 configured to
convey the cellular thermoplastic profile extruded from the
extruder and pulled by the pulling apparatus;
[0111] FIGS. 76A and 76B illustrate dispensing a thermoset material
in a non-solid phase into the internal chamber of the cellular
thermoplastic profile in the continuous extrusion system in FIGS.
70A and 70B;
[0112] FIG. 77 illustrates exemplary pulling members disposed on
the conveyor in the continuous extrusion system in FIGS. 70A and
70B to assist in providing access to the internal chamber of the
cellular thermoplastic profile for dispensing thermoset material
into the internal chamber of the thermoplastic cellular
profile;
[0113] FIG. 78 illustrates an exemplary cutting apparatus that may
be employed after the unitary composite cushioning structure is
produced by the continuous extrusion system in FIGS. 70A and 70B to
cut the continuously produced unitary composite cushioning
structure into sections;
[0114] FIG. 79 is a cross-section of an exemplary mattress
illustrating various cushioning layers where a unitary composite
cushioning structure according to exemplary embodiments disclosed
herein may be deployed;
[0115] FIG. 80A is a side lengthwise view of a thermoplastic foam
member of the mattress assembly of FIG. 4;
[0116] FIG. 80B is a side lateral view of the thermoplastic foam
member of FIG. 80A;
[0117] FIG. 81A is a side cutaway exploded partial view of another
embodiment of the mattress assembly;
[0118] FIG. 81B is a side cutaway partial view of the mattress
assembly of FIG. 81A;
[0119] FIG. 82A is a side cutaway exploded partial view of another
embodiment of the mattress assembly;
[0120] FIG. 82B is a side cutaway partial view of the mattress
assembly of FIG. 82A;
[0121] FIG. 83A is a side cutaway exploded partial view of another
embodiment of the mattress assembly;
[0122] FIG. 83B is a side cutaway partial view of the mattress
assembly of FIG. 83A;
[0123] FIG. 84A is a side cutaway exploded partial view of another
embodiment of the mattress assembly;
[0124] FIG. 84B is a side cutaway partial view of the mattress
assembly of FIG. 84A;
[0125] FIG. 85A is a side cutaway exploded partial view of another
embodiment of the mattress assembly;
[0126] FIG. 85B is a side cutaway partial view of the mattress
assembly of FIG. 85A;
[0127] FIG. 86A is a side cutaway exploded partial view of another
embodiment of the mattress assembly; and
[0128] FIG. 86B is a side cutaway partial view of the mattress
assembly of FIG. 86A.
DETAILED DESCRIPTION
[0129] Reference will now be made in detail to the embodiments,
examples of which are illustrated in the accompanying drawings, in
which some, but not all embodiments are shown. Indeed, the concepts
may be embodied in many different forms and should not be construed
as limiting herein; rather, these embodiments are provided so that
this disclosure will satisfy applicable legal requirements.
Whenever possible, like reference numbers will be used to refer to
like components or parts.
[0130] Embodiments disclosed herein include cellular mattress
assemblies and related methods. The cellular mattress assemblies
may comprise thermoplastic material and/or thermoset material to
achieve appropriate comfort and support characteristics. The
cellular mattress assemblies may also comprise one or more
components including a cellular thermoplastic foam profile to
achieve appropriate comfort and support characteristics. The
cellular mattress may include a support layer, a comfort layer, and
a transition layer between the support layer and the comfort
layer.
[0131] In this regard, embodiments disclosed in the detailed
description may include a unitary or monolithic composite (or
hybrid) cushioning structure(s) and profile(s) comprised of a
cellular thermoplastic foam and a thermoset material. Embodiments
disclosed in the detailed description also include methods of
producing a unitary or monolithic composite (or hybrid) cushioning
structure(s) and profile(s) comprised of a cellular thermoplastic
foam and a thermoset material.
[0132] In one embodiment, the thermoset material may be provided as
cellular foam as well. In another embodiment disclosed herein, the
unitary composite or hybrid cushioning structure is formed from a
cellular thermoplastic foam and a thermoset material. The cellular
thermoplastic foam provides support characteristics to the unitary
composite cushioning structure. The thermoset material provides a
resilient structure with cushioning characteristics to the
cushioning structure. A stratum is disposed between at least a
portion of the cellular thermoplastic foam and at least a portion
of the thermoset material to secure the at least a portion of the
thermoset material to the at least a portion of the cellular
thermoplastic foam to provide a unitary composite cushioning
structure. The stratum includes a cohesive or adhesive bond, such
as a mechanical or chemical bond, as examples. The stratum may
provide an intimate engagement between at least a portion of the
thermoset material and at least a portion of the cellular
thermoplastic foam to provide the unitary composite cushioning
structure. The cellular thermoplastic foam may also be provided as
a custom engineered profile to allow engagement of the thermoset
material and thus the unitary composite cushioning structure.
[0133] As will be discussed in more detail below, the stratum may
be continuously propagated between a portion of the cellular
thermoplastic foam and a portion of the thermoset material during
manufacture to secure the portion of the thermoset material to the
portion of the cellular thermoplastic foam as the thermoset
material is continuously dispensed into a continuously extruded
cellular thermoplastic foam. In one embodiment, the stratum is
formed by disposing a non-solid phase of the cellular thermoset
material on or into a cellular thermoplastic foam profile. The
cellular thermoset material undergoes a transition into a solid
phase to form a bond with the cellular thermoplastic material, to
secure the at least a portion of the cellular thermoset material to
the at least a portion of the cellular thermoplastic material to
form the unitary composite cushioning structure. The unitary
composite cushioning structure exhibits a combination of the
support characteristics and the resilient structure with cushioning
characteristics when the unitary composite cushioning structure is
placed under a load.
[0134] A unitary structure within the context of this disclosure is
a structure having the character of a unit, undivided and
integrated. The term composite or hybrid within the context of this
disclosure is a complex structure having two or more distinct
structural properties provided by two or more distinct material
structures that are cohesively or adhesively bonded together to
provide the combined functional properties of the two or more
distinct structural properties which are not present in combination
in any individual material structure.
[0135] There are several non-limiting and non-required advantages
of the unitary composite cushioning structures disclosed herein.
For example, the unitary composite cushioning structure is provided
as a unitary structure as opposed to providing disparate,
non-bonded structures each comprised exclusively of thermoplastic
or thermoset materials. This allows the tactile cushioning and
resiliency benefits of thermoset materials and the supportive and
structural capabilities of the cellular thermoplastic foams to
create a cushioning structure combining the desired characteristics
and features of both material types into one unitary composite
cushioning structure.
[0136] Further, the thermoset material provided as part of the
unitary composite cushioning structure allows the cellular
thermoplastic foam to exhibit excellent offset of compression set
while retaining support characteristics to provide stability to the
unitary composite cushioning structure. Thermoset materials can be
selected that exhibit the desired offset of compression set.
Without the employment of the thermoset material, the thermoplastic
profile may not be able to provide the desired support
characteristics without the undesired effects of compression set,
also known as "sagging." This engagement of a thermoset material
with a cellular thermoplastic foam utilizes the thermoset
material's ability to recover over long periods of repeated
deformations. Another advantage can be cost savings. The cellular
thermoplastic foam may be less expensive than the thermoset
material while still providing a suitable composite cushioning
structure exhibiting desired stability and offset of compression
set.
[0137] Before discussing examples of unitary composite cushioning
structures comprised of a cellular thermoplastic foam cohesively or
adhesively bonded to a thermoset material at a stratum, a
discussion of strains (i.e., deflections) over given stresses
(i.e., pressures) for cushioning structures not included in a
unitary composite cushioning structure, as provided herein, is
first discussed. In this regard, FIG. 2 illustrates an exemplary
chart 35 of performance curves 36, 37, 38 showing compressive
strain or deflection for given stress or pressure levels for
different types of cushioning materials. The performance curve 36
illustrates strain versus stress for an exemplary thermoplastic
material used as a cushioning structure. As illustrated in Section
I of the chart 35, when a low stress or pressure is placed on the
thermoplastic material represented by the performance curve 36, the
thermoplastic material exhibits a large strain as a percentage of
stress. As stress increases, as shown in Section II of the chart
35, the thermoplastic material represented by the performance curve
36 continues to strain or deflect, but the strain is smaller as a
percentage of stress than the strain in Section I of the chart 35.
This represents the firmer structural properties of the
thermoplastic material providing a greater role in response to
increased stress, thus decreasing the softness feel. As the stress
further increases, as shown in Section III of the chart 35,
eventually, the thermoplastic material represented by the
performance curve 36 will exhibit even greater firmness where
strain or deflection is very small as a percentage of stress, or
non-existent.
[0138] It may be determined that the thermoplastic material
represented by the performance curve 36 in FIG. 2 does not exhibit
enough softness or cushioning to a load as stress increases. In
other words, the thermoplastic material may provide a greater
firmness more quickly as a function of stress than desired, thereby
not providing the desired softness or cushioning characteristic
desired. Thus, a thermoset material may be selected for the
cushioning structure in lieu of a thermoplastic material.
[0139] In this regard, the performance curve 37 in FIG. 2
illustrates strain versus stress for an exemplary thermoset
material. As illustrated in Section I of the chart 35, when a low
stress or pressure is placed on the thermoset material represented
by the performance curve 37, the thermoplastic material exhibits a
large strain as a percentage of stress similar to the thermoplastic
material represented by performance curve 36. As stress increases,
as provided in Section II of the chart 35, the thermoset material
represented by the performance curve 37 continues to strain, but
only slightly greater than the strain in Section I of the chart 35.
Thus, the thermoset material is continuing to exhibit softness even
as the stress of a load disposed thereon increases, as opposed to
the thermoplastic material represented by the performance curve 36
in FIG. 2. However, the thermoset material represented by the
performance curve 37 does not provide the support or firmness
characteristics as provided by the thermoplastic material
represented by the performance curve 36, thereby providing a spongy
or lack of support feel to a load. As the stress further increases,
as shown in Section III of the chart 35, eventually, the thermoset
material represented by the performance curve 37 will reach a point
where it will exhibit greater firmness where strain or deflection
is very small as a percentage of stress, or non-existent.
[0140] Embodiments disclosed herein provide a cushioning structure
that has a hybrid or combined strain versus stress characteristic
of the performance curves 36 and 37. This is illustrated by the
performance curve 38 in FIG. 2. The performance curve 38 in FIG. 2
illustrates a unitary composite or hybrid cushioning structure
comprised of the thermoplastic material represented by the
performance curve 36 and the thermoset material represented by the
performance curve 37.
[0141] The unitary composite or hybrid cushioning structure
represented by performance curve 38 in FIG. 2 may be used as part
of a mattress assembly including the composite or hybrid cushioning
structure having an effective strain versus stress characteristic
which is a combination of all its individual components. FIG. 3A
depicts a performance curve 39 of a mattress assembly which is too
soft. A user may sink in the sleeping surface to a depth that is
too deep and then "bottom out." FIG. 3B depicts a performance curve
39(2) reflecting a mattress that is too hard. The user may apply a
variety of weight to the mattress causing a variety of stress, but
the mattress surface will not move much in response, resulting in a
user experience analogous to sleeping on a floor.
[0142] The shape of the performance curve may be as important as
the slope of the performance curve. For example, FIG. 3C depicts a
performance curve 39(3) of a mattress that is initially too soft as
the user first applies their weight to the mattress assembly. The
mattress assembly offers no transition zone and the immediately is
too hard. The resulting overall experience is negative upon the
user.
[0143] FIG. 3D depicts a performance curve 39(4) for a mattress
that is initially harder than the performance curve 39(3) of FIG.
3C, but yet also provides a negative user experience because there
is an abrupt "bottoming-out" at some strain amount where the
performance curve 39(4) steepens rapidly. The user may find the
initial performance of the mattress prior to the bottoming-out as
pleasant, but the bottoming-out would ruin the user's
experience.
[0144] FIG. 3E depicts a performance curve 39(5) of a mattress that
provides the most ideal user experience. The initial strain is
provided without being too soft and there is gradual strain with
increasing stress provided by the user. As higher amounts of strain
are reached, there is no bottoming out as was experienced in the
performance curves 39(3) and 39(4). Instead, the mattress allows a
gradual linear response that is supportive as the stress and strain
are increased.
[0145] FIG. 4 is an exemplary mattress assembly 40 providing the
performance curve 39(5) associated with a gradual linear response.
The mattress assembly may be covered with upholstery, which is not
shown. Many components of the mattress assembly 40 may be viewed
externally from the perspective view of FIG. 4. For example, the
mattress assembly 40 may include at least one comfort layer 41; a
base layer 42; and side support members 43, 43(2), 43(3), and
43(4).
[0146] The comfort layer 41 may be a planar shape extending across
a width W and a length L of the mattress assembly 40. The comfort
layer 41 may initially receive a load F from the user and transfer
the load F of the user to the remainder to the mattress assembly
40. The comfort layer 41 may be of uniform thickness. The comfort
layer 41 may be made of a soft material, for example, cellular foam
such as latex or thermoset.
[0147] The base layer 42 may be a planar shape extending across the
width W and the length L of the mattress assembly 40. The base
layer 42 may provide strength and rigidity to the mattress assembly
40. The base layer 42 may be made of a strong resilient material,
for example, cellular thermoplastic material. The base layer 42 may
include at least one orifice 44 through the base layer 42 that
either traverses the length L and/or the width W of the mattress
assembly 40. The orifice 44 may reduce the weight and/or cost of
the mattress assembly 40.
[0148] The side support members 43, 43(2), 43(3), 43(4) may be
disposed along a perimeter of the mattress assembly 40. The side
support members 43, 43(2), 43(3), 43(4) may be disposed along a
left side 45, right side 46, front side 47, and rear side 48 of the
mattress assembly 40 respectively. The side support members 43,
43(2), 43(3), 43(4) may be configured to provide a firmer outer
edge (perimeter) of the mattress assembly 40 so that the user does
not slip off when sitting on the outer edge of the mattress
assembly 40.
[0149] The side support members 43, 43(2), 43(3), 43(4) may each
include at least one cellular thermoplastic side support member 49,
49(2), 49(3) 49(4) respectively. Each of the cellular thermoplastic
side support members 49, 49(2), 49(3), 49(4) may be disposed
between the base layer 42 and the comfort layer 41.
[0150] The side support members 43, 43(2), 43(3), 43(4) may each
include at least one cellular thermoset side support member 50,
50(2), 50(3) 50(4) respectively. Each of the cellular thermoset
side support members 50, 50(2), 50(3), 50(4) may be disposed
between the comfort layer 41 and the cellular thermoplastic side
support members 49, 49(2), 49(3), and 49(4) respectively.
[0151] FIG. 5 depicts a perspective exploded view of the mattress
assembly 40 of FIG. 4. The mattress assembly 40 may also include at
least one transition layer 51, a second comfort layer 52, and a
support layer 53. The transition layer 51, the second comfort layer
52, and the support layer 53 may transfer the load F of the user
from the comfort layer 41 to the base layer 42.
[0152] The transition layer 51 may be disposed between the comfort
layer 41 and the base layer 42. The transition layer 51 may include
mattress members 54, 54(2), 54(3), 54(4), 54(5), 54(6). The
transition layer 51 may help transfer the load F of the user from
the comfort layer 41 to the base layer 42. The transition layer 51
may provide both cushioning and support characteristics. The
transition layer 51 may be a hybrid structure comprising both
thermoplastic and thermoset materials.
[0153] The second comfort layer 52 may be a planar shape. The
second comfort layer 52 may contribute in transferring the load F
of the user from the transition layer 51 to the support layer 53.
The second comfort layer 52 may be made of a soft resilient
material, for example, a thermoset material or latex.
[0154] The support layer 53 may be of a planar shape. The support
layer 53 may contribute in transferring the load F of the user from
the transition layer 51 to the base layer 42. The support layer 53
may be made of a stiff resilient material, for example, a
thermoplastic material. The support layer 53 may have one or more
orifices 55 through the support layer 53 that either traverses the
length L and/or the width W of the support layer 53. The orifices
55 may reduce the weight and/or cost of the mattress assembly
40.
[0155] FIGS. 6A through 6C depict a side cutaway exploded partial
view and a side cutaway partial view respectively of the mattress
assembly 40. The mattress members 54, 54(n) of the transition layer
51 may be disposed in a geometric plane P.sub.1. The mattress
members 54, 54(n) may be separated by a gap of distance D or abut
each other. The distance D may be zero when the mattress members
54, 54(n) abut each other or may be as much as three (3) inches
apart (see, for example, FIGS. 82A and 82B). The transition layer
51 including the mattress members 54, 54(n) may be disposed between
the comfort layer 41 and the support layer 53. The at least one
side support member 43, 43(n) may collectively surround the at
least one support layer 53 and the at least one mattress member 54,
54(n).
[0156] FIG. 6B shows a thickness T.sub.1 of the at least one
comfort layer 41, a thickness T.sub.2 of the at least one mattress
member 54, and a thickness T.sub.3 of the at least one support
layer 53. The thickness T.sub.1 may be at least one-inch thick and
at most thirteen-inches thick. The thickness T.sub.2 may be at
least one-inch thick and at most thirteen-inches thick. The
thickness T.sub.3 may be at least one-inch thick and at most
thirteen-inches thick. The thicknesses T.sub.1, T.sub.2, T.sub.3
may fit within a standard fourteen-inches thick mattress size.
[0157] Moreover, FIG. 6B shows the relationship of the second
comfort layer 52 to other parts of the mattress assembly 40. The
second comfort layer 52 may be disposed between the at least one
mattress member 54 and the at least one support layer 53.
[0158] The mattress assembly 40 of FIG. 6B may comprise at least
five percent and at most ninety-five percent cellular thermoplastic
material by weight or by volume. The mattress assembly 40 may
comprise at least five percent and at most ninety-five percent
cellular thermoset material by weight or by volume. The mattress
assembly 40 may be fully comprised of cellular thermoset material
and cellular thermoplastic material. In this regard, the mattress
assembly 40 may be fully metal-free.
[0159] FIG. 7 depicts a side view of a double-sided mattress
assembly 40(2). The double-sided mattress assembly 40(2) may be
used right-side up or upside down upon a planar surface (not
shown). In either case the comfort layer 41 transfers the load F of
the user to the opposite comfort layer 41' or vice versa. The
double-sided mattress assembly 40(2) includes the comfort layer 41,
the transition layer 51, the second comfort layer 52, the support
layer 53, and the side support members 43, 43(n) similar to the
mattress assembly 40(2). However, the double-sided mattress
assembly 40(2) may also include at least one comfort layer 41', a
transition layer 51', a second comfort layer 52', a support layer
53', and side support members 43', 43' (n) with similar features to
the comfort layer 41, the transition layer 51, the second comfort
layer 52, the support layer 53, and side support members 43, 43(n)
respectively. The double-sided mattress assembly 40(2) shows minor
symmetry across a geometric plane of symmetry P.sub.2 as shown in
FIG. 7. The mirror symmetry allows for similar performance with
respect to the user when the double-sided mattress is used either
right-side up or upside down.
[0160] Next, details of an example of a unitary composite
cushioning structure 60 is discussed in relation to the embodiments
of the mattress members 54, 54(n) of the transition layer 51 and/or
the mattress members 54', 54' (n) of the transition layer 51'
containing both thermoset and thermoplastic materials. FIG. 8
illustrates the unitary composite cushioning structure that can
provide the performance according to the performance curve 38 in
FIG. 2.
[0161] As illustrated in FIG. 8, a profile of a unitary composite
cushioning structure 60 is provided. The unitary composite
cushioning structure 60 is a hybrid that includes both a
thermoplastic material 61 and a thermoset material 62. A unitary
structure within the context of this disclosure is a structure
having the character of a unit, undivided and integrated. A
composite or hybrid structure within the context of this disclosure
is a complex structure having two or more distinct structural
properties provided by two or more distinct material structures
that are cohesively or adhesively bonded together to provide the
combined functional properties of the two or more distinct
structural properties which are not present in combination in any
individual material structure.
[0162] The thermoplastic material 61 and the thermoset material 62
are cohesively or adhesively bonded together to provide a unitary
or monolithic cushioning structure. In this regard, the unitary
composite cushioning structure 60 exhibits combined characteristics
of the support characteristics of the thermoplastic material 61 and
the resiliency and cushioning characteristics of the thermoset
material 62. The thermoplastic material 61 is provided to provide
support characteristics desired for the unitary composite
cushioning structure 60. The thermoplastic material 61 could be
selected to provide a high degree of stiffness to provide
structural support for the unitary composite cushioning structure
60. The thermoset material 62 can provide resiliency and softer
cushioning characteristics to the unitary composite cushioning
structure 60. A stratum 63 is disposed between at least a portion
of the thermoplastic material 61 and at least a portion of the
thermoset material 62 that includes a cohesive or adhesive bond
between at least a portion of the thermoset material 62 to the at
least a portion of the thermoplastic material 61 to provide the
unitary composite cushioning structure 60.
[0163] Non-limiting examples of thermoplastic materials that can be
used to provide the thermoplastic material 61 in the unitary
composite cushioning structure 60 include polypropylene,
polypropylene copolymers, polystyrene, polyethylenes, ethylene
vinyl acetates (EVAs), polyolefins, including metallocene catalyzed
low density polyethylene, thermoplastic olefins (TPOs),
thermoplastic polyester, thermoplastic vulcanizates (TPVs),
polyvinyl chlorides (PVCs), chlorinated polyethylene, styrene block
copolymers, ethylene methyl acrylates (EMAs), ethylene butyl
acrylates (EBAs), and the like, and derivatives thereof. The
density .rho..sub.1 of the thermoplastic material 61 may be
provided to any density desired to provide the desired weight and
support characteristics for the unitary composite cushioning
structure 60. Further, the thermoplastic material 61 may be
selected to also be inherently resistant to microbes and bacteria,
making the thermoplastic material 61 desirable for use in
cushioning structures and related applications. The thermoplastic
material 61 can also be made biodegradable and fire retardant
through the use of additive master batches.
[0164] Non-limiting examples of thermoset materials that can be
used to provide thermoset material 62 in the unitary composite
cushioning structure 60 include polyurethanes, natural and
synthetic rubbers, such as latex, silicones, ethylene propylene
diene Monomer (M-class) (EPDM) rubber, isoprene, chloroprene,
neoprene, melamine-formaldehyde, and polyester, and derivatives
thereof. The density .rho..sub.2 of the thermoset material 62 may
be provided to any density desired to provide the desired
resiliency and cushioning characteristics to the unitary composite
cushioning structure 60, and can be soft or firm depending on
formulations and density. The thermoset material 62 could also be
foamed. Further, if the thermoset material 62 selected is a natural
material, such as latex for example, it may be considered
biodegradable. Further, bacteria, mildew, and mold cannot live in
certain thermoset foams. Also note that although the unitary
composite cushioning structure 60 illustrated in FIG. 8 is
comprised of at least two materials, the thermoplastic material 61
and the thermoset material 62, more than two different types of
thermoplastic and/or thermoset materials may be provided in the
unitary composite cushioning structure 60.
[0165] Taking the example of latex as the thermoset material 62
that may be used in providing the unitary composite cushioning
structure 60, latex is a naturally derived biodegradable product
that comes from the rubber tree. Latex is hypo-allergenic, and
breathes to retain heat in the winter and not absorb heat in the
summer. Bacteria, mildew, and mold cannot live in latex foam. Tests
have shown that latex foam can be three times more resistant to
dust mites and bacteria than ordinary cushioning structures, and
thus may be desirable, especially as it would pertain to being
natural and biodegradable. There are also synthetic versions of
latex that do not fit into the natural category, but could also be
used either solely or in combination with a natural product.
[0166] In the example of the unitary composite cushioning structure
60 of FIG. 8, the thermoplastic material 61 is provided. A bottom
surface 64 of the thermoset material 62 disposed on a top surface
65 of the thermoplastic material 61. The stratum 63 is formed where
the bottom surface 64 of the thermoset material 62 contacts or
rests on and is cohesively or adhesively bonded to the top surface
65 of the thermoplastic material 61. The thermoplastic material 61
may be provided in a solid phase, such as a cellular foam for
example. The thermoset material 62 may be provided initially in the
unitary composite cushioning structure 60 as a non-solid phase,
such as in a liquid form. The thermoplastic material 61 and the
thermoset material 62 are not mixed together. The thermoset
material 62 will undergo a transition into a solid form, thereby
forming a cohesive or adhesive union with the thermoset material 62
at the stratum 63, as illustrated in FIG. 8. Thus, the
thermoplastic material 61 and the thermoset material 62 cohesively
or adhesively bond together to form a unitary structure that
provides combined properties of the support characteristics of the
thermoplastic material 61 and the resiliency and cushioning
characteristics of the thermoset material 62 that may not otherwise
be possible by providing the thermoplastic material 61 and
thermoset material 62 in separate, non-unified structures or
layers. Advantages in this example include, but are not limited to,
compression recovery, reduced weight, fewer layers of cushioning
material, less labor in assembly, smaller form factor of the
cushioning structure, less inventory, and/or antimicrobial
features.
[0167] A curing process can be performed on the unitary composite
cushioning structure 60 to set and cohesively or adhesively bond
the thermoset material 62 to the thermoplastic material 61. The
thermoset material 62 is mechanically bonded to the thermoplastic
material 61 in this embodiment, but chemical bonding can be
provided. Further, a chemical bonding agent can be mixed in with
the thermoplastic material 61, such as before or during a foaming
process for example, to produce the thermoplastic material 61, or
when the thermoset material 62 is disposed in contact with the
thermoplastic material 61 to provide a chemical bond with the
thermoset material 62 during the curing process.
[0168] It may be desired to control the combined cushioning
properties of the unitary composite cushioning structure 60 in FIG.
8. For example, it may be desired to control the degree of support
or firmness provided by the thermoplastic material 61 as compared
to the resiliency and cushioning characteristics of the thermoset
material 62. In this regard, as an example, the thermoplastic
material 61 is provided as a solid block of height H.sub.1, as
illustrated in FIG. 8. The thermoset material 62 is provided of
height H.sub.2, as also illustrated in FIG. 8. The relative volume
of the thermoplastic material 61 as compared to the thermoset
material 62 can control the combined cushioning properties, namely
the combined support characteristics and the resiliency and
cushioning characteristics, in response to a load. These combined
characteristics can also be represented as a unitary strain or
deflection for a given stress or pressure, as previously
discussed.
[0169] Further, by controlling the volume of the thermoplastic
material 61 and the thermoset material 62, the same combined
cushioning properties may be able to be provided in a smaller
overall volume or area. For example, with reference to FIG. 8, the
individual heights H.sub.1 and H.sub.2 may be less important in
providing the combined cushioning characteristics of the unitary
composite cushioning structure 60 than the ratio of the respective
heights H.sub.1 and H.sub.2. Thus, the overall height H.sub.3
(i.e., H.sub.1+H.sub.2) of the unitary composite cushioning
structure 60 may be reduced over providing distinct, non-bonded
layers of cushioning structures.
[0170] Further, a relative density .rho..sub.1 of the thermoplastic
material 61 as compared to a density .rho..sub.2 of the thermoset
material 62 can control the responsiveness of the combined
cushioning properties. For example, the density .rho..sub.1 of the
thermoplastic material 61 could be in the range between one-half
pound (lb.) per cubic foot (ft.sup.3) to 30 lbs./ft.sup.3 (i.e., 8
kilograms (kg) per cubic meter (m.sup.3) to 480 kg/m.sup.3), as an
example. The density .rho..sub.2 of the thermoset material 62 could
be in the range between one pound (lb.) per cubic foot (ft.sup.3)
to 15 lbs./ft.sup.3 (i.e., 16 kilograms (kg) per cubic meter
(m.sup.3) to 240 kg/m.sup.3), as an example. The variability of
densities .rho..sub.1 of the thermoplastic material 61 relative to
.rho..sub.2 of the thermoset material 62 can be selected to
customize the resultant properties of the unitary composite
cushioning structure 60 that may not otherwise be possible by
providing the thermoset material 62 as a distinct, non-unitary
component or structure from the thermoplastic material 61.
[0171] Further, the thermoplastic material 61 and thermoset
material 62 may each have different indentation load deflections
(ILDs). ILD is a measurement of foam firmness. Firmness is
independent of foam density, although it is often thought that
higher density foams are firmer. It is possible to have high
density foams that are soft--or low density foams that are firm,
depending on the ILD specification. ILD specification relates to
comfort. It is a measurement of the surface feel of the foam. ILD
may be measured by indenting (compressing) a foam sample
twenty-five (25) percent of its original height. The amount of
force required to indent the foam is its twenty-five (25) percent
ILD measurement. The more force required, the firmer the foam.
Flexible foam ILD measurements can range from ten (10) pounds
(supersoft) to about eighty (80) pounds (very firm).
[0172] The thermoplastic material 61 of the unitary composite
cushioning structure 60 can be provided as a cellular thermoplastic
foam profile, if desired. By providing the thermoplastic material
61 of the unitary composite cushioning structure 60 as a cellular
foam profile, control of the shape and geometry of the unitary
composite cushioning structure 60 can be provided, as desired. For
example, the extrusion foaming art, with the ability to
continuously produce and utilize specific die configurations having
the ability to geometrically design and profile elements for
cushioning support, is a method to obtain the desired thermoplastic
engineered geometry foam profiles to be used with a thermoset
material or materials to provide the unitary composite cushioning
structure 60. In this manner, the unitary composite cushioning
structure 60 can be provided for different applications based on
the desired geometric requirements of the cushioning structure.
Machine direction (MD) attributes as well as transverse direction
(TD) attributes may be employed to extrude a thermoplastic foam
profile. However, other methods of providing thermoplastic foam
profiles may also be employed, including molding, casting, thermal
forming, and other processes known to those skilled in the art.
[0173] Thermoset foam profiles can be obtained in emulsified form
and are frothed to introduce air into the emulsion to reduce
density, and are then cured (vulcanized) to remove additional
waters and volatiles as well as to set the material to its final
configuration. The cost of thermoset materials can be further
reduced through the addition of fillers such as ground foam reclaim
materials, nano clays, carbon nano tubes, calcium carbonate, fly
ash, and the like, as well as corc dust, as this material can
provide for increased stability to reduce the overall density and
weight of the thermoset material. Further, thermoplastic foams,
when used in combination with a thermoset foam, will consume space
within a cushion structure, thereby displacing the heavier-weight,
more expensive thermoset materials, such as latex rubber foam, as
an example.
[0174] In this regard, FIG. 9 provides an exemplary chart 66 of
performance curves showing strain (deflection) under a given stress
(pressure) for different types of thermoplastic foam cushioning
structures to show the ability to engineer a cellular thermoplastic
foam profile to provide the desired firmness and support
characteristics in the unitary composite cushioning structure 60. A
performance curve 67 illustrates the result of testing of strain
for a given stress of an exemplary solid block of low density
polyethylene foam before being engineered into a particular
profile. Performance curves 68, 69 represent the result of testing
of strain for a given stress of two exemplary polyethylene foam
extrusion profiles formed from the low density polyethylene foam
represented by the performance curve 67. As illustrated in FIG. 9,
the low density polyethylene foam represented by the performance
curve 67 supports a higher load or stress than the two polyethylene
foam extrusion profiles represented by the performance curves 68,
69 of the same or similar density. Further, as illustrated in FIG.
9, the polyethylene foam extrusion profile represented by the
performance curve 68 illustrates strain for a given stress that has
a greater propensity to support a higher load than the exemplary
polyethylene foam extrusion profile represented by the performance
curve 69. Thus, a thermoplastic foam profile can be engineered to
be less supportive in the unitary composite cushioning structure 60
depending on the support characteristics for the unitary composite
cushioning structure 60 desired.
[0175] In this regard, embodiments disclosed herein allow a unitary
composite cushioning structure to be provided in a customized,
engineered profile by providing a customized, engineered
thermoplastic foam profile. A thermoset material is provided in the
engineered thermoplastic foam profile to provide the unitary
composite cushioning structure. In this manner, the shape and
resulting characteristics of the unitary composite cushioning
structure can be designed and customized to provide the desired
combination of resiliency and cushioning, and support
characteristics for any application desired. In this regard, FIG.
10 is a side view of a cross-section of another exemplary unitary
composite cushioning structure 70 to further illustrate, by
example, providing an engineered cellular thermoplastic foam
profile to provide the desired support characteristics and so that
the geometry of the unitary composite cushioning structure 60 can
be provided, as desired. As illustrated in FIG. 10, the unitary
composite cushioning structure 70 includes a cellular thermoplastic
foam profile 71 profiled in the form of a C-shaped structure having
an open chamber 72 disposed therein, formed as a result of
extruding a solid block of cellular thermoplastic foam. A base 77
is also extruded with the C-shaped structure as part of the
cellular thermoplastic foam profile 71 in this embodiment. The base
77 may provide a firm lower support layer for the unitary composite
cushioning structure 70, although such as is not required. Note,
however, there is not a requirement to provide the base 77 as part
of the cellular thermoplastic foam profile 71.
[0176] A thermoset material 73 is disposed in the open chamber 72
to provide the unitary composite cushioning structure 70. The
thermoset material 73 may be disposed in the open chamber 72 when
in a non-solid phase, as previously discussed. The thermoset
material 73 will eventually transform into a solid phase and
cohesively or adhesively bond with the cellular thermoplastic foam
profile 71 to form the unitary composite cushioning structure 70. A
stratum 74 is formed where an outer surface 75 of the thermoset
material 73 contacts or rests against an inner surface 76 of the
cellular thermoplastic foam profile 71 to cohesively or adhesively
bond the thermoset material 73 to the cellular thermoplastic foam
profile 71.
[0177] The cellular thermoplastic foam profile 71 may be a
closed-cell foam, open-cell foam, or partially open or closed-cell
foam. The material selected for providing the cellular
thermoplastic foam profile 71 may be from any thermoplastic
material desired, including those previously described. The
thermoset material 73 may also be cellular foam, and may be
closed-cell foam, open-cell foam, or partially open or closed-cell
foam. The material selected for providing the cellular thermoset
foam may be from any thermoset material desired, including those
previously described above.
[0178] The cellular thermoplastic foam profile 71, the thermoset
material 73, and the unitary composite cushioning structure 70 may
have the responses represented by the performance curves 36, 37,
and 38 in FIG. 2, respectively, as an example. For example, the
response shown by the performance curve 36 in Section I of FIG. 2
may be the response curve of the cellular thermoplastic foam
profile 71 illustrating an initial soft segment generated from the
lack of resistance exhibited by C-shaped legs 78 of the cellular
thermoplastic foam profile 71. The supportive segments of the
C-shaped legs 78 begin to engage with the bottom of the cellular
thermoplastic foam profile 71 and therefore are able to tolerate a
large load or pressure factor, as illustrated by the performance
curve 36 in Sections II and III in FIG. 2. The thermoset material
73 in the unitary composite cushioning structure 70 shows an
extremely soft segment in the performance curve 37 in Section I of
FIG. 2, with a lower load factor, until it becomes fully compressed
or collapsed onto itself in Section III in FIG. 2. As illustrated
by performance curve 37 in FIG. 2, the unitary composite cushioning
structure 70 shows an overall smooth transition between a smaller
pressure or load, as illustrated in Section I of FIG. 2,
progressing into a harder, more supportive structure, as
illustrated in Sections II and III of FIG. 2.
[0179] FIG. 11 is an exemplary chart 79 illustrating the recovery
characteristics of the unitary composite cushioning structure 70 of
FIG. 10 versus the recovery characteristics of the cellular
thermoplastic foam profile 71 of FIG. 5 individually over elapsed
time to illustrate the improved compression set characteristics of
the unitary composite cushioning structure 70. The test protocol
was to approximate the load exerted by a person lying prone on a
cushion structure, then to apply this constant strain for up to
eight (8) hours, then to measure the height recovery of the unitary
composite cushioning structure 70 over time. While the cellular
thermoplastic foam profile 71 does not recover within the same time
frame as the unitary composite cushioning structure 70 in this
example, it is important to note when the cellular thermoplastic
foam profile 71 is used in combination with the thermoset material
73, not only is there less initial set, but the rate of recovery is
more rapid. The rate of recovery feature of the unitary composite
cushioning structure 70 is important from the standpoint of
assuring that the unitary composite cushioning structure 70
returned or substantially returned to its original positioning, and
that sag of the unitary composite cushioning structure 70 was not
evident.
[0180] The unitary composite cushioning structure disclosed herein
can be disposed in any number of applications for providing support
to a load. Examples include seat assemblies, cushions, helmets,
mats, grips, packaging, and bolsters. The remainder of this
disclosure provides exemplary applications in which the unitary
composite cushioning structure or structures can be disposed to
provide the desired combined support and resiliency and cushioning
characteristics.
[0181] In this regard, FIG. 12 illustrates a block diagram of an
exemplary mattress 80. The mattress 80 is a well-known example of a
load bearing structure. The unitary composite cushioning structures
disclosed herein may be incorporated as replacements into any of
the components of the mattress 80 (also referred to as "mattress
components"), which are described below. Further, the unitary
composite cushioning structures disclosed herein may form a portion
of any of the components of the mattress 80. In this regard, the
mattress 80 may include a foundation 81. A base 82 may be disposed
on top of the foundation 81. The base 82 in this embodiment is a
horizontal mattress component, meaning it extends in the horizontal
(X-direction or Z-direction) extending generally parallel to an
expected load displaced in the mattress 80. The foundation 81 and
the base 82 may be selected to provide a firm support for a load
disposed on the mattress 80. Additional support layers 83A, 83B,
which may also be horizontal mattress components, may be disposed
on top of the base 82 to provide an internal support area. In order
to provide a firmer outer edge of the mattress 80, side or edge
supports 84 may be disposed around the perimeter of the base 82 and
foundation 81 and located adjacent to the support layers 83A, 83B
and a spring set or core 85. The side or edge supports 84 may be
characterized as vertical mattress components in this embodiment,
since the side or edge supports 84 extend upward in a Y direction
towards an expected load disposed on the mattress 80 and do not
extend substantially in the horizontal (X-direction or Z-direction)
of the mattress. The spring set or core 85, which may also be
characterized as vertical mattress components, may be provided as
an innerspring comprised of coils, which may be secured by a border
wire (not shown), or may be pocketed coils, as examples.
Alternatively, a core, such as comprised of latex or memory foam,
may be disposed on the support layers 83A, 83B. One or more comfort
layers 86A-86E may be disposed on top of the spring set or core 85
to complete the mattress 80. One embodiment of the mattress 80 in
FIG. 12 may be the mattress assembly 40 of FIGS. 4-6C.
[0182] As shown in FIGS. 13A-13B, in one embodiment, an exemplary
unitary composite cushioning structure 87 is the mattress member
54, 54(n). The mattress member 54, 54(n) may include a first layer
88, and a second layer 89. The first layer 88 of each mattress
member 54, 54(n) may be configured to transfer the load F to the
second layer 89. In other embodiments of the mattress assembly, the
mattress member 54, 54(n) may be orientated upside down in the
mattress assembly 40 and thereby the second layer 89 may be
configured to transfer the load F to the first layer 88 (see, for
example, FIG. 84A).
[0183] The first layer 88 may be configured to provide support. A
thickness T.sub.4 of the first layer 88 may be at least a half-inch
thick and at most ten-inches thick as shown in FIG. 13A. The first
layer 88 may include a portion 90 of a cellular thermoplastic foam
profile 91, including cellular thermoplastic material 104,
providing support characteristics and cushioning characteristics.
The first layer 88 may include a plurality of orifices 92 parallel
to a longitudinal plane P.sub.3 of the cellular thermoplastic foam
profile 91. The first layer 88 may include at least one support
member 93 disposed between any two of the plurality of orifices 92
of the first layer 88. Each support member 93 may include at least
one support surface 94 parallel to the load F. The first layer 88
may be produced integrally with the second layer 89, so that they
are one piece.
[0184] With continuing reference to FIG. 13A, the second layer 89
of the mattress member 54, 54(n) may be configured to provide
cushioning and support. The second layer 89 may comprise at least
two extensions 95 extending orthogonally from a longitudinal plane
P.sub.3 of the cellular thermoplastic foam profile 91. The at least
two extensions 95 may be a second portion of the cellular
thermoplastic foam profile 91. The second layer 89 may include an
open chamber 96 at least partially formed by the two extensions 95.
Each of the at least two extensions 95 may be in a shape of a
hollow cylinder 97 including an orifice 105 and a center axis
A.sub.2 parallel to the longitudinal plane P.sub.3 of the cellular
thermoplastic foam profile 91. The first layer 88 may be attached
to a portion 98 of each of the extensions 95 along an outer
tangential surface 99 of the shape of the hollow cylinder 97. The
shape of the hollow cylinder 97 allows an extension 95 of the
mattress member 54(n) under the load F to expand more easily into
an adjacent extension 95 of a mattress member 54(n+1) not under the
load F. Thus, improved motion isolation is provided relative to a
mattress assembly 40 without extensions 95 in the shape of the
hollow cylinder 97.
[0185] The second layer 89 may also include cellular thermoset
material 100 providing a resilient structure with cushioning
characteristics. The open chamber 96 of the second layer 89 may be
configured to receive the cellular thermoset material 100 and a
stratum 101 which may be part of the mattress member 54, 54(n). The
stratum 101 may be disposed between at least a portion 102 of the
cellular thermoplastic material 104 and at least a portion 103 of
the cellular thermoset material 100. The stratum 101 secures the at
least a portion 103 of the cellular thermoset material 100 to the
at least the portion 102 of the cellular thermoplastic material 104
to form the unitary composite cushioning structure 87. The
resulting unitary composite cushioning structure 87 exhibits a
combination of the support characteristics and the cushioning
characteristics and the resilient structure with cushioning
characteristics when the unitary composite structure 87 is placed
under the load F.
[0186] The stratum 101 may be configured to be formed by disposing
a non-solid phase of the cellular thermoset material 100 on the
cellular thermoplastic foam profile 91 with the cellular thermoset
material 100 undergoing a transition into a solid phase to form a
bond with the cellular thermoplastic material 104.
[0187] The mattress member 54 as part of the transition layer 51
depicted in FIG. 5 may extend along the length of the mattress
assembly 40 between the side support members 43(3) and 43(4). In
alternative embodiments the mattress member 54 may extend the full
length of the mattress assembly 40. In other embodiments the
mattress member 54 may extend the width W of the mattress assembly
40 or between the side support members 43, 43(2).
[0188] As shown in FIG. 13B, the mattress member 54, 54(n) may
include at least one cross-cut 106 at least partially through the
second layer 89 to create segments 107. The at least one cross-cut
106 may be disposed orthogonal to the longitudinal axis A.sub.3 of
the at least one mattress member 54. The at least one cross-cut 106
may be configured to improve motion transfer between the comfort
layer 41 and the support layer 53. A cross-cut 106 may also improve
motion isolation to help prevent the load F from disturbing the
mattress assembly 40 in a portion of the mattress not disposed in
the direction of the load F.
[0189] Other embodiments related to cross-cuts 106 are also
possible. FIG. 13C depicts an embodiment of the mattress member 54B
without cross-cuts 106. This embodiment reduces manufacturing time
and expense by eliminating the cross-cut manufacturing operation.
FIG. 13D shows an embodiment of the mattress member 54C wherein the
cross-cuts 106 may go all the way through the mattress member 54,
54(n) to create the segments 107 that may be separated by a
distance D.sub.1 or abut each other in the mattress assembly 40.
This embodiment may be used to maximize motion transfer and motion
isolation.
[0190] As another example, FIG. 14 is a perspective view of an
exemplary composite cushioning structure 108 provided in a comfort
layer that can be disposed in a mattress or mattress assembly 40.
In this embodiment, the composite cushioning structure 108 is
comprised of a plurality of the unitary composite cushioning
structures 70 in FIG. 10. As illustrated in FIG. 14, each unitary
composite cushioning structure 70 is provided of length L.sub.1.
Length L.sub.1 could be any length. The length L.sub.1 could be the
entire length L.sub.2 of the composite cushioning structure 108
such that only one unitary composite cushioning structure 70 is
provided in the depth direction Z, if desired, as illustrated in
FIG. 14. In this embodiment, five (5) unitary composite cushioning
structures 70 are provided in the depth direction Z in the
composite cushioning structure 108. Rear sides 109 of the unitary
composite cushioning structures 70 are abutted to front sides 110
of other unitary composite cushioning structures 70 to provide a
contiguous cushioning structure in the depth direction Z. In this
manner, the unitary composite cushioning structures 70 can be
provided in any number to build a composite cushioning structure
108 of infinite depth. Rows of unitary composite cushioning
structures 70 are also aligned in the X direction as illustrated in
FIG. 14 to expand the sleep or seat surface in the X direction to
any length L.sub.3 desired.
[0191] With continuing reference to FIG. 14, the unitary composite
cushioning structures 70 are spaced apart in length L.sub.4 in the
X direction about their centerlines, as illustrated in FIG. 14, to
provide the desired cushioning characteristics. The farther the
unitary composite cushioning structures 70 are spaced apart, the
less cushioning support is provided overall in the composite
cushioning structure 108. The length L.sub.4 can be varied in this
manner to provide the desired cushioning characteristics in the
composite cushioning structure 108 desired.
[0192] Also in this embodiment, the bases 77 are produced integral
with the unitary composite cushioning structures 70 as illustrated
in FIG. 10, but the bases 77 could be provided separately. End
sides 110A, 110B of the composite cushioning structure 108 could be
provided by cutting the unitary composite cushioning structures 70
disposed on ends, as illustrated in FIG. 14. Further, the composite
cushioning structure 108 in FIG. 14 could be produced of continuous
length in the X or Z direction and spiral wound for storage. The
wound composite cushioning structure 108 could be unwound and cut
to the desired length represented by L.sub.2 or L.sub.3 in FIG.
14.
[0193] The material choices and support characteristics of the
unitary composite cushioning structures 70 can be varied, if
desired, to provide different support characteristics in the
composite cushioning structure 108 to provide different zones or
regions of support characteristics. For example, the composite
cushioning structure 108 may be designed to support different loads
in different portions of the composite cushioning structure 108
such that it may be desired to provide firmer or greater support in
certain unitary composite cushioning structures 70 than others. For
example, certain unitary composite cushioning structures 70 may be
located where head, torso, and foot loads will likely be
displaced.
[0194] As another example, FIG. 15 is a perspective view of another
exemplary composite cushioning structure 111 that is also comprised
of a plurality of unitary composite cushioning structure 70 in FIG.
10. However, in this embodiment, the unitary composite cushioning
structures 70 are offset from each other in both the X and Z
directions. The unitary composite cushioning structures 70 are
offset from each other as provided in FIG. 14. However, the rear
sides 109 and the front sides 110 of adjacent unitary composite
cushioning structures 70 disposed in the Z direction are offset
from each other as illustrated in FIG. 15. In this manner the
amount of surface area in contact between the rear sides 109 and
the front sides 110 of adjacent unitary composite cushioning
structures 70 is less so that motion in one unitary composite
cushioning structure 70 does not impart, or less significantly
imparts, force onto an adjacent unitary composite cushioning
structure 70 in the Z direction. A gap may be provided between
adjacent unitary composite cushioning structures 70 disposed in the
Z direction so that there is no contact between any of unitary
composite cushioning structures 70, if desired. Alternatively, a
gap may be provided between adjacent unitary composite cushioning
structures 70 disposed in the Z direction even if adjacent unitary
composite cushioning structures 70 are not offset from each other
in the Z direction, as illustrated in FIG. 14, to provide motion
isolation. The characteristics discussed above for composite
cushioning structures 108 in FIG. 14 can also be provided in the
composite cushioning structures 111 in FIG. 15.
[0195] As another example, FIGS. 16A and 16B are perspective and
side views, respectively, of an exemplary unitary composite
cushioning structure 112 provided in a comfort layer that can be
disposed in a mattress or mattress assembly. In this embodiment,
the unitary composite cushioning structure 112 is comprised of a
plurality of extruded cellular thermoplastic foam profiles
113A-113J. The material choices and support characteristics of the
cellular thermoplastic foam profiles 113A-113J can be varied, if
desired, to provide different support characteristics in the
unitary composite cushioning structure 112 to provide different
zones or regions of support characteristics. For example, the
unitary composite cushioning structure 112 may be designed to
support different loads in different portions of the unitary
composite cushioning structure 112 in order to provide firmer or
greater support in certain cellular thermoplastic foam profiles
113A-113J than others. For example, certain cellular thermoplastic
foam profiles 113A-113J may be located where head, torso, and foot
loads will likely be displaced.
[0196] The cellular thermoplastic foam profiles 113A-113J in this
embodiment each include open chambers 114 that are configured to
receive a thermoset material 115 to provide the unitary composite
cushioning structure 112, as illustrated in FIGS. 16A and 16B.
Stratums 116 are disposed therebetween where the thermoset material
115 is cohesively or adhesively bonded to the cellular
thermoplastic foam profiles 113A-113J. The cushioning properties of
the thermoset material 115 can be selected and be different for the
cellular thermoplastic foam profiles 113A-113J, if desired, to
provide variations in cushioning characteristics of the unitary
composite cushioning structure 112. FIG. 17 illustrates the unitary
composite cushioning structure 112 provided as a support layer
disposed on top of an innerspring 117 as part of a mattress
assembly 118. In this example, certain of the cellular
thermoplastic foam profiles 113D, 113E are designed to provide
lumbar support for the mattress assembly 118. Other variations can
be provided. For example, as illustrated in FIG. 18, convolutions
119 can be disposed in the thermoset material 115 to provide
designed resiliency and support characteristics. The convolutions
119 are not disposed at the stratum 116 in this embodiment.
[0197] FIG. 19 is another exemplary cross-section profile of a
mattress 120 employing a unitary composite cushioning structure 121
for a bedding or seating cushioning application. In this
embodiment, a base 122 is extruded as part of a cellular
thermoplastic foam profile 123 provided in the unitary composite
cushioning structure 121 for the mattress 120. The unitary
composite cushioning structure 121 is provided from a composite of
the cellular thermoplastic foam profile 123 and a thermoset
material 124 disposed in open channels 125 of the cellular
thermoplastic foam profile 123, with a stratum 126 disposed
therebetween. The open channels 125 are provided as extensions 127
that extend generally orthogonally from a longitudinal plane
P.sub.5 of the cellular thermoplastic foam profile 123. Further, in
this embodiment, convolutions 128 are provided in the thermoset
material 124, similar to those provided in FIG. 18 (element 119).
The cellular thermoplastic foam profile 123 and the thermoset
material 124 may be provided according to any of the previously
described examples and materials. The unitary composite cushioning
structure 121 may be provided according to any of the examples and
processes described above.
[0198] As previously discussed above, other components of a
mattress may also be provided with a unitary composite cushioning
structure according to embodiments disclosed herein. For example,
FIG. 20 illustrates a portion of the base 122 in FIG. 19, but
provided as a unitary composite cushioning structure 129 comprised
of a cellular thermoplastic foam profile 130 comprised of a
thermoplastic material 131 having closed channels 132 disposed
therein. A thermoset material 133 is disposed in the closed
channels 132 and cohesively or adhesively bonded to the cellular
thermoplastic foam profile 130 at a stratum 134 disposed
therebetween. The unitary composite cushioning structure 129 and
the cellular thermoplastic foam profile 130 and thermoset material
133 may be provided according to any of the previously described
examples and materials. The unitary composite cushioning structure
129 could be provided as other supports in the mattress 80,
including but not limited to side, edge, or corner supports. The
embodiments of unitary composite cushioning structures described
thus far have provided an outer thermoplastic material with a
thermoset material disposed therein. However, the embodiments
disclosed herein are not limited to this configuration. The unitary
composite cushioning structure could be formed such that a
thermoset material is disposed on the outside, partially or fully,
of a thermoplastic material. For example, the thermoset material
could partially or fully encapsulate the thermoplastic
material.
[0199] In this regard, FIGS. 21A-45 illustrate side profiles of
alternative exemplary embodiments of unitary composite cushioning
structures that involve different geometric configurations and
different thermoplastic foam and thermoset material profiles. The
thermoplastic could be a foamed polymer from a group including, but
not limited to polyethylene, an EVA, a TPO, a TPV, a PVC, a
chlorinated polyethylene, a styrene block copolymer, an EMA, an
ethylene butyl acrylate (EBA), and the like, as examples. These
thermoplastic materials may also be inherently resistant to
microbes and bacteria, making them desirable for use in the
application of cushioning structures. These materials can be made
biodegradable and fire retardant through the use of additive master
batches. The thermoplastic could be foamed to an approximate cell
size of 0.25 to 2.0 mm, although such is not required or limiting
to the scope of the embodiments disclosed herein.
[0200] The thermoset foam in these examples could be foamed latex
rubber, which is hypo-allergenic and breathes to keep you warm in
the winter and cool in the summer. Further, bacteria, mildew, and
mold cannot live in foamed latex rubber. The thermoset foam can be
obtained in emulsified form, frothed to introduce air into the
emulsion to reduce density, and then cured (vulcanized) to remove
additional waters and volatiles as well as to set the material to
its final configuration. The cost of foamed latex rubber could be
further reduced through the addition of fillers such as ground foam
reclaim materials, nano clays, carbon nano tubes, calcium
carbonate, flyash and the like. Corc dust may also be used as a
filler because this material can provide for increased stability to
the thermoset material to while reducing the overall density,
weight, and/or cost of the thermoset material. A stratum may be
disposed between interfaces of different materials of thermoplastic
and thermoset materials.
[0201] For example, FIG. 21A illustrates a side profile of another
exemplary composite cushioning structure 170. The composite
cushioning structure 170 is comprised of five separate members,
each of which can be unitary composite cushioning structures in
their own right. A base member 172 is provided that may be a
unitary composite cushioning structure. For example, a surrounding
material 174 may be disposed completely around a core material 176
to provide the base member 172. Core material is material that can
be disposed partially or wholly internal within a structure. The
surrounding material 174 may be a cellular thermoplastic material
and the core material 176 a thermoset material, or vice versa. To
provide cushioning support in the Y direction, additional unitary
composite cushioning structures 178A-178D are disposed above the
base member 172 in the Y direction. Each unitary composite
cushioning structure 178A-178D may comprise a surrounding material
180A-180D disposed around a core material 182A-182D to provide the
unitary composite cushioning structures 178A-178D. The surrounding
materials 180A-180D may be a cellular thermoplastic material and
the core materials 182A-182D a thermoset material, or vice versa.
The unitary composite cushioning structures 178A-178D can each be
provided of different material composites or arrangements.
[0202] Two unitary composite cushioning structures 178A, 178B are
stacked on top of each other. The unitary composite cushioning
structure 178B may be secured to the base member 172 adhesively or
cohesively. The unitary composite cushioning structure 178A may be
secured to the unitary composite cushioning member 178B adhesively
or cohesively. The arrangement is provided for the unitary
cushioning structures 178C and 178D, as illustrated in FIG. 21A.
The unitary composite cushioning structures 178A, 178B and 178C,
178D are arranged such that a minimum gap of length L5 is provide
therebetween. The number of stacked unitary cushioning structures
178, their stacked height, their material composition, and the
length L5 all determine the overall cushioning and support
characteristics provided by the composite cushioning structure
170.
[0203] As another example, FIG. 21B illustrates a side profile of
another exemplary composite cushioning structure 190. The composite
cushioning structure 190 is comprised of five separate members like
the composite cushioning structure 170 in FIG. 21A, each of which
can be unitary composite cushioning structures in their own right.
The base member 172 in FIG. 21A is provided. To provide cushioning
support in the Y direction, additional unitary composite cushioning
structures 192A-192D are disposed above the base member 172 in the
Y direction. Each unitary composite cushioning structure 192A-192D
may comprise a surrounding material 194A-194D disposed completely
around intermediate material 196A-196D, which is disposed
completely around a core material 198A-198D to provide the unitary
composite cushioning structures 192A-192D. The surrounding
materials 194A-194D may be comprised of a cellular thermoplastic
material or a thermoset material. The intermediate materials
196A-196D may be comprised of a cellular thermoplastic material or
a thermoset material. The core materials 198A-198D may be comprised
of a cellular thermoplastic material or a thermoset material. The
materials provided in the surrounding material 194, the
intermediate material 196, and the core material 198 may be such
that adjacent materials alternate between thermoplastic material
and thermoset material to provide the desired cushioning and
support characteristics. Note that intermediate material 196 may
not be included inside the surrounding material 194 to provide a
hollow portion where the intermediate material 196 is disposed in
FIG. 21B. Also note that core material 198 may not be included
inside the intermediate material 196 to provide a hollow portion
where the core material 198 is disposed in FIG. 21B.
[0204] As another example, FIG. 22 illustrates a side profile of
another exemplary composite cushioning structure 200. The composite
cushioning structure 200 is comprised of a first layer 202 of
cylindrical unitary composite cushioning structures 204 aligned
side-by-side in the X direction to provide a base cushioning and
support structure. The unitary composite cushioning structures 204
may be secured to each other adhesively or cohesively. Each unitary
composite cushioning structure 204 may comprise a surrounding
material 206 disposed completely around a core material 208 to
provide the unitary composite cushioning structures 204. The
surrounding materials 206 may be comprised of a cellular
thermoplastic material and the core materials 208 comprised of
thermoset material, or vice versa. Alternatively, the core material
208 may not be included to provide a hollow portion disposed within
the surrounding material 206.
[0205] With continuing reference to FIG. 22, a second layer 210 of
unitary composite cushioning structures 212 are disposed
side-by-side and collectively on top of the unitary composite
cushioning structures 204 in the Y direction. The second layer 210
of unitary composite cushioning structures 212 may be adhesively or
cohesively secured to the first layer 202 of unitary composite
cushioning structures 204. The unitary composite cushioning
structures 212 may be secured to each other adhesively or
cohesively. The unitary composite cushioning structures 212 may
comprised of open profiles of surrounding materials 214 disposed in
a U-shape or C-shape and not closed with a core material 216
disposed therein as illustrated in FIG. 22 to provide more
influence of the core material 216 in the cushioning and support
characteristics of the unitary cushioning structure 200. Note that
core materials 208 and/or 216 may not be included inside the
surrounding materials 206, 214, respectively, to provide hollow
portions where the core materials 208 and/or 216 are disposed in
FIG. 22.
[0206] As another example, FIG. 23 illustrates a side profile of
another exemplary composite cushioning structure 220. The composite
cushioning structure 220 is comprised of a first layer 222 of open
unitary composite cushioning structures 224 aligned side-by-side in
the X direction to provide a base cushioning and support structure.
The unitary composite cushioning structures 224 may be secured to
each other adhesively or cohesively. Each unitary composite
cushioning structure 224 may comprise a surrounding material 226 in
an open profile disposed partially around a core material 228 to
provide the unitary composite cushioning structures 224 and to
provide more influence of the core material 228. The surrounding
materials 226 may be comprised of a cellular thermoplastic material
and the core materials 228 comprised of thermoset material, or vice
versa. Alternatively, the core material 228 may not be included to
provide a hollow portion disposed within the surrounding material
226.
[0207] With continuing reference to FIG. 23, unitary composite
cushioning structures 232 are disposed side-by-side as a second
layer 230, collectively on top of the unitary composite cushioning
structures 224 in the Y direction. The second layer 230 of unitary
composite cushioning structures 232 may be adhesively or cohesively
secured to the first layer 222 of unitary composite cushioning
structures 224. The unitary composite cushioning structures 232 may
be secured to each other adhesively or cohesively. The unitary
composite cushioning structures 232 may comprised of open profiles
of surrounding materials 234 with a core material 236 disposed
therein as illustrated in FIG. 23 to provide more influence of the
core material 236 in the cushioning and support characteristics of
the composite cushioning structure 220. Note that core materials
228 and/or 236 may not be included inside the surrounding materials
226, 234, respectively, to provide hollow portions where the core
materials 228 and/or 236 are disposed in FIG. 23.
[0208] As another example, FIG. 24 illustrates a side profile of
another exemplary unitary composite cushioning structure 240. The
unitary composite cushioning structure 240 is comprised of a first
layer 242 of a closed unitary composite cushioning structure 244 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 244 comprises an outer material 245
with openings 246 disposed therein with a core material 248
disposed in the openings 246 to provide the unitary composite
cushioning structures 244. The outer material 245 may be extruded
with the openings 246 present, or the openings 246 may be portions
of the outer material 245 cut from internal portions. The outer
material 245 may be comprised of a cellular thermoplastic material
and the core materials 248 comprised of thermoset material, or vice
versa. Alternatively, the core material 248 may not be included to
provide a hollow portion disposed within the outer material
245.
[0209] With continuing reference to FIG. 24, a second layer 250 of
cushioning structures 252 provided in the form of C-shaped members
are disposed in pairs, side-by-side and cohesively or adhesively
attached to each other, or provided as a single member on top of
the first layer 242 in the Y direction. The second layer 250 of
cushioning structures 252 may be adhesively or cohesively secured
to the first layer 242 of the unitary composite cushioning
structures 244.
[0210] As another example, FIG. 25A illustrates the same first
layer 242 of a closed unitary composite cushioning structure 244 in
FIG. 24 to provide a base cushioning and support structure. A
second layer 262 of cushioning structures 264 is provided in the
form of closed cylindrical-shaped members cohesively or adhesively
attached on top of the unitary composite cushioning structure 244
in the first layer 242 in the Y direction. Each unitary composite
cushioning structure 264 may comprise a surrounding material 266
disposed completely around a core material 268 to provide the
unitary composite cushioning structures 264. The surrounding
materials 266 may be comprised of a cellular thermoplastic material
and the core materials 268 comprised of thermoset material, or vice
versa. Alternatively, the core material 268 may not be included to
provide a hollow portion disposed within the surrounding material
266. FIG. 25B illustrates a unitary composite cushioning structure
280 similar to the unitary composite cushioning structure 260 in
FIG. 25B. The second layer 282 is comprised of the unitary
composite cushioning structures 266 stacked on top of each other
above the unitary composite cushioning structure 244 in pairs to
provide additional height in the unitary composite cushioning
structure 280 and to provide more influences from the unitary
composite cushioning structure 280.
[0211] As another example, FIG. 26A illustrates a side profile of
another unitary composite cushioning structure 290. The unitary
composite cushioning structure 290 comprises unitary composite
cushioning members 292A, 292B provided as separate members and
arranged side-by-side and adhesively or cohesively attached at
interface 294. Unitary composite cushioning members 292A, 292B each
provide an open profile with openings 294A, 294B disposed in an
outer material 295A, 295B. The profile of the neck portions 297A,
297B define the size and shape of the openings 294A, 294B. Instead
of core material being disposed inside the openings 294A, 294B,
core material 296A, 296B is disposed in interior openings 298A,
298B. The outer materials 295A, 295B may be comprised of a cellular
thermoplastic material and the core materials 296A, 296B comprised
of thermoset material, or vice versa. Alternatively, the core
materials 296A, 296B may not be included to provide a hollow
portion disposed within the outer materials 295A, 295B. FIG. 26B
illustrates a unitary composite cushioning structure 300 similar to
the unitary composite cushioning structure 290 in FIG. 26B.
However, the profile of openings 304A, 304B are defined by the
profile of different shaped neck portions 306A, 306B disposed in
the outer materials 302A, 302B.
[0212] As another example, FIG. 27A illustrates a side profile of
another unitary composite cushioning structure 310. The unitary
composite cushioning structure 310 includes an outer material 312
having the closed profile. The profile of the unitary composite
cushioning structure 310 is comprised of a base portion 314 and a
head portion 316 having neck portions 318A, 318B disposed
therebetween. The profile of the neck portions 318A, 318B defines
the size and shape of the head portion 316. A core material 320 may
be disposed inside an opening 322 disposed in the outer material
312 to provide the unitary composite cushioning structure 310. The
outer material 312 may be comprised of a cellular thermoplastic
material and the core material 320 comprised of thermoset material,
or vice versa. Alternatively, the core material 320 may not be
included to provide a hollow portion disposed within the outer
material 312.
[0213] As another example, FIG. 27B illustrates a side profile of
another unitary composite cushioning structure 310. The unitary
composite cushioning structure 320 includes an outer material 323
having an open profile with opening 324. The profile of the unitary
composite cushioning structure 310 is comprised of a base portion
326 and a head portion 328 having neck portions 330A, 330B disposed
therebetween. The profile of the neck portions 330A, 330B defines
the size and shape of the head portion 328. A core material 332 may
be disposed inside the base portion 326. The base portion 326 may
be comprised of a cellular thermoplastic material and the core
material 332 comprised of thermoset material, or vice versa. An
intermediate material 334 may be disposed inside the head portion
328, which is disposed around a core material 336, as illustrated
in FIG. 27B. The outer material 322, the intermediate material 334,
and the core material 336 may be comprised of a cellular
thermoplastic material or thermoset materials, in any combination
of each.
[0214] FIGS. 27C and 27D illustrate the same head portion 328 in
FIG. 27B, but with different base portion arrangements. In FIG.
27C, a unitary composite cushioning structure 310' is provided that
provides core material 332A, 332B only in smaller, separate
designated portions of the base portion 326. In the unitary
composite cushioning structure 310'' in FIG. 27D, the base portion
340 is provided of a different profile with a base material 323
that does not include openings for disposition of a core
material.
[0215] As another example, FIG. 28 illustrates a side profile of
another exemplary unitary composite cushioning structure 350. The
unitary composite cushioning structure 350 is comprised of a first
layer 352 of a closed unitary composite cushioning structure 354 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 354 comprises an outer material 356
with openings 358, 360, 362 disposed therein with a core material
364 disposed in the openings 358, 360, 362 to provide the unitary
composite cushioning structure 354. The outer material 356 may be
extruded with the openings 358, 360, 362 present, or the openings
358, 360, 362 may be portions of the outer material 356 cut from
internal portions. The outer material 356 may be comprised of a
cellular thermoplastic material and the core materials 364
comprised of thermoset material, or vice versa. Alternatively, the
core material 364 may not be included to provide a hollow portion
disposed within the outer material 356.
[0216] With continuing reference to FIG. 28, a second layer 366 of
a cushioning structure 368 provided in the form of C-shaped member
with an open profile is disposed on top of the first layer 352 in
the Y direction either cohesively or adhesively. A core material
370 may be disposed within the cushioning structure 368 if desired.
The cushioning structure may be comprised of a cellular
thermoplastic material and the core materials 370 comprised of
thermoset material, or vice versa. Alternatively, the core material
370 may not be included to provide a hollow portion disposed within
the cushioning structure 368.
[0217] As another example, FIG. 29A illustrates a side profile of
another exemplary unitary composite cushioning structure 380. The
unitary composite cushioning structure 380 is comprised of a first
layer 382 of closed unitary composite cushioning structures 383A,
383B arranged side-by-side and cohesively or adhesively attached to
each other to provide a base cushioning and support structure. Each
unitary composite cushioning structure 383A, 383B comprises an
outer material 384A, 384B with openings 386A, 386B, 388A, 388B,
390A, 390B disposed therein with a core material 392A, 392B
disposed in the openings 386A-390B to provide the unitary composite
cushioning structures 383A, 383B. The outer materials 384A, 384B
may be extruded with the openings 386A-390B present, or the
openings 386A-390B may be portions of the outer materials 384A,
384B cut from internal portions. The outer materials 384A, 384B may
be comprised of a cellular thermoplastic material and the core
materials 392A, 392B comprised of thermoset material, or vice
versa. Alternatively, the core materials 392A, 392B may not be
included to provide a hollow portion disposed within the outer
materials 384A, 384B.
[0218] With continuing reference to FIG. 29A, a second layer 394 of
cushioning structures 396A, 396B arranged side-by-side and each
provided in the form of C-shaped member with an open profile is
disposed on top of the first layer 382 in the Y direction either
cohesively or adhesively. Core materials 398A, 398B may be disposed
within the cushioning structures 396A, 396B if desired. The
cushioning structures 396A, 396B may be comprised of a cellular
thermoplastic material and the core materials 398A, 398B comprised
of thermoset material, or vice versa. Alternatively, the core
materials 398A, 398B may not be included to provide a hollow
portion disposed within the cushioning structures 396A, 396B.
[0219] As another example, FIG. 29B illustrates a side profile of
another exemplary unitary composite cushioning structure 400. The
unitary composite cushioning structure 400 is similar to the
unitary composite cushioning structure 380 in FIG. 29B, except that
the first layer provides a modified profile. In this regard, the
unitary composite cushioning structure 400 is comprised of a first
layer 402 of closed unitary composite cushioning structures 403A,
403B arranged side-by-side and cohesively or adhesively attached to
each other to provide a base cushioning and support structure. Each
unitary composite cushioning structure 403A, 403B comprises an
outer material 404A, 404B with openings 406A, 406B, 408A, 408B,
410A, 410B disposed therein with a core material 412A, 412B
disposed in the openings 406A-410B to provide the unitary composite
cushioning structures 403A, 403B. The outer materials 404A, 404B
may be extruded with the openings 406A-410B present, or the
openings 406A-410B may be portions of the outer materials 404A,
404B cut from internal portions. The outer materials 404A, 404B may
be comprised of a cellular thermoplastic material and the core
materials 412A, 412B comprised of thermoset material, or vice
versa. Alternatively, the core materials 412A, 412B may not be
included to provide a hollow portion disposed within the outer
materials 404A, 404B.
[0220] With continuing reference to FIG. 29B, a second layer 414 of
cushioning structures 416A, 416B arranged side-by-side and each
provided in the form of C-shaped member with an open profile is
disposed on top of the first layer 402 in the Y direction either
cohesively or adhesively. Core materials 418A, 418B may be disposed
within the cushioning structures 416A, 416B if desired. The
cushioning structures 416A, 416B may be comprised of a cellular
thermoplastic material and the core materials 418A, 418B comprised
of thermoset material, or vice versa. Alternatively, the core
materials 418A, 418B may not be included to provide a hollow
portion disposed within the cushioning structures 416A, 416B.
[0221] As another example, FIG. 30A illustrates a side profile of
another exemplary unitary composite cushioning structure 420. The
unitary composite cushioning structure 420 is comprised of two
cushioning structures 422A, 422B arranged side-by-side and
cohesively or adhesively attached to each other at interfaces 424A,
424B. Each unitary composite cushioning structure 422A, 422B
comprises an outer material 426A, 426B having open profiles with
openings 428A, 428B disposed therein. The cushioning structures
422A, 422B each provide closed openings 430A, 430B in corners of
the outer material 426A, 426B, as illustrated in FIG. 30A. A core
material 432A, 432B can be disposed in the openings 430A, 430B to
provide the unitary composite cushioning structures 422A, 422B. The
outer materials 426A, 426B may be extruded with the openings
430A-430B present, or the openings 430A-430B may be portions of the
outer materials 426A, 426B cut from internal portions. The outer
materials 426A, 426B may be comprised of a cellular thermoplastic
material and the core materials 432A, 432B comprised of thermoset
material, or vice versa. Alternatively, the core materials 432A,
432B may not be included to provide a hollow portion disposed
within the outer materials 426A, 426B.
[0222] As another example, FIG. 30B illustrates a side profile of
another exemplary unitary composite cushioning structure 440. The
unitary composite cushioning structure 440 is comprised of two
cushioning structures 442A, 442B arranged side-by-side and
cohesively or adhesively attached to each other at interfaces 444A,
444B. Each unitary composite cushioning structure 442A, 442B
comprises an outer material 446A, 446B having open profiles with
openings 448A, 448B disposed therein. The cushioning structures
442A, 442B provide a closed opening 450 as a result of the
cushioning structures 442A, 442B being secured side-by-side to each
other as illustrated in FIG. 30B. A core material 452A, 452B can be
disposed in the openings 448A, 448B to provide the unitary
composite cushioning structures 442A, 442B. A core material 454 may
also be disposed in the opening 450. The outer materials 446A, 446B
may be comprised of a cellular thermoplastic material and the core
materials 452A, 452B, and/or 454 comprised of thermoset material,
or vice versa. Alternatively, the core materials 452A, 452B, 454
may not be included to provide a hollow portion disposed within the
outer materials 446A, 446B.
[0223] As another example, FIG. 31 illustrates a side profile of
another exemplary unitary composite cushioning structure 460. The
unitary composite cushioning structure 460 is comprised of two
cushioning structures 462A, 462B arranged side-by-side and
cohesively or adhesively attached to each other at interface 464.
Each unitary composite cushioning structure 462A, 462B comprises an
outer material 466A, 466B having open profiles with openings 468A,
468B disposed therein. The cushioning structures 462A, 462B each
provide round-shaped closed openings 470A, 470B in corners of the
outer material 466A, 466B, as illustrated in FIG. 31. A core
material 472A, 472B can be disposed in the openings 470A, 470B to
provide the unitary composite cushioning structures 462A, 462B. The
outer materials 466A, 466B may be extruded with the openings 470A,
470B present, or the openings 470A, 470B may be portions of the
outer materials 466A, 466B cut from internal portions. The outer
materials 466A, 466B may be comprised of a cellular thermoplastic
material and the core materials 472A, 472B comprised of thermoset
material, or vice versa. Alternatively, the core materials 472A,
472B may not be included to provide a hollow portion disposed
within the outer materials 466A, 466B.
[0224] As another example, FIG. 32 illustrates a side profile of
another exemplary unitary composite cushioning structure 480. The
unitary composite cushioning structure 480 is comprised of a
cushioning structure 482. The unitary composite cushioning
structure 482 comprises an outer material 484 having an open
profile with an opening 486 disposed therein. The cushioning
structure 482 provides rectangular-shaped closed openings 488A,
488B, 488C, 488D in corners of the outer material 484, as
illustrated in FIG. 32. A core material 490A-490D can be disposed
in the openings 488A-488D to provide the unitary composite
cushioning structure 480. The outer material 484 may be extruded
with the openings 486, 488A-488D present, or the openings 486,
488A-488D may be portions of the outer material 484 cut from
internal portions. The outer material 484 may be comprised of a
cellular thermoplastic material and the core materials 490A-490D
comprised of thermoset material, or vice versa. Alternatively, the
core materials 490A-490D may not be included to provide a hollow
portion disposed within the outer material 484.
[0225] As another example, FIG. 33 illustrates a side profile of
another exemplary unitary composite cushioning structure 470. The
unitary composite cushioning structure 470 is comprised of a first
layer 472 of a closed unitary composite cushioning structure 474 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 474 comprises an outer material 476
with openings 478 disposed therein. A core material 480 may be
disposed in the openings 478 if desired. The outer material 476 may
be extruded with the openings 478 present. The outer material 476
may be comprised of a cellular thermoplastic material and the core
material 480 comprised of thermoset material, or vice versa.
Alternatively, the core material 480 may not be included to provide
a hollow portion disposed within the outer material 476.
[0226] With continuing reference to FIG. 33, a second layer 483 of
closed cushioning structures 484A, 484B comprised of an outer
materials 485A, 485B having openings 488A, 488B disposed therein
with extension members 486A, 486B disposed on top of the first
layer 472 in the Y direction either cohesively or adhesively. A
core material 490A, 490B may be disposed within the openings 488A,
488B of the cushioning structures 484A, 484B if desired. The
cushioning structures 484A, 484B may be comprised of a cellular
thermoplastic material and the core materials 490A, 490B comprised
of thermoset material, or vice versa. Alternatively, the core
material 490A, 490B may not be included to provide a hollow portion
disposed within the cushioning structures 484A, 484B.
[0227] As another example, FIG. 34 illustrates a side profile of
another exemplary unitary composite cushioning structure 500 that
contains the same second layer 483 as in FIG. 33. However, a first
layer 502 of the unitary composite cushioning structure 500 is
comprised of an alternative closed unitary composite cushioning
structure 504 to provide a base cushioning and support structure.
The unitary composite cushioning structure 504 comprises an outer
material 506 with openings 508 disposed therein. The openings 508
are semi-circular shaped in this embodiment. A core material 510
may be disposed in the openings 408 if desired. The outer material
506 may be extruded with the openings 508 present. The outer
material 506 may be comprised of a cellular thermoplastic material
and the core material 510 comprised of thermoset material, or vice
versa. Alternatively, the core material 510 may not be included to
provide a hollow portion disposed within the outer material 506.
Circular voids 512A, 512B are disposed on ends 514A, 514B of the
first layer 502.
[0228] As another example, FIG. 35A illustrates a side profile of
another exemplary unitary composite cushioning structure 520. The
unitary composite cushioning structure 520 is comprised of a first
layer 522 of a closed unitary composite cushioning structure 524 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 524 comprises an outer material 526
with openings 528 disposed therein. A core material 530 may be
disposed in the openings 528 if desired. The outer material 526 may
be extruded with the openings 528 present. The outer material 526
may be comprised of a cellular thermoplastic material and the core
material 530 comprised of thermoset material, or vice versa.
Alternatively, the core material 530 may not be included to provide
a hollow portion disposed within the outer material 526. With
continuing reference to FIG. 35A, a second layer 532 of an open
cushioning structure 534 comprised of an outer material 536 having
a structure 538 with an opening 540 disposed therein.
[0229] As another example, FIG. 35B illustrates a side profile of
another exemplary unitary composite cushioning structure 542. The
unitary composite cushioning structure 542 is comprised of a first
layer 544 of a closed unitary composite cushioning structure 546 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 546 comprises an outer material 548
with openings 550 disposed therein. A core material 552 may be
disposed in the openings 550 if desired. The outer material 548 may
be extruded with the openings 550 present. The outer material 548
may be comprised of a cellular thermoplastic material and the core
material 552 comprised of thermoset material, or vice versa.
Alternatively, the core material 552 may not be included to provide
a hollow portion disposed within the outer material 548. With
continuing reference to FIG. 35B, a second layer 554 of an open
cushioning structure 556 comprised of an outer material 558 having
a structure 562 with an opening 540 disposed therein.
[0230] As another example, FIG. 35C illustrates a side profile of
another exemplary unitary composite cushioning structure 570. The
unitary composite cushioning structure 570 is comprised of a first
layer 572 of a closed unitary composite cushioning structure 574 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 574 comprises an outer material 576
with openings 578, 580 disposed therein. Openings 578 are of
complementary geometry different from the geometry of opening 580.
A core material 582 may be disposed in the openings 578, 580 if
desired. The outer material 574 may be extruded with the openings
578, 580 present. The outer material 576 may be comprised of a
cellular thermoplastic material and the core material 582 comprised
of thermoset material, or vice versa. Alternatively, the core
material 582 may not be included to provide a hollow portion
disposed within the outer material 576. With continuing reference
to FIG. 35C, a second layer 584 comprised of open cushioning
structures 586A, 586B are provided each comprised of an outer
material 588A, 588B, wherein the opening cushioning structures
586A, 586B are C-shaped and disposed opposed from each other in the
unitary composite cushioning structure 570.
[0231] As another example, FIG. 36 illustrates a side profile of
another exemplary unitary composite cushioning structure 590. The
unitary composite cushioning structure 590 is comprised of a first
layer 592 of a closed composite cushioning structure 594A to
provide a base cushioning and support structure. The unitary
composite cushioning structure 594A comprises an outer material 596
arranged to provide three (3) side-by-side circular structures
598A-598C each having openings 600A-600C disposed therein. A core
material 602A-602C may be disposed in the openings 598A-598C if
desired. The outer material 596 may be extruded with the openings
600A-600C present as one piece. The outer material 596 may be
comprised of a cellular thermoplastic material and the core
material 602A-602C comprised of thermoset material, or vice versa.
Alternatively, the core material 602A-602C may not be included to
provide a hollow portion disposed within the openings 600A-600C.
With continuing reference to FIG. 36, a second layer 604 comprised
of a composite cushioning structure 594B that is the same as
provided in the first layer 592 is provided and disposed on top of
the first layer 592 and secured either cohesively or
adhesively.
[0232] As another example, FIG. 37 illustrates a side profile of
another exemplary unitary composite cushioning structure 610. The
unitary composite cushioning structure 610 is comprised of a first
layer 612 of a closed composite cushioning structure 614 to provide
a base cushioning and support structure. The unitary composite
cushioning structure 614 comprises an outer material 616 arranged
to provide side-by-side triangular structures 618 each having
openings 620 disposed therein. A core material 622 may be disposed
in the openings 620 if desired. The outer material 616 may be
extruded with the openings 620 present as one piece. The outer
material 616 may be comprised of a cellular thermoplastic material
and the core material 622 comprised of thermoset material, or vice
versa. Alternatively, the core material 622 may not be included to
provide a hollow portion disposed within the openings 620.
[0233] With continuing reference to FIG. 37, a closed unitary
composite cushioning structure 626 is provided and comprised of a
second layer 624 to provide an additional cushioning and support
structure. The unitary composite cushioning structure 626 comprises
an outer material 628 arranged to provide side-by-side elliptical
structures 630 each having openings 632 disposed therein. A core
material 634 may be disposed in the openings 632 if desired. The
outer material 628 may be extruded with the openings 632 present as
one piece. The outer material 628 may be comprised of a cellular
thermoplastic material and the core material 634 comprised of
thermoset material, or vice versa. Alternatively, the core material
634 may not be included to provide a hollow portion disposed within
the openings 632. By providing the side-by-side elliptical
structures 630, additional openings 636 are provided when the
unitary composite cushioning structure 626 is disposed on top of
the unitary composite cushioning structure 614 and attached thereto
either adhesively or cohesively.
[0234] As another example, FIG. 38A illustrates a side profile of
another exemplary unitary composite cushioning structure 640. The
unitary composite cushioning structure 640 is comprised of a first
layer 643 of a closed composite cushioning structure 644A to
provide a base cushioning and support structure. The unitary
composite cushioning structure 640 comprises an outer material 646
arranged to provide side-by-side triangular structures 648A-648C
each having openings 650A-650C disposed therein. A core material
652A-652C may be disposed in the openings 650A-650C if desired. The
outer material 646 may be extruded with the openings 650A-650C
present as one piece. The outer material 646 may be comprised of a
cellular thermoplastic material and the core material 652A-652C
comprised of thermoset material, or vice versa. Alternatively, the
core material 652A-652C may not be included to provide a hollow
portion disposed within the openings 650A-650C. With continuing
reference to FIG. 38A, a second layer 654 is comprised of a
composite cushioning structure 644B that is the same as the
structure 644A provided in the first layer 642, but flipped 180
degrees and disposed on top of the first layer 643 and secured
either cohesively or adhesively. In this manner, additional
openings 656A, 656B are disposed in the unitary composite
cushioning structure 640. FIG. 38B illustrates a unitary composite
cushioning structure 640' that is the same as the unitary composite
cushioning structure 640, except that ends 658A, 658B are closed
off to form additional openings 660A, 660B
[0235] As another example, FIG. 39A illustrates a side profile of
another exemplary unitary composite cushioning structure 670. The
unitary composite cushioning structure 670 is comprised of a first
layer 672 of a closed unitary composite cushioning structure 674 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 674 comprises an outer material 676
with openings 678, 680 disposed therein. A core material 682 may be
disposed in the openings 678, 680 if desired. The outer material
676 may be extruded with the openings 678, 680 present as one
piece. The outer material 676 may be comprised of a cellular
thermoplastic material and the core material 682 comprised of
thermoset material, or vice versa. Alternatively, the core material
682 may not be included to provide a hollow portion disposed within
the outer material 676. With continuing reference to FIG. 39C, a
second layer 684 comprised of cushioning structures 686, 688A,
688B, each comprised of the same outer material 676. The opening
cushioning structures 688A, 688B are C-shaped and disposed opposed
from each other in the unitary composite cushioning structure 670
on each side of the closed cushioning structure 686.
[0236] As another example, FIG. 39B illustrates a side profile of
another exemplary unitary composite cushioning structure 690. The
unitary composite cushioning structure 690 is comprised of a first
layer 692 of a closed unitary composite cushioning structure 694 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 694 comprises an outer material 696
with openings 698, 700, 702 disposed therein. A core material 704
may be disposed in the openings 698, 700, 702 if desired. The outer
material 696 may be extruded with the openings 698, 700, 702
present as one piece. The outer material 696 may be comprised of a
cellular thermoplastic material and the core material 704 comprised
of thermoset material, or vice versa. Alternatively, the core
material 704 may not be included to provide a hollow portion
disposed within the outer material 696. With continuing reference
to FIG. 39B, a second layer 706 is comprised of cushioning
structures 708, 710A, 710B, each comprised of the same outer
material 712. The opening cushioning structures 710A, 710B are
C-shaped and disposed opposed from each other in the unitary
composite cushioning structure 690 on each side of the closed
cushioning structure 708. FIG. 39C illustrates a unitary composite
cushioning structure 690' that is the same as unitary composite
cushioning structure 690 in FIG. 39B, except the cushioning
structure 708 is not provided and instead an alternative cushioning
structure 714 is provided. FIG. 39D illustrates a unitary composite
cushioning structure 690'' that is the same as unitary composite
cushioning structure 690 in FIG. 39A, except the cushioning
structure 708 is not provided, thus leaving an opening 716.
[0237] As another example, FIGS. 40A and 40B illustrate a
perspective and a side profile of another exemplary unitary
composite cushioning structure 720. The unitary composite
cushioning structure 720 is comprised of a plurality of unitary
cushioning structures 722. The unitary cushioning structures 722
are attached to each other either cohesively or adhesively in a
side-by-side arrangement or extruded as one piece, wherein each
comprises an outer material 724 with openings 726, 728 disposed
therein. A core material 730 may be disposed in either or both of
the openings 726, 728 if desired, as shown in one unitary
cushioning structure 722 in FIG. 40A. Each unitary cushioning
structure 722 may be extruded with the openings 726, 728 present as
one piece. The outer material 724 may be comprised of a cellular
thermoplastic material and the core material 730 comprised of
thermoset material, or vice versa. Alternatively, the core material
730 may not be included to provide hollow portions disposed within
the openings 726, 728.
[0238] As another example, FIG. 40C illustrates a side profile of
another exemplary unitary composite cushioning structure 731. The
unitary composite cushioning structure 731 is comprised of a
plurality of unitary cushioning structures 732. The unitary
cushioning structures 732 are attached to each other either
cohesively or adhesively in a side-by-side arrangement or extruded
as one piece, wherein each comprises an outer material 734 with
openings 736, 738 disposed therein. A core material 740 may be
disposed in either or both of the openings 736, 738 if desired, as
shown in FIG. 40C. Each unitary cushioning structure 732 may be
extruded with the openings 736, 738 present as one piece. The outer
material 734 may be comprised of a cellular thermoplastic material
and the core material 740 comprised of thermoset material, or vice
versa. Alternatively, the core material 740 may not be included to
provide hollow portions disposed within the openings 736, 738.
Additional openings 742 are formed by the arrangement of the
unitary cushioning structures 732 being disposed side-by-side.
[0239] As another example, FIG. 40D illustrates a side profile of
another exemplary unitary composite cushioning structure 750. The
unitary composite cushioning structure 750 is comprised of a
plurality of unitary cushioning structures 752. The unitary
cushioning structures 752 are attached to each other either
cohesively or adhesively in a side-by-side arrangement or extruded
as one piece, wherein each comprises an outer material 754 with
openings 756A, 756B, 758 disposed therein. A core material 760 may
be disposed in either or both of the openings 756A, 756B, 758 if
desired, as shown in FIG. 40D. Each unitary cushioning structure
752 may be extruded with the openings 756A, 756B, 758 present as
one piece. The outer material 754 may be comprised of a cellular
thermoplastic material and the core material 760 comprised of
thermoset material, or vice versa. Alternatively, the core material
760 may not be included to provide hollow portions disposed within
the openings 756A, 756B, 758. Additional openings 762 are formed by
the arrangement of the unitary cushioning structures 732 being
disposed side-by-side.
[0240] As another example, FIG. 41A illustrates a side profile of
another exemplary unitary composite cushioning structure 770. The
unitary composite cushioning structure 770 is comprised of a first
layer 772 of a closed unitary composite cushioning structure 774 to
provide a base cushioning and support structure. The unitary
composite cushioning structure 774 comprises an outer material 776
with openings 778, 780 disposed therein. A core material 782 may be
disposed in the openings 778, 780 if desired. The outer material
776 may be extruded with the openings 778, 780 present as one
piece. The outer material 776 may be comprised of a cellular
thermoplastic material and the core material 782 comprised of
thermoset material, or vice versa. Alternatively, the core material
782 may not be included to provide a hollow portion disposed within
the outer material 776. With continuing reference to FIG. 41A, a
second layer 784 comprised of cushioning structure 786A, 786B are
provided, each comprised of the same outer material 776, wherein
the opening cushioning structures 786A, 786B are L-shaped and
disposed opposed from each other in the unitary composite
cushioning structure 770 on each side of the unitary composite
cushioning structure 770 as one-piece with the first layer 772.
FIG. 41B illustrates a unitary composite cushioning structure 770'
that is the same as unitary composite cushioning structure 770 in
FIG. 41A, except the cushioning structures 786A, 786B are moved
inward towards the center of the unitary composite cushioning
structure 770' from the unitary composite cushioning structure 770
in FIG. 41A.
[0241] As another example, FIG. 42 illustrates a side profile of
another exemplary unitary composite cushioning structure 790. The
unitary composite cushioning structure 790 is comprised of a first
layer 792 of a closed unitary composite cushioning structures 794
to provide a base cushioning and support structure. The unitary
composite cushioning structures 794 comprise an outer material 796
with openings 798 disposed therein. A core material 800 may be
disposed in the openings 798 if desired. The outer material 796 may
be extruded with the openings 798 present as one piece. The outer
material 796 may be comprised of a cellular thermoplastic material
and the core material 800 comprised of thermoset material, or vice
versa. Alternatively, the core material 800 may not be included to
provide a hollow portion disposed within the outer material 796.
With continuing reference to FIG. 42, a second layer 802 comprised
of cushioning structure 804 comprised of an outer material 806 and
disposed on top of the cushioning structures 794 in the first layer
792. Openings 810, 812 are disposed in the cushioning structure
804. A core material may be disposed in the openings 810, 812, if
desired.
[0242] As another example, FIG. 43 illustrates a side profile of
another exemplary unitary composite cushioning structure 820. The
unitary composite cushioning structures 820 are comprised of a
first layer 824 of a closed unitary composite cushioning structures
844 to provide a base cushioning and support structure. The unitary
composite cushioning structures 844 comprise an outer material 846
with openings 848 disposed therein. A core material 850 may be
disposed in the openings 848 if desired. The outer material 846 may
be comprised of a cellular thermoplastic material and the core
material 800 comprised of thermoset material, or vice versa.
Alternatively, the core material 850 may not be included to provide
a hollow portion disposed within the outer material 846. With
continuing reference to FIG. 43, a second layer 852 comprised of
cushioning structures 854 disposed between a first layer 824 and a
third layer 856 of the same closed unitary composite cushioning
structures 844. The cushioning structures 854 are each comprised of
a solid material 858, which may be either a cellular thermoplastic
material or thermoset material. FIG. 44 illustrates a side profile
of another exemplary unitary composite cushioning structure 820'
that is the same as the unitary composite cushioning structure 820
in FIG. 43, except that the cushioning structure 854 is provided as
a single piece of material and not separately cushioning
structures.
[0243] As another example, FIG. 45 illustrates a side profile of
another exemplary unitary composite cushioning structure 860. The
unitary composite cushioning structure 860 is comprised of a
plurality of unitary cushioning structures 862. The unitary
cushioning structures 862 are arranged in a side-by-side
arrangement such that an opening 864 is created therebetween. A
core material 866 may be disposed in opening 864. Each unitary
cushioning structure 862 may be extruded. A material 868 used to
form the plurality of unitary cushioning structures 862 may be
comprised of a cellular thermoplastic material and the core
material 866 may be comprised of thermoset material, or vice
versa.
[0244] In another embodiment, FIG. 46 illustrates an exemplary
embodiment of a unitary composite cushioning structure 870
comprised of one or more thermoplastic closed and/or open cell foam
872 embedded in and/or substantially surrounded by a closed and/or
open cell thermoset foam 874. The unitary composite cushioning
structure 870 may be used as a cushion structure. As illustrated
herein, the thermoplastic foam 872 is provided as an engineered
cylindrically-shaped cellular thermoplastic foam profile 876
geometrically designed in a vertical profile. The cellular
thermoplastic foam profile 876 provides a controlled deformation
support characteristic and stability to the unitary composite
cushioning structure 870. To form the unitary composite cushioning
structure 870, the cellular thermoplastic foam profile 876 is
surrounded by the thermoset foam 874, which in this example is a
foamed latex rubber. The thermoset foam 874 may be elastomeric. The
foamed latex rubber as the thermoset foam 874 may be manufactured
from an emulsion of latex rubber, as one possible example. An inner
cylindrical chamber 875 is provided in the cellular thermoplastic
foam profile 876, which can either be left void or a thermoset
material (not shown), such as foamed latex rubber for example, may
be poured inside the inner cylindrical chamber 875 to provide
additional offset of compression.
[0245] A curing process can be performed on the unitary composite
cushioning structure 870 to set and cohesively or adhesively bond
the thermoplastic foam 872 and the thermoset foam 874 to each
other. The thermoset foam 874 is not chemically bonded to the
thermoplastic foam 872 in this embodiment, but chemical bonding can
be provided. Further, a chemical bonding agent can be mixed in with
a thermoplastic material before or during the foaming process to
produce the thermoplastic foam 872, or when the thermoset foam 874
is poured into the inner cylindrical chamber 875 to provide a
chemical bond with the thermoset foam 874 during the curing
process.
[0246] The unitary composite cushioning structure 870 has a
geometry that can be used in a vertical position relative to an
overall structure providing individual spring qualities to an
otherwise unitary or monolithic structure that is stable due to the
thermoplastic foam 872 and exhibits excellent offset of compression
set due to the thermoset foam 874. For example, the unitary
composite cushioning structure 870 may be used like a spring and in
place of metal or other types of springs or coils. Further, a
thermoplastic foam may be provided to encapsulate the thermoset
foam 874 to provide additional support to the unitary composite
cushioning structure 870.
[0247] For example, the unitary composite cushioning structure 870
may be used as a foam spring for use in a knock down or buildable
mattress. Also, this unitary composite cushioning structure 870 can
be used to add support into specific regions of a cushion structure
to satisfy individual demands, such as lumbar and/or head and foot
support as examples, depending on the type of cushion structure
used while providing the tactile cushioning characteristic desired.
The thermoset foam 874 has cushioning abilities and can be soft or
firm depending on formulations and density, but without
individualized resilient support zones as can be obtained from
using the engineered geometrically supportive profiles of the
thermoplastic foam 872. This engagement of the thermoplastic foam
872 and the thermoset foam 874 has the ability to recover over long
periods of repeated deformations.
[0248] In this unitary composite cushioning structure 870, the
thermoplastic foam 872 could be a foamed polymer from a group
including, but not limited to polyethylene, an EVA, a TPO, a TPV, a
PVC, a chlorinated polyethylene, a styrene block copolymer, an EMA,
an ethylene butyl acrylate (EBA), and the like, as examples. These
thermoplastic materials may also be inherently resistant to
microbes and bacteria, making them desirable for use in the
application of cushioning structures. These materials can be also
made biodegradable and fire retardant through the use of additive
master batches. The thermoplastic could be foamed to an approximate
cell size of 0.25 to 2.0 mm, although such is not required or
limiting to the scope of the embodiments disclosed herein.
[0249] The thermoset foam 874 in this example is foamed latex
rubber and is hypo-allergenic, and breathes to keep you warm in the
winter and cool in the summer. Further, bacteria, mildew, and mold
cannot live in foamed latex rubber. The thermoset foam 874 is
generally obtained in emulsified form and is frothed to introduce
air into the emulsion to reduce density, and is then cured
(vulcanized) to remove additional waters and volatiles as well as
to set the material to its final configuration. Latex, however, may
only be foamed (density reduction) down to a 5 lb. or 80 kg/m.sup.3
range without sacrificing other desirable features, such as tear
and tensile strength. However, when engineered with the inner foam,
which can be foamed to densities down to 1 lb. and/or 16 kg/m.sup.3
effectively, the inner foam is used in combination with the foamed
latex rubber and can displace the heavier weight of the foamed
latex rubber. Further cost reductions of the foamed latex can be
achieved through the addition of fillers into the foamed latex
rubber such as ground foam reclaim materials, nano clays, carbon
nano tubes, calcium carbonate, flyash and the like, as well as corc
dust, as this material can provide for increased stability to the
thermoset material while reducing the overall density, weight,
and/or cost of the thermoset material.
[0250] In another embodiment, as illustrated in FIG. 47, another
unitary composite cushioning structure 890 may be manufactured. In
this embodiment, the unitary composite cushioning structure 890
also has a vertical geometric profile similar to the unitary
composite cushioning structure 870 of FIG. 46. This allows for
controlled deformation relative to the unitary composite cushioning
structure 890 providing individual spring qualities to an otherwise
monolithic structure. However, in this embodiment, an inner
thermoset foam 892 is provided and geometrically designed in a
vertical profile surrounded by an outer thermoplastic foam 894
provided in a cellular thermoplastic foam profile 896. A stratum
898 is disposed therebetween wherein the outer thermoplastic foam
894 is cohesively or adhesively bonded to the inner thermoset foam
892.
[0251] The inner thermoset foam 892 may be manufactured from an
emulsion of latex rubber as an example. The unitary composite
cushioning structure 890 has a geometry that can be used in a
vertical position relative to an overall structure providing
individual spring qualities to an otherwise monolithic structure.
For example, the unitary composite cushioning structure 890 may be
used like a spring and in place of metal or other types of springs.
For example, one aspect would be the use of the unitary composite
cushioning structure 890 as a pocketed coil assembly for a mattress
or other application in a similar fashion to the current metal coil
spring variety and covered with the appropriate cloth structure in
similar fashion to the metal coil spring design. The materials and
application possibilities discussed for the unitary composite
cushioning structure 870 of FIG. 46 are also possible for the
unitary composite cushioning structure 890 of FIG. 47 and thus will
not be repeated here.
[0252] In the unitary composite cushioning structure 890 of FIG.
47, the outer thermoplastic foam 894 can be hypo-allergenic, and
can breathe to retain heat in the winter and to release heat in the
summer. The inner thermoset foam 892 can be obtained in emulsified
form and is frothed to introduce air into the emulsion to reduce
density, and is then cured (vulcanized) to remove additional waters
and volatiles as well as to set the material to its final
configuration. The other possibilities for the thermoset foams
discussed above are also possible for the inner thermoset foam 892
of FIG. 47 and thus will not be repeated here.
[0253] The inner thermoset foam 892 could be a foamed polymer from
a polyethylene, an EVA, a TPO, a TPV, a PVC, a chlorinated
polyethylene, a styrene block copolymer, an EMA, an ethylene butyl
acrylate (EBA), and the like, as examples, or any of the other
recited thermoplastics previously discussed. These thermoplastic
materials may also be inherently resistant to microbes and
bacteria, making them desirable for use in the application of
cushioning structures. These materials can be also made
biodegradable and fire retardant through the use of additive master
batches. The thermoplastic could be foamed to an approximate cell
size of 0.25 to 2.0 mm, although such is not required or limiting
to the scope of the embodiments disclosed herein. These foam
springs of thermoplastic open or closed cell foam can be
interspersed at some frequency throughout the cushion structure.
The foam springs may be formed as an array. Further, a thermoset
material, including but not limited to latex rubber, may also be
provided to encapsulate the cellular thermoplastic foam profile 896
of the unitary composite cushioning structure 890 to provide
additional offset of compression.
[0254] FIG. 48 illustrates the unitary composite cushioning
structure 890 of FIG. 47, but the inner thermoset foam 892
additionally includes a filler material, which in this example is
corc dust 900. The corc dust 900 adds stability to the inner
thermoset foam 892 without changing the cushioning characteristics
and benefits of the thermoplastic material and reduces the weight
of the unitary composite cushioning structure 890. For example, the
amount of corc dust 900 added per unit of latex rubber may be 25%
to 75%, although this range is only exemplary and is not limiting
to the scope of the embodiments disclosed herein.
[0255] FIG. 49 illustrates yet another embodiment of a structure
910 that can be used to form one or more unitary composite
cushioning structures 912, including any of the embodiments
disclosed herein. In this embodiment, a plurality of unitary
composite cushioning structures 912 is provided in an array 914.
Each unitary composite cushioning structure 912 is comprised of an
outer foam piece 916 comprised of a foamed thermoplastic material.
The outer foam pieces 916 have internal chambers 918 that can be
filled with a thermoset material. Further, corc dust or other
filler may be added to the thermoset material poured inside the
internal chambers 918 of the outer foam pieces 916 to provide the
unitary composite cushioning structure 912. The outer foam pieces
916 can also be encapsulated either internally, externally, or both
with a cellular thermoset foam or other thermoset material.
[0256] FIG. 50 illustrates yet another embodiment of a mattress
assembly 920 that can incorporate the unitary composite cushioning
structures like the unitary composite cushioning structures 870 or
890 previously described above. In this embodiment, the unitary
composite cushioning structures 870 or 890 are used to replace
traditional coils or springs in an innerspring 922 as part of the
mattress assembly 920. The unitary composite cushioning structures
870 or 890 are disposed inside and adjacent edge or side support
profiles 924. The edge or side support profiles 924 may also be
provided as a unitary composite cushioning structure according to
any of the embodiments described herein and may also be
encapsulated either internally, externally, or both with a
thermoset material or foam. The edge or side support profiles 924
may provide an anti-roll off feature on a mattress or other
bedding, as illustrated in the example in FIG. 50.
[0257] Other examples for the thermoplastic foam profiles that may
be provided according to any of the embodiments disclosed herein
for providing a unitary composite cushioning structure are
illustrated in FIG. 51. As illustrated therein, thermoplastic foam
profiles 930A-930M may be constructed out of a thermoplastic
material including foam. The thermoplastic foam profiles 930A-930M
may have one or more chambers 932A-932M, which may be open or
closed and which can either be left void or filled with a thermoset
material to provide a unitary composite cushioning structure. The
thermoplastic foam profiles 930A-930M can also be encapsulated with
a thermoset material in addition to or in lieu of being filled with
a thermoset material as part of a composite structure. All other
possibilities for thermoplastic foam profiles, thermoset materials,
and unitary composite cushioning structures discussed above are
also possible for the thermoplastic foam profiles 930A-930M in FIG.
51.
[0258] Other examples for the thermoplastic foam profiles that may
be provided according to any of the embodiments disclosed herein
for providing a unitary composite cushioning structure are
illustrated in FIGS. 52A-52F. As illustrated therein, thermoplastic
foam profiles 934A-934F may be constructed out of a thermoplastic
material including foam. The thermoplastic foam profiles 934A-934F
may have one or more chambers 936A-936F, which may be open or
closed and which can either be left void or filled with a thermoset
material to provide a unitary composite cushioning structure. The
thermoplastic foam profiles 934A-934F can also be encapsulated with
a thermoset material in addition to or in lieu of being filled with
a thermoset material as part of a composite structure. All other
possibilities for thermoplastic foam profiles, thermoset materials,
and unitary composite cushioning structures discussed above are
also possible for the thermoplastic foam profiles 934A-934F in FIG.
51. In FIG. 52B, the thermoplastic foam profile 934B contains vent
holes 935 that allow for a thermoset material to be disposed in the
chamber 936B and air to escape from inside the chamber 936B. In
FIG. 52C, the thermoplastic foam profile 934C provides two internal
chambers 936C for a thermoset material to be disposed. In FIG. 52E,
the thermoplastic foam profile 934E contains a high density
thermoset core 936E in one embodiment that may be co-extruded with
a low density thermoset material exterior.
[0259] FIG. 53A illustrates examples of foam springs 940 that may
be according to any of the embodiments disclosed herein for
providing a unitary composite cushioning structure. In this
example, an outer material 942 is disposed around a spring 944,
which may be for example a metal spring. The outer material 942 may
be a cellular thermoplastic material and the spring 944 may be made
from a thermoset material, or vice versa. FIG. 53B illustrates
other examples of foam springs 946 that may be according to any of
the embodiments disclosed herein for providing a unitary composite
cushioning structure. In this example, an outer material 948 is
disposed around the foam spring 930K previously illustrated in FIG.
51K. The outer material 948 may be a cellular thermoplastic
material and the foam spring 930K made from a thermoset material,
or vice versa. Also, the outer material 948 may be disposed inside
the openings 932K disposed in the foam spring 930K.
[0260] FIG. 54A illustrates an example of a foam spring arrangement
950 comprised of a plurality of foam springs 952 arranged in an
array that may be according to any of the embodiments disclosed
herein for providing a unitary composite cushioning structure. Side
cuts 953 may be disposed between adjacent foam springs 952 to
further control cushioning and support characteristics. FIG. 54B
illustrates another example of a foam spring arrangement 954
comprised of a plurality of the foam springs 930J arranged in an
array that may be according to any of the embodiments disclosed
herein for providing a unitary composite cushioning structure. Side
cuts 955 may be disposed between adjacent foam springs 952 to
further control cushioning and support characteristics. FIG. 54C
illustrates another example of a foam spring arrangement 956
comprised of a plurality of foam springs 958 arranged in an array
that may be according to any of the embodiments disclosed herein
for providing a unitary composite cushioning structure. Side cuts
957 may be disposed between adjacent foam springs 958 to further
control cushioning and support characteristics.
[0261] As previously discussed, the unitary composite cushioning
structures can be employed to provide bedding or seating
arrangements or assemblies. In this regard, FIG. 55A illustrates a
plurality of the foam spring arrangements 956 that are arranged
side-by-side to provide a mattress assembly 960. FIG. 55B
illustrates the mattress assembly 960 in FIG. 55A, but with
mattress assembly covers 962A, 962B disposed on the top and bottom
of the foam spring arrangements 956 to further complete the
mattress assembly 960. FIG. 56 illustrates another embodiment of a
mattress assembly 964 that may be provided using foam springs that
are unitary composite cushioning structures according to any of the
embodiments disclosed herein. In this example, the mattress
assembly 964 is formed from foam spring arrangements 966 that are
comprised of the foam springs 934A illustrated in FIG. 52. A base
968 is provided that contains a matrix of openings 970 configured
to support the outer diameter of the foam springs 934A to retain
the foam springs 934A in designated areas. A top 972 is also
provided that contains a similar matrix of openings 974 to retain
the top portions of the foam springs 934A in the mattress assembly
964. Lastly, a cover portion 976 can be disposed on top of the top
972 to close off access to the foam springs 934A and/or limit the
movement of the foam springs 934A and/or to spread loads onto the
foam springs 934A.
[0262] Each of the unitary composite cushioning structure profiles
discussed above will have a certain strain (i.e., deflection) for a
given stress (i.e., pressure) characteristic based on the composite
composition and its geometry. One goal may be to determine if the
strain vs. stress characteristic for a given unitary composite
cushioning structure profiles is representative of a baseline or
target strain vs. stress characteristic when determining the
likability or feasibility of a given unitary composite cushioning
structure profile for cushioning applications, including but not
limited to bedding and seating applications. For example, FIG. 57
illustrates a graph 1000 illustrating stress for a given strain for
various unitary composite cushioning structures previously
described above with regard to a pressure limit 1002. In this
example, the pressure limit 1002 is the theoretical pressure that
should not be exceeded in order to provide comfort as perceived to
an average person. In this example, the pressure limit is 4.3 kilo
Pascals (kPa) of pressure or 32 mm Hg, which is theorized as the
maximum pressure limit before blood vessels and capillaries in a
human start to become restricted. Thus, it is desired to provide a
cushioning structure that provides less pressure for a given stress
that the pressure limit 1002. In this example, a characteristic
curve 1004 is shown for pure polyurethane.
[0263] As can been seen in chart 1000 in FIG. 57, the pressure in
the characteristic curve 1004 does not exceed the pressure limit
1002 until a percentage strain beyond approximately 65% is reached.
Characteristic curves 1006, 1008 are for the unitary composite
cushioning structure 70 with integrated base 77 in FIG. 10 without
the thermoset material 73 included. Characteristic curves 1010,
1012 are for the unitary composite cushioning structure 70 with
integrated base 77 in FIG. 10 that includes the thermoset material
73. As can be seen, the unitary composite cushioning structure 70
with integrated base 82 exceeds the pressure limit 1002 at a much
lower strain percentage than the pure polyurethane (as shown by
characteristic curve 1004). One goal may be to provide a unitary
composite cushioning structure that has a stress vs. strain
characteristic curve that is similar to polyurethane or
viscoelastic, but in a lower density form by use of a thermoplastic
material, which may also result in lower cost.
[0264] In this regard, FIG. 58 illustrates a graph 1020
illustrating stress for a given strain for various unitary
composite cushioning structures previously described above with
regard to a baseline characteristic curve 1022. In this example,
the pressure limit 1022 is the theoretical pressure that should not
be exceeded in order to provide comfort as perceived to an average
person. In this example, characteristic curves 1024, 1026, 1028,
1030, 1032, 1034, 1036 are for different variations of polyurethane
foam. Characteristic curves 1038 and 1040 are for two density
variations of viscoelastic material. Characteristic curve 1042 is
for latex. Characteristic curves 1044, 1046 are for unitary
composite cushioning structures. As can be seen, the characteristic
curve 1044 is closer to the characteristic curves 1024-1040 in
terms of not exceeding the pressure limit 1022 until a greater
percentage of strain is reached.
[0265] As another example, FIG. 59 illustrates a graph 1050
illustrating stress for a given strain for various unitary
composite cushioning structures previously described above with
regard to a baseline characteristic curve 1052. In this example,
the pressure limit 1052 is the theoretical pressure that should not
be exceeded in order to provide comfort as perceived to an average
person. In this example, characteristic curves 1054, 1056 are for
unitary composite cushioning structures.
[0266] As another example, FIG. 60 illustrates a graph 1060
illustrating stress for a given strain for various unitary
composite cushioning structures previously described above with
regard to a baseline characteristic curve 1062. In this example,
the pressure limit 1062 is the theoretical pressure that should not
be exceeded in order to provide comfort as perceived to an average
person. In this example, characteristic curves 1064, 1066, 1068,
1070, 1072, 1074, 1076, 1078 are for unitary composite cushioning
structures.
[0267] As another example, FIG. 61 illustrates a graph 1080
illustrating stress for a given strain for various unitary
composite cushioning structures previously described above with
regard to a baseline characteristic curve 1082. In this example,
the pressure limit 1082 is the theoretical pressure that should not
be exceeded in order to provide comfort as perceived to an average
person. In this example, characteristic curves 1084, 1086, 1088,
1090, 1092, 1094, 1096, 1100 are for unitary composite cushioning
structures.
[0268] As another example, FIG. 62 illustrates a graph 1110
illustrating stress for a given strain for various unitary
composite cushioning structures previously described above with
regard to a baseline characteristic curve 1112. In this example,
the pressure limit 1112 is the theoretical pressure that should not
be exceeded in order to provide comfort as perceived to an average
person. In this example, characteristic curves 1114, 1116, 1118,
1120 are for unitary composite cushioning structures.
[0269] As another example, FIG. 63 illustrates a graph 1130
illustrating stress for a given strain for various unitary
composite cushioning structures previously described above with
regard to a baseline characteristic curve 1132. In this example,
the pressure limit 1132 is the theoretical pressure that should not
be exceeded in order to provide comfort as perceived to an average
person. In this example, characteristic curves 1134, 1136, 1138,
1140, 1142 are for unitary composite cushioning structures. The
characteristic curves 1138, 1140, and 1142 represent a density of
25.0 kg/m3, thickness of 8 to 10 mm, and foam cell size of 1.2 mm,
+-0.2 mm. The characteristic curves 1134, 1136 represent a density
of 24.4 kg/m3, thickness of 7 mm, and foam cell size of 0.9 mm,
+-0.2 mm.
[0270] As another example, FIG. 64 illustrates a graph 1150
illustrating stress for a given strain for various unitary
composite cushioning structures previously described above with
regard to a baseline characteristic curve 1152. In this example,
the pressure limit 1152 is the theoretical pressure that should not
be exceeded in order to provide comfort as perceived to an average
person. In this example, characteristic curves 1154, 1156, 1158,
1160, 1162, 1164, 1166 are for unitary composite cushioning
structures.
[0271] FIG. 65 illustrates a bar graph 1170 of exemplary support
factors for various cushioning structures, including viscoelastic,
latex, and unitary composite cushioning structures. The support
factors were analyzed to determine the amount of support provided
by different cushioning structures, including unitary composite
cushioning structures, for comparison purposes. Support factor in
this example is the ratio of compression force deflection (CFD),
which is the force exerted by a 10,000 mm2 area on a sample after a
sixty second hold while compressing, to a given strain. As
illustrated in FIG. 65, the support factors for pink viscolelastic
1172, white viscoelastic 1174, latex 1176, polyurethane foam 1178,
and the unitary composite cushioning structures 1180, 1182, 1184,
1186, which correspond to the unitary composite cushioning
structure profiles.
[0272] FIG. 66 illustrates a bar graph 1190 of exemplary percentage
reduction in height vs. deflection cycles for various cushioning
structures, including polyurethane and unitary composite cushioning
structures. The percentage reduction in height was determined for
two different cycles: 40,000 cycles and 80,000 cycles. A cycle is a
deflection of the cushioning structure. Reduction in height can be
used to analyze and compare compression set. As illustrated in FIG.
66, a control polyurethane 1192 and two unitary composite
cushioning structures 1194, 1196 were tested with the results
provided in bar graph 1190.
[0273] FIG. 67 illustrates a bar graph 1200 of exemplary percentage
stiffness reduction in height vs. deflection cycles for various
cushioning structures, including polyurethane and unitary composite
cushioning structures. The percentage stiffness reduction was
determined for two different cycles: 40,000 cycles and 80,000
cycles. A cycle is a deflection of the cushioning structure.
Stiffness reduction can be used to analyze and compare support
characteristics. As illustrated in FIG. 67, a control polyurethane
1202 and two unitary composite cushioning structures 1204, 1206
were tested with the results provided in bar graph 1200.
[0274] FIG. 68 illustrates a graph 1210 of exemplary mean reduction
in height vs. deflection cycles for various cushioning structures,
including polyurethane and unitary composite cushioning structures,
using a stork twin cities rollator testing standard. The mean
reduction in height was determined for two different cycles: 50,000
cycles and 100,000 cycles. A cycle is a deflection of the
cushioning structure. Stiffness reduction can be used to analyze
and compare support characteristics. As illustrated in FIG. 68, a
control polyurethane 1212 and three unitary composite cushioning
structures 1214, 1216, 1218 were tested with the results provided
in bar graph 1210.
[0275] FIG. 69 illustrates a graph 1220 of exemplary mean change in
firmness vs. deflection cycles for various cushioning structures,
including polyurethane and unitary composite cushioning structures
using a stork twin cities rollator testing standard. The mean
percentage change in firmness was determined for two different
cycles: 50,000 cycles and 100,000 cycles. A cycle is a deflection
of the cushioning structure. Firmness change can be used to analyze
and compare support characteristics. As illustrated in FIG. 69, a
control polyurethane 1222 and three unitary composite cushioning
structures 1224, 1226, 1228 were tested with the results provided
in bar graph 1220.
[0276] The present disclosure also involves the producing or
manufacturing of unitary composite cushioning profiles. In one
embodiment as previously discussed and as discussed in more detail
below, the process involves the securing of the thermoset material
to the cellular thermoplastic material in a continuous process. In
this regard, the unitary composite cushioning structure formed from
a cellular thermoplastic material and a cellular thermoset material
can be formed by continuously extruding the cellular thermoplastic
material providing support characteristics and cushioning
characteristics. During the continuous extrusion of the cellular
thermoplastic materials, a thermoset material providing a resilient
structure with cushioning characteristics is dispensed in an
initial non-solid phase on the cellular thermoplastic material
provided in a profile by continuous extrusion.
[0277] The stratum may be continuously propagated between a portion
of the cellular thermoplastic foam and a portion of the thermoset
material during manufacture to secure the portion of the thermoset
material to the portion of the cellular thermoplastic foam as the
thermoset material is continuously dispensed into a continuously
extruded cellular thermoplastic foam. Adhesive promoter(s) may be
provided or mixed into the thermoset material and/or cellular
thermoplastic material and dispensed in the cellular thermoplastic
material to form a continuously propagated stratum disposed between
at least a portion of the cellular thermoplastic material and at
least a portion of the cellular thermoset material to secure to the
cellular thermoplastic material profile to form a unitary composite
cushioning structure.
[0278] By disposing a non-solid phase of the cellular thermoset
material on a cellular thermoplastic foam profile, the cellular
thermoset material undergoes a transition into a solid phase to
secure the thermoset material with the cellular thermoplastic
material. In this manner, at least a portion of the cellular
thermoset material is secured to the at least a portion of the
cellular thermoplastic material to form the unitary composite
cushioning structure. The extruded profile of the cellular
thermoplastic material and the amount and form of the thermoset
material transforming into a solid phase in the cellular
thermoplastic material is controlled according to the desired
profiles and designs to exhibit the desired combination of the
support characteristics and the resilient structure with cushioning
characteristics when the unitary composite cushioning structure is
placed under a load.
[0279] In this regard, FIGS. 70A and 70B illustrate one embodiment
of a continuous extrusion system 1250 that may be employed to
produce a unitary composite cushioning structure formed from a
continuous extrusion of cellular thermoplastic material profile
with a non-solid phase of thermoset material dispensed therein. The
thermoset material will transform into a solid phase, thereby
forming a stratum to secure the thermoset material to the cellular
thermoplastic material. FIG. 70A illustrates the continuous
extrusion system 1250 in an upstream view when looking back towards
an extruder 1252 that extrudes the cellular thermoplastic material
into a desired cellular thermoplastic profile 1253 onto a conveyor
1254. FIG. 70B illustrates the continuous extrusion system 1250 in
a downstream view when facing away from the extruder 1252 that
extrudes the cellular thermoplastic material into the cellular
thermoplastic profile 1253 towards the conveyor 1254. As will be
described in more detail below, the extruder 1252 extrudes a
cellular thermoplastic material into a desired profile to provide
the thermoplastic component unitary composite cushioning structure.
The extruded cellular thermoplastic material profile will be
extruded and pulled on the conveyor 1254 in a continuous process.
In this regard, part of the disclosure herein will describe how the
unitary composite cushioning structure can be manufactured in a
continuous process.
[0280] FIG. 71 illustrates a close-up view of the extruder 1252 in
the continuous extrusion system 1250 in FIGS. 70A and 70B. As
illustrated therein, the initial portion 1256 of the cellular
thermoplastic profile 1253 is shown as being extruded by the
extruder 1252 adjacent the extruder die 1258 (also illustrated in
FIG. 72). As illustrated in FIG. 72, the extruder die 1258 is
configured to extrude cellular thermoplastic material 1259 into the
desired cellular thermoplastic profile, which is the cellular
thermoplastic profile 1253 in this embodiment. In this embodiment,
the extruder die 1258 has dimensions of approximately 0.5 inches
height H.sub.4 with a 1/32'' width W1 wall opening to extrude the
cellular thermoplastic material 1259. The cellular thermoplastic
material 1259 may be mixed, injected with a blowing agent (e.g.,
isobutene) to be foamed, plasticized, pressurized, and/or cooled
before being extruded by the extruder 1252. The cellular
thermoplastic material 1259 may include an adhesion promoter if
desired to promote adhesion with the thermoset material to create
the continuously propagated stratum.
[0281] The cellular thermoplastic profile 1253 in this embodiment
is extruded in a U-shaped form as illustrated in FIGS. 72 and 73.
As shown in FIG. 73, the cellular thermoplastic profile 1253 is
extruded with cylindrical shaped walls 1260, having a base portion
1262 and two side walls 1264A, 1264B extending up from the base
portion 1262 on each side of the base portion 1262. In this
embodiment as a non-limiting example, the continuous extrusion
system 1250 is designed to produce the cellular thermoplastic
profile 1253 in a height H.sub.5 of approximately 2.5 inches with a
wall thickness W2 in the cylindrical-shaped walls 1260 of
approximately 5/16 inches. An internal chamber 1266 is formed
inside the cellular thermoplastic profile 1253. In this embodiment,
the internal chamber 1266 is an open chamber and is configured and
provided to receive a dispensed thermoset material in a non-solid
phase. The side walls 1264A, 1264B will contain and hold the
thermoset material in place as the thermoset material transforms
into a solid form to form the stratum between the thermoset
material and the cellular thermoplastic material 1259. The
geometric configuration, density, and/or range of cell sizes can be
varied in the cellular thermoplastic material 1259 to provide the
desired support characteristics in a unitary composite cushioning
structure. At the initial portion 1256 of the extruded cellular
thermoplastic profile 1253 in FIG. 70, the cellular thermoplastic
profile 1253 is not ready to receive the dispensed non-solid phase
of thermoset material into the internal chamber 1266. The cellular
thermoplastic profile 1253 needs to cool down to provide a more
stable form before the thermoset material is dispensed in a
non-solid phase into the internal chamber 1266 in this
embodiment.
[0282] FIG. 74 illustrates the opposite end of the continuous
extrusion system 1250 from the extruder 1252 of FIG. 71. In this
embodiment, the puller apparatus 1268 is illustrated. The pulling
apparatus 1268 receives and is coupled to the cellular
thermoplastic profile 1253 as it is being extruded from the
extruder 1252. The pulling apparatus 1268 applies a pulling force
F1 as illustrated in FIG. 74 to produce the cellular thermoplastic
profile 1253 in an elongated form according to the desired
characteristics. The cellular thermoplastic profile 1253 is pulled
along the conveyor 1254 from the extruder 1252 to the pulling
apparatus 1268, as illustrated in FIG. 75. The conveyor 1254 may be
employed with a guide system, such as guide rails 1270A, 1270B as
illustrated in FIG. 75 to guide the extruded cellular thermoplastic
profile 1253 from the extruder 1252 to the pulling apparatus 1268.
A cooling system may be employed on the conveyor 1254 to cool the
cellular thermoplastic profile 1253 to cool the cellular
thermoplastic material 1259 after being extruded by the extruder
1252 to allow the cellular thermoplastic material 1259 to more
quickly take shape into its profile form to prepare the internal
chamber 1266 to receive the non-solid phase of thermoset
material.
[0283] Once the cellular thermoplastic materials 1259 in the
cellular thermoplastic profile 1253 achieve a desired level of
stability in formation, then a thermoset material can be dispensed
into the internal chamber 1266 of the cellular thermoplastic
profile 1253. In this regard, FIGS. 76A and 76B illustrate
dispensing a thermoset material in a non-solid phase into the
internal chamber 1266 of the cellular thermoplastic profile 1253.
As illustrated in FIG. 76A, a dispensing apparatus 1272 is provided
in the continuous extrusion system 1250. The dispensing apparatus
1272 is lowered and configured to dispense a thermoset material
1273 into the internal chamber 1266 of the cellular thermoplastic
profile 1253 as the cellular thermoplastic profile is being
continuously extruded and pulling on the conveyor 1254, as
illustrated in FIG. 76B. The dispensing apparatus 1272 in this
embodiment includes a dispensing head 1274 that is disposed at a
point along the conveyor 1254 wherein the cellular thermoplastic
profile 1253 is stable enough to receive the thermoset material
1273. The dispensing head 1274 dispenses the thermoset material
1273 continuously as the cellular thermoplastic profile 1253 is
continuously extruded to provide a continuous process of producing
a unitary composite cushioning structure 1275.
[0284] As non-limiting examples, the thermoset material 1273 may be
a polyurethane. The polyurethane dispensing process may begin by
reacting a liquid isocyanate and a liquid polyol brought to a
desired temperature and subjected to an intense high pressure mix.
The two streams of isocynate and polyol are brought together in the
dispensing head 1274 wherein the two streams are pumped through a
defined size orifice to create adequate pressure for mixing. The
two streams can then be directed to impinge on one antler to create
an eddy effect for efficient mixing. An endothermic reaction, which
creates carbon dioxide from water within the polyol may begin at
the point of impingement. The polyurethane liquid reactant being
tempered and mixed is dispensed by the dispensing head 1274
directly into the internal chamber 1266 of the continuously
extruded cellular thermoplastic profile 1253 which is moving along
the conveyor 1254. The liquid reactant of the polyurethane begins
to foam and rise within the internal chamber 1266 of the cellular
thermoplastic profile 1253. Alternatively, the two streams could be
dispensed separately into the internal chamber 1266 of the cellular
thermoplastic profile 1253 by separate dispensing heads if
desired.
[0285] The thermoset material 1273 free rising begins inside the
internal chamber 1266 of the cellular thermoplastic profile 1253
soon after the thermoset material 1273 is dispensed in the internal
chamber 1266 of the cellular thermoplastic profile 1253, which is
approximately six (6) to eight (8) feet downstream towards the
pulling apparatus 1268 from the dispensing head 1274 in this
embodiment. The thermoset material 1273 may nominally rise to its
maximum rise within the internal chamber 1266 of the cellular
thermoplastic profile 1253 at approximately twenty (20) feet and
maximally rise approximately thirty (30) to forty (40) feet
downstream towards the pulling apparatus 1268 from the dispensing
head 1274 in this embodiment.
[0286] To assist in the dispensing of the thermoset material 1273
into the internal chamber 1266 of the cellular thermoplastic
profile 1253, pulling members 1274A, 1274B can be provided along
the conveyor 1254 between the extruder 1252 and the dispensing
apparatus 1272, as illustrated in FIG. 77, to manipulate and pull
apart the side walls 1264A, 1264B of the cellular thermoplastic
profile 1253 as the thermoset material 1273 is dispensed, as
illustrated in FIGS. 76A and 76B. Further, as illustrated in FIG.
77, the conveyor 1254 may include rollers 1278A, 1278B disposed
inside the guide rails 1270A, 1270B to assist in conveying the
cellular thermoplastic profile 1253 down the conveyor 1254 to the
pulling apparatus 1268.
[0287] As illustrated in FIG. 78, the unitary composite cushioning
structure 1275 can be disposed through a cutting machine 1280
downstream of the pulling apparatus 1268 to cut the unitary
composite cushioning structure 1275 into sections 1282, if desired
to produce an inventory of the sections 1282. The cutting machine
1280 may employ any type of cutting apparatus, including but not
limited to a knife, fly knife, traveling saw (e.g., band saw,
rotary blade saw), and water jet. The cutting machine 1280 should
preferably be able to cut partially cured thermoset material 1273
since the thermoset material may not have fully cured by the time
the unitary composite cushioning structure 1275 reaches the cutting
machine 1280. The sections 1282 can be employed to provide
cushioning devices or apparatuses, including but not limited to any
of the unitary composite cushioning structures discussed above.
These sections 1282 may be provided as separate sections in a
cushioning structure to provide motion isolation as one example, as
previously discussed. The sections 1282 may be arranged
horizontally, vertically, or a combination thereof for a cushioning
structure.
[0288] Although the embodiment of the unitary composite cushioning
structure 1275 manufactured by the continuous extrusion system 1250
involves providing a cellular thermoplastic cellular profile 1253
having an internal chamber 1266 that is open, alternatives are
possible. For example, the cellular thermoplastic profile could be
extruded as a closed profile. In this regard, the extruder die 1258
could be provided that contains a closed die shape to provide a
closed cylindrical (or other shaped) cellular thermoplastic
profile. In this regard, the closed cellular thermoplastic profile
could be cut open and in a continuous process if desired, and the
thermoset material 1273 could be dispensed therein inside an
internal chamber in the cellular thermoplastic profile. Thereafter,
the opening in the cellular thermoplastic profile could be sealed
closed with the thermoset material disposed therein to form a
unitary composite cushioning structure. The cellular thermoplastic
profile could be sealed closed with any technique desired,
including but not limited to gluing, welding, and stitching.
Alternatively, the dispensing head could include needles that are
configured to be inserted into a cellular thermoplastic profile and
to dispense thermoset material inside the cellular thermoplastic
profile. In this regard, the dispensing needles could be provided
in a needle system that travels on a second conveyor above the
conveyor 1254 to travel at the same speed as the conveyor 1254 to
inject the cellular thermoplastic profile.
[0289] FIG. 79 depicts for convenience FIG. 12 showing the mattress
80 including the side/edge support 84. The side/edge support 84 may
be designed for various amounts of comfort and support based on the
thermoplastic profile and the materials. As discussed above, FIG.
6B depicted the side support member 43. The side support member 43
may be analogous to the unitary composite cushioning structure 60
shown in FIG. 8. The side support member 43 may include the
cellular thermoplastic side support member 49 and cellular
thermoset side support member 50, which may be unattached or
alternatively attached through an adhesive, cohesive, or an
intermediate component. The thermoplastic side support member 49
has various features to change the support and comfort
characteristics of the side support member 43.
[0290] FIG. 80A depicts a close-up of a longitudinal view of the
thermoplastic side support member 49 including at least one side
support orifice 1300, 1300(2) parallel to a longitudinal axis
A.sub.1 of the cellular thermoplastic side support member 49. The
side support orifice 1300, 1300(2) may be circular, or
non-circular, for example, oblong-shaped within a cross-section
orthogonal to the longitudinal axis A.sub.1. The side support
orifice 1300, 1300(2) may extend within this cross-section to an
end point 1302 which is a distance D.sub.2 from a side surface 1304
of the thermoplastic side support member 49. The side support
orifice 1300, 1300(2) may include at least an orifice opening 1301
on a distal end 1303 of the thermoplastic side support member 49.
The orifice opening 1301 may be elongated in a direction orthogonal
to the load F. The side support orifice 1300, 1300(2) may also
include at least one second orifice opening 1305, 1305(2) on a
second distal end 1307 of the thermoplastic side support member 49.
The thermoplastic side support member 49 may extend from the distal
end 1303 to the second distal end 1307 along the longitudinal axis
A1. The thermoplastic side support member 49 further comprises at
least one groove 1306 disposed along the longitudinal axis A.sub.1
of each of the at least one thermoplastic side support member 49 as
shown in FIG. 80B. The at least one groove 1306 may include at
least two grooves 1306, 1306(2) on opposite side surfaces 1304,
1304(2) of the thermoplastic side support member 49.
[0291] With continuing reference to FIG. 80A showing the
cross-section orthogonal to the longitudinal axis A1 of the
thermoplastic side support member 49, the groove 1306 may include
an opening 1308 in the side surface 1304 along a length of the
thermoplastic side support member 49. The opening 1308 of the
groove 1306 is at least partially directed orthogonal to the load
F.
[0292] As shown in FIG. 80A, a width W3 of the opening 1308 of the
groove 1306 may be smaller than a maximum width W4 of the groove
1306. The opening 1308 with the smaller width W3 permits the
thermoplastic side support member 49 to maintain abutments with
under the load F to improve support.
[0293] Further, the groove 1306 extends into each of the elongated
side support members a distance D.sub.3 from the side surface 1304.
The groove 1306 may taper to a point of maximum depth 1310 which is
the distance D.sub.3 from the side surface 1304. The distance
D.sub.3 extends beyond the at least one side support orifice 1300
represented by the end point 1302 because D.sub.3 may be greater
than D.sub.2. In this regard, a portion 1312 of the at least one
cellular thermoplastic side support member 49 may be configured to
twist in a direction orthogonal to the longitudinal axis A.sub.1
under a moment M created by the load F. The twisting may reduce the
resistance to strain of the thermoplastic side support member 49
and help distribute the load F at least partially in a lateral
direction (see FIG. 5, directions X and Z) to provide additional
support.
[0294] In this regard, FIGS. 81A and 81B depict an embodiment of
the mattress assembly 40(3) including the side support member 43
comprising the cellular thermoplastic side support member 49 of
FIGS. 80A and 80B and the cellular thermoset side support member
50. The mattress assembly 40(3) may also include mattress members
54'' in the shape of the side support member within the transition
layer 51''. Any one of the side support orifices 1300, 1300(2),
orifices 1314, 1314(2) of the mattress members 54'', or grooves
1316, 1316(2) of the mattress members 54'' may or may not be filled
with the thermoset material 62.
[0295] FIGS. 82A and 82B show an exemplary side support member
43.sup.I of a mattress assembly 40(4) comprising a soft portion
1318, a medium-support portion 1320, and a high-support portion
1322 orientated in an order of increasing support in the direction
of the load F. The soft portion 1318 may include at least one
orifice 1324 of a height H.sub.6. The medium-support portion 1320
may include at least one orifice 1326 of a height H.sub.7. The
high-support portion 1322 may include at least one orifice 1328 of
a height H.sub.8. The orifices 1324, 1326, 1328 may be of equal
width. The height H.sub.7 may be shorter than the height H.sub.6 to
provide more support for the medium-support portion 1320. The
height H.sub.8 may be shorter than the height H.sub.7 to provide
more support for the high-support portion 1322. There may be
recesses 1330 disposed in a surface 1332 of the side support member
43.sup.I at a height between any two of the orifices 1324, 1326,
1328 to provide for improved softness. The side support member
43.sup.I may be made of closed cell foam, thermoplastic, or
thermoset material.
[0296] FIGS. 83A and 83B depict an exemplary side support member
43.sup.II of a mattress assembly 40(5) comprising a composite-soft
portion 1334, a medium-support portion 1336, and a high-support
portion 1338 orientated in an order of increasing support in the
direction of the load F. The composite-soft portion 1334 may
include at least one open chamber 1340 at least partially filled
with an open-cell thermoplastic material 1342. The medium-support
portion 1336 may include at least one orifice 1344 of a height
H.sub.9. The high-support portion 1338 may include at least one
orifice 1346 of a height H.sub.10. The orifices 1344, 1346 may be
of equal width. The height H.sub.10 may be shorter than the height
H.sub.9 to provide more support for the high-support portion 1338.
The surfaces 1348 of the open chamber 1340 may not be parallel to
the load F to improve deformation (strain) while under the load F.
The side support member 43.sup.II may be made of thermoplastic or
thermoset material.
[0297] FIGS. 84A and 84B show an exemplary side support member
43.sup.III of a mattress assembly 40(6) comprising a soft portion
1350 and a high-support portion 1352 orientated in an order of
increasing support in the direction of the load F. The soft portion
1350 may comprise the open-cell thermoplastic material 1342. The
high-support portion 1352 may comprise closed-cell thermoplastic
material.
[0298] FIGS. 85A and 85B depict an exemplary side support member
43.sup.IV of a mattress assembly 40(7) comprising a support portion
1354 and a deflection portion 1356 orientated in an order of the
direction of the load F. The support portion 1354 and the
deflection portion 1356 may comprise closed-cell foam material. The
deflection portion 1356 may comprise at least one orifice 1358
configured to collapse under the load F.
[0299] FIGS. 86A and 86B show an exemplary side support member
43.sup.V of a mattress assembly 40(8) comprising a hybrid-support
portion 1360 and a deflection portion 1362 orientated in an order
of the direction of the load F. The hybrid-support portion 1360 may
comprise an open cell foam material and a closed cell foam
material. The fraction of the closed foam material increases in the
direction of the load F. The deflection portion 1362 may comprise
closed-cell foam material. The deflection portion 1362 may comprise
the at least one orifice 1358 configured to collapse under the load
F.
[0300] Many modifications and other embodiments not 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.
* * * * *