U.S. patent application number 14/533367 was filed with the patent office on 2015-02-26 for cellular cushion.
The applicant listed for this patent is Skydex Technologies, Inc.. Invention is credited to Eric T. DiFelice, Peter M. Foley, Bryant R. Hadden, Collin Metzer, Eric W. Sugano.
Application Number | 20150052683 14/533367 |
Document ID | / |
Family ID | 48290665 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150052683 |
Kind Code |
A1 |
Sugano; Eric W. ; et
al. |
February 26, 2015 |
CELLULAR CUSHION
Abstract
A cellular cushioning system includes cells or support units
arranged in one or more stacked arrays. The cells are hollow
chambers that resist deflection due to compressive forces, similar
to compression springs. The arrays are attached to one or more
intermedial binding layers. The intermedial binding layer(s) links
the cells together while allowing the cells to deform independently
of one another. An external load compresses of one of the void
cells within an independent compression range without significantly
compressing at least one void cell adjacent the compressed void
cell. The independent compression range is the displacement range
of the compressed void cell that does not significantly affect the
compression of adjacent void cells. If the void cell is compressed
beyond the independent compression range, the intermedial binding
layers may be deflected and/or the void cells adjacent the
compressed void cell may be compressed.
Inventors: |
Sugano; Eric W.; (Denver,
CO) ; Metzer; Collin; (Highlands Ranch, CO) ;
Foley; Peter M.; (Castle Rock, CO) ; DiFelice; Eric
T.; (Parker, CO) ; Hadden; Bryant R.;
(Westminster, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Skydex Technologies, Inc. |
Centennial |
CO |
US |
|
|
Family ID: |
48290665 |
Appl. No.: |
14/533367 |
Filed: |
November 5, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13674293 |
Nov 12, 2012 |
8904584 |
|
|
14533367 |
|
|
|
|
61558564 |
Nov 11, 2011 |
|
|
|
Current U.S.
Class: |
5/652 ; 156/60;
264/250 |
Current CPC
Class: |
B29C 66/1312 20130101;
B32B 37/182 20130101; B29D 99/0092 20130101; B29L 2031/751
20130101; B29C 66/21 20130101; B29C 66/727 20130101; B29C 66/54
20130101; B29C 66/71 20130101; B32B 2398/20 20130101; B65D 81/03
20130101; B32B 5/18 20130101; Y10T 156/10 20150115; B29D 22/00
20130101; B29C 66/73921 20130101; A47C 27/142 20130101; A47C 27/10
20130101; B29K 2105/045 20130101; Y10S 5/932 20130101; A47C 27/00
20130101; B32B 2266/06 20130101; B32B 7/04 20130101; B32B 2307/50
20130101; B32B 37/24 20130101; B29K 2995/0046 20130101; B32B 37/10
20130101; B32B 2266/0292 20130101; B29C 66/71 20130101; B29K
2075/00 20130101; B29C 66/71 20130101; B29K 2021/003 20130101; B29C
66/71 20130101; B29K 2025/08 20130101; B29C 66/71 20130101; B29K
2021/00 20130101 |
Class at
Publication: |
5/652 ; 156/60;
264/250 |
International
Class: |
A47C 27/00 20060101
A47C027/00; B29D 99/00 20060101 B29D099/00; B32B 37/10 20060101
B32B037/10; B32B 37/18 20060101 B32B037/18; B32B 37/24 20060101
B32B037/24 |
Claims
1. A method comprising: applying a cushioning material to a curved
surface, the material comprising a first matrix of void cells
opposing a second matrix of void cells, wherein at least two of the
void cells in the first matrix are coupled to at least two of the
void cells in the second matrix via an intermedial binding layer
and at each void cell of the first matrix and the second matrix
includes an opening in continuous fluid communication with an
environment external to the cushioning material.
2. The method of claim 1, further comprising: compressing a void
cell in the first matrix within an independent compression range of
the cushioning material and in a direction substantially normal to
the intermedial binding layer without substantially compressing at
least one neighboring void cell in the first matrix and at least
one opposing void cell in the second matrix of void cells.
3. The method of claim 2, further comprising: compressing the void
cell outside the independent compression range to deflect the
intermedial binding layer and compress the opposing void cell in
the second matrix of void cells.
4. The method of claim 3, wherein compressing the void cell outside
the independent compression range requires greater force than
compressing the void cell within the independent compression
range.
5. The method of claim 2, wherein each void cell in the first
matrix of void cells has a substantially equal resistance to
deformation at all deformation magnitudes within the independent
compression range.
6. The method of claim 1, wherein each void cell in the first
matrix of void cells has an increased resistance to deformation
with increased deformation magnitude outside the independent
compression range.
7. The method of claim 1, wherein the void cells in the first
matrix have a higher resistance to deflection than the void cells
in the second matrix.
8. A cushioning material comprising: a first matrix of void cells;
a second matrix of void cells opposing the first matrix of void
cells, each void cell of the first matrix and the second matrix
including an opening in continuous fluid communication with an
environment external to the cushioning material; and an intermedial
binding layer coupling at least two of the void cells in the first
matrix to at least two of the void cells in the second matrix.
9. The cushioning material of claim 8, wherein the cushioning
material conforms to a curved surface of an adjacent object.
10. The cushioning material of claim 8, wherein each of the void
cells in the first matrix have an open face that faces an open face
of each of the void cells in the second matrix, wherein the open
faces in the first matrix generally align with the open faces in
the second matrix.
11. The cushioning material of claim 8, wherein compression of a
void cell within the first matrix in a direction substantially
normal to the intermedial binding layer occurs without substantial
deflection of at least one neighboring void cell in the first
matrix and at least one opposing void cell in the second
matrix.
12. The cushioning material of claim 11, wherein de-compression of
the void cell occurs without de-compression of the neighboring void
cell.
13. The cushioning material of claim 11, wherein compression and
compression of the void cell outside of an independent compression
range of the cushioning material deflects the intermedial binding
layer and compresses the at least one adjacent void cell.
14. The cushioning material of claim 13, wherein compression of the
void cell outside the independent compression range requires
greater force than compression of the void cell within the
independent compression range.
15. The cushioning material of claim 8, wherein the intermedial
binding layer has an opening where each void cell meets the
intermedial binding layer.
16. The cushioning material of claim 8, wherein the intermedial
binding layer includes a first half that couples the first matrix
of void cells together and a second half that couples the second
matrix of void cells together, and wherein the first half and the
second half are attached together.
17. The cushioning material of claim 8, wherein the first half and
the second half are attached together using periodic spot welds of
the first half to the second half.
18. A method of manufacturing a cellular cushioning system
comprising: molding a first matrix of void cells open toward and
interconnected by a first intermedial binding layer; molding a
second matrix of void cells open toward and interconnected by a
second intermedial binding layer, each void cell in the first
matrix and the second matrix including an opening in continuous
fluid communication with an environment external to the cellular
cushioning system; and welding the first and the second intermedial
binding layers together so that openings in the void cells of the
first matrix and the second matrix face one another.
19. The method of claim 18, further comprising: molding a pixilated
layer; and attaching the pixilated layer to an outer surface of
each void cell of the first matrix of void cells.
20. The method of claim 19, further comprising: compressing a void
cell in the first matrix in a direction substantially normal to the
first intermedial binding layer without substantial deflection of
at least one neighboring void cell in the first matrix and at least
one opposing void cell in the second matrix.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit of priority to U.S.
Provisional Patent Application No. 61/558,564, entitled "Cellular
Cushion" and filed on Nov. 11, 2011, which is specifically
incorporated by reference herein for all that it discloses or
teaches. In addition, the present application is a continuation of
U.S. application Ser. No. 13/674,293 entitled "Cellular Cushion,"
and filed on Nov. 12, 2012, which is also specifically incorporated
by reference herein for all that it discloses or teaches.
BACKGROUND
[0002] Cushioning systems are used in a wide variety of
applications including comfort and impact protection of the human
body. A cushioning system is placed adjacent a portion of the body
and provides a barrier between the body and one or more objects
that would otherwise impinge on the body. For example, a pocketed
spring mattress contains an array of close-coupled metal springs
that cushion the body from a bed frame. Similarly, chairs, gloves,
knee-pads, helmets, etc. may each include a cushioning system that
provides a barrier between a portion of the body and one or more
objects.
[0003] A variety of structures are used for cushioning systems. For
example, an array of close-coupled closed-cell air and/or water
chambers often constitute air and water mattresses. An array of
close-coupled springs often constitutes a conventional mattress.
Further examples include open or closed cell foam and elastomeric
honeycomb structures. For cushioning systems utilizing an array of
closed or open cells or springs, either the cells or springs are
directly coupled together or one or more unifying layers are used
to couple each of the cells or springs together at their
extremities. While directly coupling the cells or springs together
or indirectly coupling the extremities of the cells or springs
together is effective in tying the cushioning system together, the
independence of each of the cells or springs is reduced. This lack
of independence can lead to an increased load being placed on a
small area of the body (referred to herein as a point load). A
point load deforming one of the cells or springs is likely to
deform adjacent cells or springs directly or by stressing the
unifying layer(s). As a result, the resistance to deflection at the
point of contact increases due to the deflection of multiple cells
or springs. The increased resistance to deflection may cause
pressure points on portions of a user's body that protrude into the
cushioning system more than other portions of the user's body
(e.g., at a user's shoulders and hips on a mattress).
SUMMARY
[0004] Implementations described and claimed herein address the
foregoing problems by decoupling individual void cells in a
cellular cushioning system and allowing the void cells to deform
independently of one another, within an independent deformation
range. This reduces the potential for pressure points on a user's
body. Further, the void cells deform independently under loads
oriented in multiple directions, within the independent deformation
range.
[0005] The presently disclosed technology further addresses the
foregoing problems by compressing a void cell in a matrix of void
cells coupled together with an intermedial binding layer in a
direction normal to the intermedial binding layer without
substantially compressing at least one adjacent void cell, wherein
the void cell is compressed within an independent compression range
of the void cell.
[0006] The presently disclosed technology still further addresses
the foregoing problems by providing an apparatus for interfacing a
body with an object comprising a first matrix of void cells and an
intermedial binding layer coupling at least two of the void cells
in the first matrix of void cells, wherein compression of a void
cell in a direction normal to the intermedial binding layer occurs
without substantial deflection of at least one adjacent void cell,
wherein compression of the void cell is within an independent
compression range of the void cell.
[0007] The presently disclosed technology further yet addresses the
foregoing problems by providing a method of manufacturing a
cellular cushioning system comprising molding a first matrix of
void cells open toward and interconnected by a first intermedial
binding layer; molding a second matrix of void cells open toward
and interconnected by a second intermedial binding layer; and
laminating the first and second intermedial binding layers together
so that openings in the void cells of the first and second
intermedial binding layers face one another, wherein compression of
a void cell in a direction normal to the intermedial binding layer
occurs without substantial deflection of at least one adjacent void
cell, and wherein compression of the void cell is within an
independent compression range of the void cell.
[0008] Other implementations are also described and recited
herein.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0009] FIG. 1 illustrates a user lying on an example cellular
cushioning system.
[0010] FIG. 2 illustrates a perspective view of an example cellular
cushioning system.
[0011] FIG. 3 illustrates an elevation view of an example cellular
cushioning system in an unloaded state.
[0012] FIG. 4 illustrates an elevation view of an example offset
cellular cushioning system in an unloaded state.
[0013] FIG. 5 illustrates an elevation view of an example stacked
cellular cushioning system 500 in an unloaded state.
[0014] FIG. 6 illustrates an elevation view of an example cellular
cushioning system in a partially loaded state.
[0015] FIG. 7 illustrates an elevation view of an example cellular
cushioning system in a fully loaded state.
[0016] FIG. 8 illustrates a perspective view of an example cellular
cushioning system with a pixilated layer.
[0017] FIG. 9 illustrates an elevation view of an example cellular
cushioning system with a pixilated layer in an unloaded state.
[0018] FIG. 10 illustrates an elevation view of an example cellular
cushioning system with a pixilated layer in a partially loaded
state.
[0019] FIG. 11 illustrates an elevation view of an example cellular
cushioning system with a pixilated layer in a fully loaded
state.
[0020] FIG. 12 illustrates a perspective view of an example curved
cellular cushioning system.
[0021] FIG. 13 illustrates a displacement over force graph for
neighboring void cells in an example cellular cushioning
system.
[0022] FIG. 14 illustrates a displacement over force graph for
opposing void cells in an example cellular cushioning system.
[0023] FIG. 15 illustrates a pressure over displacement graph for
two example cellular cushioning systems compared to three other
cushioning systems.
[0024] FIG. 16 illustrates a kneepad incorporating an example
cellular cushioning system.
[0025] FIG. 17 illustrates example operations for manufacturing and
using a cellular cushioning system.
DETAILED DESCRIPTIONS
[0026] FIG. 1 illustrates a user 102 lying on an example cellular
cushioning system 100. The cellular cushioning system 100 includes
void cells (e.g., void cell 104) or support units arranged in a top
matrix 106 (or array) and a bottom matrix 108 (or array). The
cellular cushioning system 100 is depicted on a frame 103. Some
implementations will not include the frame 103. The void cells are
hollow chambers that resist deflection due to compressive forces,
similar to compression springs. The top matrix 106 is attached to a
top surface of a central or intermedial binding layer 110 and the
bottom matrix 108 is attached to a bottom surface of the
intermedial binding layer 110. The intermedial binding layer 110
links the void cells together while allowing the void cells to
compress independently of one another, at least within an
independent compression range of the void cells (discussed in more
detail with regard to FIG. 13).
[0027] In one implementation, each of the void cells are
individually attached to the intermedial binding layer 110 and not
to each other. Further, each of the void cells within the top
matrix 106 or bottom matrix 108 are individually compressible under
load without compression of adjacent (i.e., neighboring, opposing,
and/or neighbor opposing) void cells, within the independent
compression range of the void cells. Outside of the independent
compression range, compression of an individual void cell causes
adjacent void cells to compress via deflection of the intermedial
binding layer 110. For example, void cells forming the top matrix
106 under the neck, lower back, and knees of the user 102 are
individually compressed and distribute the weight of the user 102
evenly over those areas. However, void cells under the upper back
and buttocks of the user 102 are compressed sufficiently to cause
the intermedial binding layer 110 to deflect, which in turn causes
void cells in the bottom matrix 108 to compress. Deflection of the
intermedial binding layer 110 also causes adjacent void cells in
the top matrix 106 to deflect and adjacent void cells in the bottom
matrix 108 to compress.
[0028] Each of the void cells creates a relatively constant force
to resist deflection. In one implementation, the void cells in the
bottom matrix 108 have a higher resistance to deflection that the
void cells in the top matrix 106. As a result, in less compressed
areas (e.g., the user's neck, lower back, and knees), only void
cells in the top matrix 106 are engaged and the user's weight is
distributed evenly over contact of the user 102 with the cellular
cushioning system 100. In more compressed areas (e.g., the user's
upper back and buttocks), the user experiences increased pressure
because the user's weight is sufficient to additionally deflect the
intermedial binding layer 110 and thus engage the void cells in the
bottom matrix 108. In another implementation, resistance to
deflection of the individual void cells within the top and/or
bottom matrices are varied according to expected loading of the
cellular cushioning system 100. For example, void cells located
near the user's upper back and buttocks may be stiffer than void
cells located near the user's neck, lower back, and knees.
[0029] In one implementation, an optional pixilation layer (see
e.g., FIGS. 8-11) is attached to extremities of the top matrix 106
and/or the bottom matrix 108 opposite the intermedial binding layer
110. The pixilation layer provides a substantially planar surface
on the top or bottom of the cellular cushioning system 100 to aid
in comfort or cleanliness concerns and yet sill allows for
substantially independent compression of individual void cells, for
example. The pixilation layer is discussed in more detail with
regard to FIGS. 8-11.
[0030] FIG. 2 illustrates a perspective view of an example cellular
cushioning system 200. The cellular cushioning system 200 includes
void cells (e.g., void cell 204) arranged in a top matrix 206 and a
bottom matrix 208. The void cells are hollow chambers that resist
deflection due to compressive forces, similar to compression
springs. However, unlike compression springs, deflection of the
void cells does not yield a linear increase in resistive force.
Instead, the resistive force to deflection of the void cells is
relatively constant for the majority of the void cell's compression
displacement. This allows the cellular cushioning system 200 to
conform to a user's body with an even force on the user's body. In
other implementations, each of the void cells may have a positive
or negative spring rate. Further, the spring rate of each of the
void cells may vary depending upon the void cell's relative
position within the cellular cushioning system 200.
[0031] At least the material, wall thickness, size, and shape of
each of the void cells define the resistive force each of the void
cells can apply. Materials used for the void cells are generally
elastically deformable under expected load conditions and will
withstand numerous deformations without fracturing or suffering
other breakdown impairing the function of the cellular cushioning
system 200. Example materials include thermoplastic urethane,
thermoplastic elatomers, styrenic co-polymers, rubber, Dow
Pellethane.RTM., Lubrizol Estane.RTM., Dupont.TM. Hytrel.RTM.,
ATOFINA Pebax.RTM., and Krayton polymers. Further, the wall
thickness may range from 5 mil to 80 mil. Still further, the size
of each of the void cells may range from 5 mm to 70 mm sides in a
cubical implementation. Further yet, the void cells may be cubical,
pyramidal, hemispherical, or any other shape capable of having a
hollow interior volume. Other shapes may have similar dimensions as
the aforementioned cubical implementation. Still further, the void
cells may be spaced a variety of distances from one another. An
example spacing range is 2.5 mm to 150 mm.
[0032] In one implementation, the void cells have a square base
shape, with a trapezoidal volume and a rounded top. That void cell
geometry may provide a smooth compression profile of the system 200
and minimal bunching of the individual void cells. Bunching occurs
particularly on corners and vertical sidewalls of the void cells
where the material buckles in such a way as to create multiple
folds of material that can cause pressure points and a less uniform
feel to the cellular cushioning system overall. Still further,
rounded tops of the void cells may enhance user comfort and the
spacing of the individual void cells may create a user feel similar
to convoluted foam.
[0033] In another implementation, the void cells have a round base
shape, with a cylindrical-shaped volume and a rounded top. That
void cell geometry may also provide a smooth compression profile of
a cellular cushioning system and minimal bunching of the individual
void cells. Still further, the rounded tops may enhance user
comfort and the closer spacing of the individual void cells (as
compared to the void cells of FIG. 13) may create a more uniform
feel to a user. Other void cell shapes are contemplated herein.
[0034] The material, wall thickness, cell size, and/or cell spacing
of the cells within the cellular cushioning system 200 may be
optimized to minimize generation of mechanical noise by compression
(e.g., buckling of the side walls) of the void cells. For example,
properties of the cells may be optimized to provide a smooth
relationship between displacement and an applied force (see e.g.,
FIGS. 13 and 14). Further, a light lubricating coating (e.g.,
talcum powder or oil) may be used on the exterior of the void cells
to reduce or eliminate noise generated by void cells contacting and
moving relative to one another. Reduction or elimination of
mechanical noise may make use of the cellular cushioning system 200
more pleasurable to the user. Still further, geometry of the top of
the void cells may be smooth to enhance user comfort.
[0035] The top matrix 206 is attached to a top surface of a central
or intermedial binding layer 210 and the bottom matrix 208 is
attached to a bottom surface of the intermedial binding layer 210.
The intermedial binding layer 210 links the void cells together
while allowing the void cells in the top matrix 206 to deform
independently of one another, at least to an extent. The
intermedial binding layer 210 may be constructed with the same
potential materials as the void cells and in one implementation is
contiguous with the void cells. In the cellular cushioning system
200, the void cells in the top matrix 206 align with the void cells
in the bottom matrix 208.
[0036] In other implementations, the void cells in the top matrix
206 are not aligned with the void cells in the bottom matrix 208
(see e.g., FIG. 4). In yet other implementations, the void cells in
the top matrix 206 are a substantially different size and/or shape
than the void cells in the bottom matrix 208. Further still, one or
more coupling ribs (not shown) may be attached to the exterior of
the void cells extending vertically to the intermedial binding
layer 210. These ribs can add additional stiffness to the void
cells, but may in some implementations affect the independency of
the void cells.
[0037] Each void cell is surrounded by neighboring void cells
within a matrix. For example, void cell 204 is surrounded by three
neighboring void cells 205 within the top matrix 206. In cellular
cushioning system 200, there are three neighboring void cells for
each corner void cell, five neighboring void cells for each edge
cell, and eight neighboring void cells for the rest of the void
cells. Other implementations may have greater or fewer neighboring
void cells for each void cell. Further, each void cell has a
corresponding opposing void cell within an opposite matrix. For
example, void cell 204 in the top matrix 206 is opposed by void
cell 207 in the bottom matrix 208. Other implementations do not
include opposing void cells for some or all of the void cells.
Still further, each void cell has corresponding neighbor opposing
cells within an opposite matrix. For example, void cell 204 in the
top matrix 206 has corresponding neighbor opposing cells 209 in the
bottom matrix 208. The neighbor opposing cells are opposing void
cells for each neighboring void cell of a particular void cell.
[0038] The neighboring void cells, opposing void cells, and
neighbor opposing void cells are collectively referred to herein as
adjacent void cells. In various implementations, one or more of the
neighboring void cells, opposing void cells, and opposing neighbor
void cells are not substantially compressed within an independent
compression range of an individual void cell.
[0039] In one implementation, the void cells are filled with
ambient air. In another implementation, the void cells are filled
with a foam or a fluid other than air. The foam or certain fluids
may be used to insulate a user's body, facilitate heat transfer
from the user's body to/from the cellular cushioning system 200,
and/or affect the resistance to deflection of the cellular
cushioning system 200. In a vacuum or near-vacuum environment
(e.g., outer space), the hollow chambers may be un-filled.
[0040] Further, the void cells may have one or more holes (e.g.,
hole 211) through which air or other fluid may pass freely when the
void cells are compressed and de-compressed. By not relying on air
pressure for resistance to deflection, the void cells can achieve a
relatively constant resistance force to deformation. Still further,
the void cells may be open to one (i.e., fluidly connected) another
via passages (e.g., passage 213) through the intermedial binding
layer 210. The holes and/or passages may also be used to circulate
fluid for heating or cooling purposes. For example, the holes
and/or passages may define a path through the cellular cushioning
system 200 in which a heating or cooling fluid enters the cellular
cushioning system 200, follows a path through the cellular
cushioning system 200, and exits the cellular cushioning system
200. The holes and/or passages may also control the rate at which
air may enter, move within, and/or exit the cellular cushioning
system 200. For example, for heavy loads that are applied quickly,
the holes and/or passages may restrict how fast air may exit or
move within the cellular cushioning system 200, thereby providing
additional cushioning to the user.
[0041] The holes may be placed on a top of a void cell and a bottom
of an opposing void cell on the cellular cushioning system 200 to
facilitate cleaning. More specifically, water and/or air could be
forced through the holes in the opposing void cells to flush out
contaminants. In an implementation where each of the void cells are
connected via passages, water and/or air could be introduced at one
end of the cellular cushioning system 200 and flushed laterally
through the cellular cushioning system 200 to the opposite end to
flush out contaminants. Further, the cellular cushioning system 200
could be treated with an anti-microbial substance or the cellular
cushioning system 200 material itself may be anti-microbial.
[0042] The cellular cushioning system 200 may be manufactured using
a variety of manufacturing processes (e.g., blow molding,
thermoforming, extrusion, injection molding, laminating, etc.). In
one implementation, the system 200 is manufactured in two halves, a
first half comprises the top matrix 206 attached to an upper half
of the intermedial binding layer 210. The second half comprises the
bottom matrix 208 attached to a lower half of the intermedial
binding layer 210. The two halves of the intermedial binding layer
210 are then laminated, glued, or otherwise attached together with
the top matrix 206 and the bottom matrix 208 on opposite sides of
the intermedial binding layer 210. In one implementation, the two
halves of the intermedial binding layer 210 are periodically bonded
together, leaving a gap between the two halves of the intermedial
binding layer 210 that fluidly connects the void cells in one or
both of the top matrix 206 and the bottom matrix 208.
[0043] Further, each of the void cells in the two halves may be
open or closed at its interface with the intermedial binding layer
210. As a result, when the two halves are joined, opposing void
cells on the top matrix 206 and bottom matrix 208 may be either
open or closed to each other. In another implementation, the
cellular cushioning system 200 is manufactured in one piece rather
than two pieces as discussed above. Further, a cellular cushioning
system 200 according to the presently disclosed technology may
include more than two matrices of void cells stacked on top of one
another (e.g., two or more cellular cushioning systems 200 stacked
on top of one another).
[0044] FIG. 3 illustrates an elevation view of an example cellular
cushioning system 300 in an unloaded state. The cellular cushioning
system 300 includes void cells (e.g., void cell 304) arranged in a
top matrix 306 and a bottom matrix 308. The top matrix 306 is
attached to a top surface of a central or intermedial binding layer
310 and the bottom matrix 308 is attached to a bottom surface of
the intermedial binding layer 310. The intermedial binding layer
310 links the void cells together while allowing the void cells to
deform independently of one another, at least within an independent
compression range of the void cells.
[0045] In one implementation, the thickness of each of the void
cells varies over a height of the void cell. For example, near
bottom 316 of void cell 304, the wall thickness may be greater than
near top 318 of void cell 304, or vice versa. This phenomenon may
be a by-product of the manufacturing process or may be
intentionally designed into the manufacturing process. Regardless,
varying the thickness of the void cells over their height can be
used to yield a changing resistive force depending upon the amount
of compression of the void cells (i.e., yielding a positive and/or
increasing spring rate).
[0046] In another implementation, the height of the void cells in
the bottom matrix 308 is different than the height of the void
cells in the top matrix 306. In yet another implementation, the
size and shape of the void cells in the top matrix 306 differ
substantially than that in the bottom matrix 308. The void cells in
the top matrix 306 may substantially collapse into the void cells
in the bottom matrix 308 under compression, or vice versa. In other
implementations, void cells in the top matrix 306 and the bottom
matrix 308 may be offset such that they are only partially opposing
or not opposing (see e.g., FIG. 4).
[0047] FIG. 4 illustrates an elevation view of an example offset
cellular cushioning system 400 in an unloaded state. The cellular
cushioning system 400 includes void cells (e.g., void cell 404)
arranged in a top matrix 406 and a bottom matrix 408. The void
cells in the top matrix 406 are offset from those in the bottom
matrix 408 such that each void cell in a matrix overlaps 2 or more
opposing void cells. The top matrix 406 is attached to a top
surface of a central or intermedial binding layer 410 and the
bottom matrix 408 is attached to a bottom surface of the
intermedial binding layer 410. The intermedial binding layer 410
links the void cells together while allowing the void cells to
deform independently of one another, at least within an independent
compression range of the void cells.
[0048] For example, void cell 404 in the top matrix 406 overlaps
void cells 428, 430 in the bottom matrix 408 (i.e., 1:2
overlapping). In some implementations, the void cell 404 in the top
matrix 406 also overlaps 2 additional void cells in the bottom
matrix 408 extending into the depicted illustration (i.e., 1:4
overlapping). If void cell 404 is compresses, it will deform
substantially independently within an independent compression range
of the void cell 404. Outside of the independent compression range
of the void cell 404, compression of the system 400 will largely
engage void cells 428, 430 and to a lesser extent, neighboring void
cells via the intermedial binding layer 410. Further, the
overlapping cells provide fluid passageways between the void cell
in the top matrix 406 and the bottom matrix 408. This allows air or
other fluid within a compressed void to enter and exit the void
cell freely or substantially freely. In other implementations, one
void cell in the top matrix 406 may overlap any number of void
cells in the bottom matrix 408 (e.g., 1:3 overlapping, 1:6
overlapping, etc.).
[0049] FIG. 5 illustrates an elevation view of an example stacked
cellular cushioning system 500 in an unloaded state. The cellular
cushioning system 500 includes void cells (e.g., void cells 503,
504) stacked within one another. Stacking void cells within one
another increases the resistance to deflection of the combined
stacked void cell. In one implementation, void cell 503 is smaller
than void cell 504 to allow a better fit. Further, the void cells
are arranged in a top matrix 506 and a bottom matrix 508. The top
matrix 506 is attached to a top surface of a central or intermedial
binding layer 510 and the bottom matrix 508 is attached to a bottom
surface of the intermedial binding layer 510. The intermedial
binding layer 510 links the void cells together while allowing the
void cells to deform independently of one another, at least within
an independent compression range of the void cells.
[0050] FIG. 6 illustrates an elevation view of an example cellular
cushioning system 600 in a partially loaded state. The cellular
cushioning system 600 includes void cells (e.g., void cell 604)
arranged in a top matrix 606 and a bottom matrix 608. The top
matrix 606 is attached to a top surface of a central or intermedial
binding layer 610 and the bottom matrix 608 is attached to a bottom
surface of the intermedial binding layer 610. The intermedial
binding layer 610 links the void cells together while allowing the
void cells to deform independently of one another, at least within
an independent compression range of the void cells.
[0051] A load is applied to the void cell 604 using a test
apparatus 620. The void cell 604 compresses vertically without
substantially affecting neighboring void cells (e.g., void cells
622, 624) in the top matrix 606. Further, an opposing void cell 626
in the bottom matrix 608 and neighboring opposing void cells 628,
630 are deflected very little because the intermedial binding layer
610 distributes the point load applied to the void cell 604 to
multiple void cells within the bottom matrix 608. Further, the void
cells within the bottom matrix 608 may have more or less resistance
to compression than the cells in the top matrix 606 to provide a
desired relationship between displacement and an applied force (see
e.g., FIGS. 13 and 14). If the load were applied to a group of void
cells as opposed to the single void cell 604, the group of void
cells would be compressed and adjacent void cells to the group of
void cells would remain relatively uncompressed. This relationship
is referred to herein as decoupling the void cells from one
another. The decoupling is only applicable up to a threshold based
on an independent compression range, as illustrated by FIG. 7.
[0052] FIG. 7 illustrates an elevation view of an example cellular
cushioning system 700 in a fully loaded state. The cellular
cushioning system 700 includes void cells (e.g., void cell 704)
arranged in a top matrix 706 and a bottom matrix 708. The top
matrix 706 is attached to a top surface of a central or intermedial
binding layer 710 and the bottom matrix 708 is attached to a bottom
surface of the intermedial binding layer 710. The intermedial
binding layer 710 links the void cells together while allowing the
void cells to deform independently of one another, at least within
an independent compression range of the void cells.
[0053] Similar to that shown in FIG. 6, a load is applied to the
void cell 704 using a test apparatus 720. The test apparatus 720 is
applying a greater force than test apparatus 620 of FIG. 6, and is
compressing the cellular cushioning system 700 further. Void cell
704 is fully compressed and opposing void cell 726 is nearly, if
not fully compressed. Since the intermedial binding layer 710 is
engaged once the void cell 704 is compressed beyond an independent
compression threshold, opposing void cell 726 is compressed and
neighbor opposing void cells (e.g., void cells 728, 730) are
partially compressed via the intermedial binding layer 710.
Further, neighbor void cells (e.g., void cells 722, 724) are
deflected, but not substantially compressed, by compression of void
cell 704. By engaging adjacent void cells, this yields a higher
resistance to compression as the cellular cushioning system 700
nears a fully deflected state.
[0054] FIG. 8 illustrates a perspective view of an example cellular
cushioning system 800 with a pixilated layer 832. The cellular
cushioning system 800 includes void cells (e.g., void cell 804)
arranged in a top matrix 806 and a bottom matrix 808. The top
matrix 806 is attached to a top surface of a central or intermedial
binding layer 810 and the bottom matrix 808 is attached to a bottom
surface of the intermedial binding layer 810. The intermedial
binding layer 810 links the void cells together while allowing the
void cells of the top matrix 806 to deform independently of one
another, at least within an independent compression range of the
void cells.
[0055] The pixilated layer 832 is a thin sheet of material affixed
to upper extremities of each of the void cells in the top matrix
806. In other implementations, the pixilated layer 832 is affixed
to lower extremities of each of the void cells in the bottom matrix
808. The pixilated layer 832 may be made of similar materials as
the void cells and intermedial binding layer 810. The thickness of
the pixilated layer 832 may vary according to desired flexibility
and durability, for example. The pixilated layer 832 is flat on top
of each void cell and has grooves (e.g., groove 834) between each
of the void cells. The grooves help maintain independent
compression of each of the void cells from adjacent void cells, at
least within an independent compression range of the void cells.
The groove depth and width may be tailored for an intended
independent compression range of the void cells.
[0056] FIG. 9 illustrates an elevation view of an example cellular
cushioning system 900 with a pixilated layer 932 in an unloaded
state. The cellular cushioning system 900 includes void cells
(e.g., void cell 904) arranged in a top matrix 906 and a bottom
matrix 908. The top matrix 906 is attached to a top surface of a
central or intermedial binding layer 910 and the bottom matrix 908
is attached to a bottom surface of the intermedial binding layer
910. The intermedial binding layer 910 links the void cells
together while allowing the void cells to deform independently of
one another, at least within an independent compression range of
the void cells. The pixilated layer 932 is a thin sheet of material
affixed to upper extremities of each of the void cells in the top
matrix 906. The pixilated layer 932 is flat on top of each void
cell and has grooves (e.g., groove 934) between each of the void
cells.
[0057] FIG. 10 illustrates an elevation view of an example cellular
cushioning system 1000 with a pixilated layer 1032 in a partially
loaded state. The cellular cushioning system 1000 includes void
cells (e.g., void cell 1004) arranged in a top matrix 1006 and a
bottom matrix 1008. The top matrix 1006 is attached to a top
surface of a central or intermedial binding layer 1010 and the
bottom matrix 1008 is attached to a bottom surface of the
intermedial binding layer 1010. The intermedial binding layer 1010
links the void cells together while allowing the void cells to
deform independently of one another, at least within an independent
compression range of the void cells. The pixilated layer 1032 is a
thin sheet of material affixed to upper extremities of each of the
void cells in the top matrix 1006. The pixilated layer 1032 is flat
on top of each void cell and has grooves (e.g., groove 1034)
between each of the void cells.
[0058] A load is applied to the void cell 1004 using a test
apparatus 1020. The void cell 1004 compresses vertically without
substantially affecting neighboring void cells (e.g., void cells
1022, 1024) in the top matrix 1006. While void cells 1004, 1022,
1024 are connected with the pixilated layer 1032, grooves 1034,
1036 spread open or otherwise distort to help prevent deflection of
void cell 1004 from substantially affecting the neighboring void
cells. Further, an opposing void cell 1026 in the bottom matrix
1008 is deflected very little because it has a higher resistance to
compression than cell 1004 and load is distributed via binding
layer 1010. If the load were applied to a group of void cells as
opposed to the single void cell 1004, the group of void cells would
be compressed and void cells adjacent to the compressed group of
void cells would remain relatively uncompressed. This relationship
is referred to herein as decoupling the void cells from one
another. The decoupling is only applicable up to a predetermined
deflection, as illustrated by FIG. 11.
[0059] FIG. 11 illustrates an elevation view of an example cellular
cushioning system 1100 with a pixilated layer 1132 in a fully
loaded state. The cellular cushioning system 1100 includes void
cells (e.g., void cell 1104) arranged in a top matrix 1106 and a
bottom matrix 1108. The top matrix 1106 is attached to a top
surface of a central or intermedial binding layer 1110 and the
bottom matrix 1108 is attached to a bottom surface of the
intermedial binding layer 1110. The intermedial binding layer 1110
links the void cells together while allowing the void cells to
deform independently of one another, at least within an independent
compression range of the void cells. The pixilated layer 1132 is a
thin sheet of material affixed to upper extremities of each of the
void cells in the top matrix 1106. The pixilated layer 1132 is flat
on top of each void cell and has grooves (e.g., groove 1134)
between each of the void cells.
[0060] Similar to that shown in FIG. 10, a load is applied to the
void cell 1104 using a test apparatus 1120. The test apparatus 1120
is applying a greater force than test apparatus 1020 of FIG. 10,
and is compressing the cellular cushioning system 1100 further.
Void cell 1104 is fully compressed and opposing void cell 1126 is
nearly, if not fully compressed. While void cells 1104, 1122, 1124
are connected with the pixilated layer 1132, grooves 1134, 1136
unfold and prevent deflection of the void cell 1104 from fully
engaging the neighboring void cells, even in a fully deflected
state. Since the intermedial binding layer 1110 is engaged once the
void cell 1126 is compressed, neighbor opposing void cells in the
bottom matrix 1108 are partially compressed by compression of void
cell 1104. The depth and width of the grooves within the pixilated
layer 1132 affects to what degree deflection of a void cell affects
adjacent void cells. By engaging adjacent void cells, this yields a
higher resistance to compression as the cellular cushioning system
1100 nears a fully deflected state.
[0061] FIG. 12 illustrates a perspective view of an example curved
cellular cushioning system 1200. The cellular cushioning system
1200 includes void cells (e.g., void cell 1204) arranged in a top
matrix 1206 and a bottom matrix 1208. The top matrix 1206 is
attached to a top surface of a central or intermedial binding layer
1210 and the bottom matrix 1208 is attached to a bottom surface of
the intermedial binding layer 1210. The intermedial binding layer
1210 links the void cells together while allowing the void cells to
deform independently of one another, at least within an independent
compression range of the void cells.
[0062] The cellular cushioning system 1200 may be applied over a
curved surface 1253 (e.g., an interior of a helmet). Because the
intermedial binding layer 1210 is located between the top matrix
1206 and bottom matrix 1208 of void cells, the intermedial binding
layer 1210 does not restrict the cellular cushioning system 1200 to
planar applications. The cellular cushioning system 1200 may be
manipulated to conform to any surface that is to be cushioned from
contact with a user's body. Even when the cellular cushioning
system 1200 is manipulated to conform to a curved surface, the void
cells are still oriented substantially perpendicular to the curved
surface. This ensures consistent resistance to compression from the
void cells.
[0063] FIG. 13 illustrates a displacement over force graph 1300 for
neighboring void cells in an example cellular cushioning system.
The graph 1300 illustrates the relationship between force and
displacement of a loaded void cell (dotted line 1310) versus the
relationship between force and displacement of neighboring void
cells (solid line 1320). At lower forces (e.g., at approximately
0.0-2.5 lbs.), the loaded void cell is compressed significantly
with little change in force (i.e., non-spring like behavior or
non-compliant with Hooke's Law), at least within an independent
compression range of the void cells. As the void cell becomes
nearly fully compressed, it takes an increasing amount of force to
continue to compress the loaded void cell (e.g., at approximately
2.5-7.5 lbs). When the void cell is nearly fully compressed, it
takes a relatively large increase of force to compress the void
cell a relatively small additional amount (e.g., approximately
7.5-17.5 lbs).
[0064] At smaller compression displacements of the loaded void cell
(e.g., 0.0-1.5 in), neighboring void cells are not significantly
compressed (e.g., illustrated by independent compression range
1338. As the loaded void cell becomes more compressed (e.g.,
1.5-2.7 in), however, the neighboring void cells experience some
compression. In one implementation, this is due to deformation of a
central or intermedial binding layer and/or pixilated layer
associated with both the loaded void cell and the neighboring void
cells. However, the relative magnitude of the compression of the
neighboring void cells as compared to the loaded void cell remains
relatively small (in one implementation, a maximum of approximately
20%). As a result, even under fully or nearly fully loaded
conditions, the neighboring void cells in the cellular cushioning
system remain mostly independent.
[0065] FIG. 14 illustrates a displacement over force graph 1400 for
opposing void cells in an example cellular cushioning system. The
graph 1400 illustrates the relationship between force and
displacement of a void cell in a top matrix of void cells (solid
line 1410) versus the relationship between force and displacement
of an opposing void cell in a bottom matrix of void cells (dotted
line 1420). At lower forces (e.g., at approximately 0.0-5.0 lbs.),
the force/displacement relationship of each of the opposing void
cells is substantially linear and equal. Above approximately 5.0
lbs., but below approximately 30.0 lbs., the top void cell achieves
substantial deflection before the bottom void cell. Above 30.0
lbs., the force/displacement relationship of each of the opposing
void cells is again substantially linear and equal.
[0066] In other implementations, the void cell in the top matrix of
void cells will have an independent compression range within which
the opposing void cell in the bottom matrix of void cells is
substantially uncompressed, similar to the relationship between
neighboring void cells as illustrated in FIG. 13.
[0067] FIG. 15 illustrates a pressure over displacement graph 1500
for two example cellular cushioning systems compared to three other
cushioning systems. The graph 1500 illustrates the relationship
between pressure applied to the cushioning systems and compressive
displacement of the cushioning systems. Line 1510 represents a
first example thermoplastic elastomer cellular cushioning system
with 0.5'' wide, tall, and deep square void cells. Further, the
void cells are aligned and opposing each other with a 25 mil wall
thickness. Line 1520 represents a second example cellular
cushioning system with 0.5'' wide, tall, and deep flat top square
void cells. The void cells are offset and opposing each other with
a 25 mil wall thickness. Line 1530 represents a 2.0'' thick
reticulated urethane comfort foam used in mattress applications and
lines 1540 and 1550 each represent a convoluted comfort foam
mattress topper.
[0068] Lines 1510 and 1520, which represent cellular cushioning
systems, as disclosed herein illustrate that a relatively low
pressure is required to cause displacement (e.g., from 0 to about
0.4 inches) of the cellular cushioning systems as compared to the
foam illustrated by line 1530). This may enhance user comfort under
lower load conditions. Further, under higher load conditions (e.g.,
from about 0.4 to about 0.8 inches), lines 1510 and 1520 illustrate
that the cellular cushioning systems exhibit a relatively high
pressure required to cause additional displacement of the cellular
cushioning systems as compared to all three foams (lines 1530,
1540, and 1550). As a result, the cellular cushioning systems are
able to offer a user greater support under higher load conditions
than any the foam systems and better comfort to the user under low
load conditions than at least one of the foam systems.
[0069] FIG. 16 illustrates a kneepad 1600 incorporating an example
cellular cushioning system 1605. The cellular cushioning system
1605 includes void cells (e.g., void cell 1604) or support units
arranged in a top matrix and a bottom matrix (not shown). The
cellular cushioning system 1600 is depicted conforming to a curved
inner surface of the kneepad 1600. In various implementations, the
kneepad 1600 is rigid, semi-rigid, or flexible, depending on the
purpose of the kneepad 1600. The top matrix is attached to a top
surface of a central or intermedial binding layer 1610 and the
bottom matrix is attached to a bottom surface of the intermedial
binding layer 1610. The intermedial binding layer 1610 links the
void cells together while allowing the void cells to compress
independently of one another, at least within an independent
compression range of the void cells (as discussed in detail
above).
[0070] In one implementation, each of the void cells are
individually attached to the intermedial binding layer 1610 and not
to each other. Further, each of the void cells within the top
matrix are individually compressible under load without compression
of adjacent (i.e., neighboring, opposing, and/or neighbor opposing)
void cells, within the independent compression range of the void
cells. Outside of the independent compression range, compression of
an individual void cell causes adjacent void cells to compress via
deflection of the intermedial binding layer 1610. For example, void
cells forming the top matrix conform to the surface contour of a
user's knee and individually compress and distribute a load on the
user's knee evenly over those areas.
[0071] Each of the void cells creates a relatively constant force
to resist deflection. In one implementation, the void cells in the
bottom matrix have a higher resistance to deflection that the void
cells in the top matrix. As a result, in less highly loaded areas
(e.g., sides of the user's knees), only void cells in the top
matrix are engaged and the user's weight is distributed evenly over
contact of the user with the cellular cushioning system 1605. In
more compressed areas (e.g., the center of the user's knees), the
user experiences increased pressure because the user's weight is
sufficient to additionally deflect the intermedial binding layer
1610 and thus engage the void cells in the bottom matrix.
Resistance to deflection of the individual void cells within the
top and/or bottom matrices may be varied according to expected
loading of the kneepad 1600.
[0072] FIG. 17 illustrates example operations 1700 for
manufacturing and using a cellular cushioning system. A first
molding operation 1705 molds a first matrix of void cells
interconnected by a first planar intermedial binding layer. A
second molding operation 1710 molds a second matrix of void cells
interconnected by a second planar intermedial binding layer. The
intermedial binding layers may have openings at each of the void
cells. In another implementation, the matrices of void cells are
formed simultaneously from a sheet of material using a blow molding
tube (e.g., parison tube). In yet other implementation, the first
matrix of void cells and second matrix of void cells are
interconnected by singular planar intermedial binding layer.
[0073] A bonding operation 1715 bonds a face of the first planar
intermedial binding layer to a face of the second planar
intermedial binding layer with the matrices of void cells extending
away from the planar intermedial binding layers. In one
implementations, the bonding operation 1715 results in a single
intermedial binding layer linking the first matrix of void cells
and the second matrix of void cells together. In another
implementation, the bonding operation 1715 periodically tack welds
the intermedial binding layers together resulting in two distinct
binding layers fixedly attached together. Periodically bonding the
intermedial binding layers together may leave fluid passageways
between the void cells lying between the intermedial binding
layers.
[0074] Further, the first and second intermedial binding layers may
be laminated together such that openings in opposing void cells in
the first half and second half of the cellular cushioning system
meet one another. Alternatively, the first half and second half of
the cellular cushioning system may be manufactured in one step
using any known manufacturing techniques. Further yet, the first
half and second half of the cellular cushioning system may be
manufactured using techniques other than molding (e.g., vacuum
forming, pressure forming, and extruding).
[0075] In implementations utilizing a pixilated layer, an optional
molding operation 1720 molds the pixilated layer for the cellular
cushioning system. The pixilated layer is generally planar with a
series of channels that frame areas of the pixilated layer
generally corresponding to the sizes and positions of individual
void cells in the first and/or second matrices of void cells. The
pixilated layer is further configured with a thickness, stiffness,
channel depth, channel width to achieve a desired degree of
independent compression of the individual void cells. If the
pixilated layer is utilized, optional attaching operation 1725
attaches the pixilated layer to an outer surface of either the
first or the second matrices of void cells oriented generally
parallel to the planar intermedial binding layer. The pixilated
layer may be attached by being glued, welded, or using any other
attachment methods. Further, two pixilated layers may be used, one
attached to the first matrix of void cells and a second attached to
the second matrix of void cells.
[0076] A decision operation 1727 decides if the cellular cushioning
system needs additional layers of void cells bound together with a
binding layer. If yes, operations 1705 through 1727 are repeated.
If no, attaching operation 1729 attaches the multiple layers of the
cellular cushioning system together. If there is only one layer of
the cellular cushioning system, operation 1729 is inapplicable.
[0077] A compressing operation 1730 compresses one or more of the
void cells within an independent compression range without
significantly compressing one or more adjacent void cells. Adjacent
void cells include one or more of neighboring void cells, opposing
void cells, and neighbor opposing void cells. In one
implementation, the neighboring void cells are fluidly connected by
dedicated passages or merely gaps between the first and second
intermedial binding layers. This allows the air or other fluid
within the compressed void cell to enter and exit the void
cell.
[0078] The independent compression range is the displacement range
of the compressed void cell that does not significantly compress
adjacent void cells. The void cell is compressed in a general
direction substantially normal to the intermedial binding layers.
If the void cell is compressed beyond the independent compression
range, the intermedial binding layers will be deflected and/or the
void cells adjacent the compressed void cell will be compressed. In
one implementation, even after the independent compression
displacement is exceeded, the void cells adjacent the compressed
void cell are compressed significantly less than the compressed
void cell itself. Further, multiple void cells may be compressed in
compressing operation 1725.
[0079] A de-compressing operation 1735 de-compresses one or more
compressed void cells without substantially de-compressing at least
one adjacent compressed void cell, so long as the de-compressed
void cell is within its independent compression range. If the
de-compressed void cell is outside its independent compression
range, adjacent void cells will also de-compress until the
de-compressed void cell returns within its independent compression
range. If the de-compressed void cell is de-compressed to a zero
load, the cellular cushioning system will return to its original
state. In other implementations, the cellular cushioning system may
be permanently deformed (e.g., in a one-time use cellular
cushioning system).
[0080] The above specification, examples, and data provide a
complete description of the structure and use of exemplary
embodiments of the invention. Since many embodiments of the
invention can be made without departing from the spirit and scope
of the invention, the invention resides in the claims hereinafter
appended. Furthermore, structural features of the different
embodiments may be combined in yet other embodiments without
departing from the recited claims.
* * * * *