U.S. patent application number 15/849335 was filed with the patent office on 2018-04-26 for cushion system.
The applicant listed for this patent is Neven Sleep, LLC. Invention is credited to Randy A. Reynolds.
Application Number | 20180110341 15/849335 |
Document ID | / |
Family ID | 61971125 |
Filed Date | 2018-04-26 |
United States Patent
Application |
20180110341 |
Kind Code |
A1 |
Reynolds; Randy A. |
April 26, 2018 |
CUSHION SYSTEM
Abstract
Embodiments of the disclosure include a cushion system, which
may be part of a sleeping system or a seating system, for example.
A seating system may comprise a cushion, which comprises a cushion
cover; and one or more foam layers within the cushion cover,
wherein the cushion is spring-free. The one or more foam layers may
each comprise a plurality of substantially vertical air passageways
which pass through the entire thickness of the corresponding foam
layer. The one or more foam layers may comprise a base layer of
foam; a middle sculpted layer of foam having for example a sculpted
surface with a plurality of foam pillars projecting outward; and a
top layer of foam with uniform thickness, with the sculpted layer
sandwiched between the top and base layers.
Inventors: |
Reynolds; Randy A.; (High
Point, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Neven Sleep, LLC |
Dallas |
TX |
US |
|
|
Family ID: |
61971125 |
Appl. No.: |
15/849335 |
Filed: |
December 20, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15419386 |
Jan 30, 2017 |
|
|
|
15849335 |
|
|
|
|
15183348 |
Jun 15, 2016 |
|
|
|
15419386 |
|
|
|
|
14681278 |
Apr 8, 2015 |
|
|
|
15419386 |
|
|
|
|
62289773 |
Feb 1, 2016 |
|
|
|
62175767 |
Jun 15, 2015 |
|
|
|
61977989 |
Apr 10, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 21/044 20130101;
A47C 19/025 20130101; A47C 27/15 20130101; A47C 27/144
20130101 |
International
Class: |
A47C 21/04 20060101
A47C021/04; A47C 27/14 20060101 A47C027/14; A47C 19/02 20060101
A47C019/02; A47C 27/15 20060101 A47C027/15 |
Claims
1. A seating system comprising: a cushion, which comprises: a
cushion cover; and one or more foam layers within the cushion
cover; wherein the cushion is spring-free; wherein the one or more
foam layers each comprise a plurality of substantially vertical air
passageways which pass through the entire thickness of the
corresponding foam layer; and wherein the one or more foam layers
comprise: a base layer of foam; a middle sculpted layer of foam
having a sculpted lower surface with a plurality of foam pillars
projecting downward, wherein the middle sculpted layer of foam is
located atop and in contact with the base layer of foam; and a top
layer of foam with uniform thickness, which is located above the
middle sculpted layer.
2. The seating system of claim 1, wherein the middle sculpted layer
of foam further comprises a sculpted upper surface with a plurality
of foam pillars projecting upward.
3. A cushion comprising: a cover; and one or more foam layers
comprising: at least one sculpted foam layer comprising a plurality
of foam pillars; and at least one additional foam layer.
4. The cushion of claim 3, wherein the cushion is part of the
seating system.
5. The cushion of claim 3, wherein the cushion is spring-free.
6. The cushion of claim 3, wherein the one or more foam layers each
comprise a plurality of substantially vertical air passageways.
7. The cushion of claim 6, wherein at least some of the
substantially vertical air passageways in the foam layers align to
provide continuous airflow paths from the bottom surface of the
cushion to an upper surface of the cushion.
8. The cushion of claim 3, wherein the one or more foam layers
comprise: a base layer of foam; a middle sculpted layer of foam
having a sculpted lower surface with a plurality of foam pillars
projecting downward, wherein the middle sculpted layer of foam is
located atop and in contact with the base layer of foam; and a top
layer of foam with uniform thickness, which is located above the
middle sculpted layer.
9. The cushion of claim 8, wherein the middle sculpted layer of
foam further comprises a sculpted upper surface with a plurality of
foam pillars projecting upward.
10. The cushion of claim 9, wherein the sculpted upper surface of
the middle sculpted layer of foam comprises pillars of a different
size than the sculpted lower surface of the middle sculpted layer
of foam.
11. The cushion of claim 8, wherein the base layer of foam
comprises a thickness that is approximately double the thickness of
the top layer of foam.
12. The cushion of claim 3, further comprising an outer wrap
configured to wrap around at least a portion of the one or more
foam layers and positioned between the one or more foam layers and
the cover.
13. The cushion of claim 12, wherein the outer wrap comprises
polyethylene terephthalate (PET).
14. The cushion of claim 3, wherein the one or more foam layers
comprise: a base layer of foam; a middle sculpted layer of foam
having a sculpted upper surface with a plurality of foam pillars
projecting upward, wherein the middle sculpted layer of foam is
located atop and in contact with the base layer of foam; and a top
layer of foam with uniform thickness, which is located above the
middle sculpted layer.
15. The cushion of claim 3, wherein the cover comprises an air
permeable element in a bottom surface of the cover.
16. A cushion for use in a seating system, the cushion comprising:
one or more foam layers, at least one foam layer comprising a
plurality of foam pillars; a cushion cover configured to surround
the one or more foam layers; and an outer wrap located between the
one or more foam layers and the cushion cover, configured to wrap
around at least a portion of the foam layers, wherein the cushion
is spring-free.
17. The cushion of claim 16, wherein the one or more foam layers
comprise: a base layer of foam; a middle sculpted layer of foam
having a sculpted lower surface with a plurality of foam pillars
projecting downward, wherein the middle sculpted layer of foam is
located atop and in contact with the base layer of foam; and a top
layer of foam with uniform thickness, which is located above the
middle sculpted layer.
18. The cushion of claim 16, wherein the base layer of foam
comprises a thickness that is approximately double the thickness of
the top layer of foam.
19. The cushion of claim 16, wherein the middle sculpted layer
comprises a dual independent foam pillar layer comprising a
plurality of foam pillars projecting downward from a bottom surface
of the middle sculpted layer, and comprising a plurality of foam
pillars projecting upward from a top surface of the middle sculpted
layer.
20. The cushion of claim 16, wherein the middle sculpted layer
comprises a solid edge portion without any foam pillars located
about at least a portion of the outer edge of the middle sculpted
layer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent Ser. No.
15/419,386 filed Jan. 30, 2017 and entitled "Ventilating Sleep
System" which is a non-provisional of and claims priority to
related U.S. provisional patent application Ser. No. 62/289,773
filed Feb. 1, 2016 and entitled "Mattress Ventilating Foundation
and Sleep System". This application also claims priority to U.S.
patent Ser. No. 15/183,348 (entitled "Mattress Ventilating
Foundation and Sleep System" and filed Jun. 15, 2016) and to
related U.S. provisional patent application Ser. No. 62/175,767
(filed Jun. 15, 2015 and entitled "Mattress Ventilating Foundation
and Sleep System"); and to U.S. patent application Ser. No.
14/681,278 (entitled "Independent Foam Spring Mattress" and filed
Apr. 8, 2015), and to related provisional patent application Ser.
No. 61/977,989 (entitled "Independent Foam Spring Mattress" and
filed Apr. 10, 2014). Thus, this application claims priority to all
six applications set forth above. All of the above-cited priority
documents are hereby incorporated by reference for all purposes as
if reproduced in their entirety to the extent that they are
compatible (e.g. not inconsistent) with and/or do not directly
contradict disclosure herein (e.g. the explicit disclosure herein
would always govern/trump in instances of contradiction,
inconsistency, or incompatibility).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more complete understanding of the present disclosure,
reference is now made to the following brief description, taken in
connection with the accompanying drawings and detailed description,
wherein like reference numerals represent like parts.
[0005] FIG. 1A is a schematic diagram illustrating an exemplary
sleep/bedding system, in which a mattress may be used atop one of
two possible ventilating foundation exemplary variants;
[0006] FIG. 1B is a schematic diagram illustrating an alternate
exemplary sleep/bedding system, in which a mattress may be used
atop one of two possible ventilating foundation exemplary
variants;
[0007] FIGS. 1Ca, 1Cb and 1Cc illustrate a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
internal air input unit with optional HEPA filter and an access
panel, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view (from the foot of the bed), and FIG. 1Cc showing a top
view;
[0008] FIGS. 1Da, 1Db and 1Dc illustrate a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
external air input unit with optional HEPA filter and an access
panel, with FIG. 1Da showing a side view, FIG. 1Db showing an end
view (from the foot of the bed), and FIG. 1Dc showing a top
view;
[0009] FIG. 1E illustrates a perspective view of an exemplary
sleep/bedding system similar to FIGS. 1Ca, 1Cb and 1Cc;
[0010] FIGS. 2A1 and 2A2 illustrate an exemplary mattress
embodiment (without the cover being shown, to allow viewing of
internal components) which is an all-foam (e.g. spring-free)
mattress configured for ventilation, with FIG. 2A1 showing an
exploded perspective view of an exemplary mattress and FIG. 2A2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2A1;
[0011] FIGS. 2B1 and 2B2 illustrate an exemplary mattress
embodiment (similar to that of FIG. 2A1 in configuration, but
comprising different foam materials for at least some of the
layers) configured for ventilation, with FIG. 2B1 showing an
exploded perspective view of an exemplary mattress and FIG. 2B2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2B1;
[0012] FIG. 3 illustrates a top/plan view of an exemplary base
(sculpted) layer of foam (of the sort that might be used in FIG.
2A1, for example);
[0013] FIG. 4 illustrates a bottom/plan view of an exemplary middle
sculpted foam layer (of the sort that might be used in FIG. 2A1,
for example);
[0014] FIGS. 5A and 5B illustrate exemplary mattress embodiments
configured for ventilation;
[0015] FIGS. 6A and 6B illustrate detailed views of the middle
sculpted foam layers;
[0016] FIGS. 7A and 7B illustrate alternative detailed views of the
middle sculpted foam layers; and
[0017] FIG. 8 illustrates an exemplary base foam layer similar to
that shown and described in FIG. 3.
[0018] FIG. 9A illustrates an exemplary cushion embodiment (without
the cover being shown, to allow viewing of internal components)
which is an all-foam (e.g. spring-free) cushion configured for
seating.
[0019] FIG. 9B illustrates an exemplary cover that may be installed
over the cushion shown in FIG. 9A.
[0020] FIG. 10 illustrates a cut-away (e.g. cross-section)
elevation view of an exemplary cushion embodiment.
[0021] FIG. 11 illustrates a cut-away (e.g. cross-section)
elevation view of another exemplary cushion embodiment.
[0022] FIG. 12 illustrates a cut-away (e.g. cross-section)
elevation view of another exemplary cushion embodiment.
[0023] FIG. 13 illustrates a cut-away (e.g. cross-section)
elevation view of another exemplary cushion embodiment.
[0024] FIG. 14 illustrates a cut-away (e.g. cross-section)
elevation view of an exemplary cushion embodiment comprising one or
more pinholes through one or more layers of the cushion.
[0025] FIG. 15 illustrates a cut-away (e.g. cross-section)
elevation view of another exemplary cushion embodiment comprising
one or more pinholes through one or more layers of the cushion.
[0026] FIG. 16 illustrates a cut-away (e.g. cross-section)
elevation view of another exemplary cushion embodiment comprising
one or more pinholes through one or more layers of the cushion.
[0027] FIG. 17 illustrates a cut-away (e.g. cross-section)
elevation view of another exemplary cushion embodiment comprising
one or more pinholes through one or more layers of the cushion.
[0028] FIG. 18 illustrates an exploded perspective view of the
cushion as described in FIG. 14.
[0029] FIG. 19 illustrates another exploded perspective view of the
cushion as described in FIG. 14.
[0030] FIG. 20 illustrates an exploded perspective view of the
cushion as described in FIG. 1.
DETAILED DESCRIPTION
[0031] It should be understood at the outset that although
illustrative implementations of one or more embodiments are
illustrated below, the disclosed systems and methods may be
implemented using any number of techniques, whether currently known
or not yet in existence. The disclosure should in no way be limited
to the illustrative implementations, drawings, and techniques
illustrated below, but may be modified within the scope of the
appended claims along with their full scope of equivalents.
[0032] The following brief definition of terms shall apply
throughout the application:
[0033] The term "comprising" means including but not limited to,
and should be interpreted in the manner it is typically used in the
patent context.
[0034] The term "foam" means a material in a lightweight cellular
form, for example resulting from introduction of gas bubbles during
manufacture to produce a consistent cell structure, and/or any of
various light, porous, semirigid or spongy materials or cellular
solids, usually the solidified form of a liquid full of gas
bubbles, which may be used as a building material or for shock
absorption, and includes open cell foams such as polyurethane foam,
latex, memory foam, specialty memory foam, gel memory foam, gel
latex foam or other gel foams, etc.;
[0035] The term "IFD" means indentation force deflection, and
describes a well-known measurement system for foam firmness;
[0036] Directions, such as up (e.g. upward) and/or down (e.g.
downward), typically are intended to be based on the mattress (or
sleep system or foundation) in its normal sleeping position as
understood by persons of skill; for example, the upper surface of
the mattress might face the ceiling and/or serve as the sleep
surface upon which the user might lie, while the bottom surface of
the mattress might face the floor or ground and/or be placed atop a
foundation;
[0037] The phrases "in one embodiment," "according to one
embodiment," and the like generally mean that the particular
feature, structure or characteristic following the phrase may be
included in at least one embodiment of the present invention, and
may be included in more than one embodiment of the present
invention (importantly, such phrases do not necessarily refer to
the same embodiment);
[0038] If the specification describes something as "exemplary" or
as an "example," it should be understood that refers to a
non-exclusive example:
[0039] The terms "about" or "approximately" or the like, when used
with a number may mean that specific number, or alternatively, a
range in proximity to the specific number, as understood by persons
of skill in the art field (for example, +/-10%); and
[0040] If the specification states a component or feature "may,"
"can," "could," "should," "would," "preferably," "possibly,"
"typically," "optionally," "for example," "often," or "might" (or
other such language) be included or have a characteristic, that
particular component or feature is not required to be included or
have the characteristic. Such component or feature may be
optionally included in some embodiments, or it may be excluded.
[0041] Typical sleep or bedding systems may have a conventional
(typically inner-spring) cushion (or mattress) located atop a
conventional box spring foundation unit. In such conventional sleep
systems, there is typically no interaction between the mattress and
the box spring foundation, other than the fact that the box spring
foundation supports (e.g. underlies) the mattress. While
conventional sleep systems may be sufficient for some
sleepers/users, many users might desire and are looking for an
improved sleep experience.
[0042] For example, many users might find conventional sleep
systems rather hot (especially when the mattress includes foam, and
most especially when the mattress includes memory foam), resulting
in a rather sweaty, uncomfortable night's sleep of the sort that
may result in restlessness and lack of deep slumber. Other users
may have allergy problems, and a conventional mattress may, over
time, collect dust and other allergens that might trouble the user
during sleep. Additionally, conventional inner-spring mattresses
may not support the user's body as effectively as desired, perhaps
resulting in discomfort.
[0043] Similar cushions may also be used for seating systems, such
as chairs, sofas, vehicle seats, and/or supplemental seating
cushions, where these seating cushions may suffer from similar
issues as the mattress (or sleep cushion) described above.
[0044] The presently disclosed embodiments may address one or more
of these issues. For example, disclosed embodiments may provide
ventilation (e.g. airflow), such that the cushion may better
breathe and/or disperse heat (e.g. improving sleep comfort while a
user is atop the mattress, or comfort while a user is sitting on
the cushion); disclosed embodiments may refresh the cushion, for
example sucking out stale air with potential allergens (which could
happen either when the user is atop the cushion or, alternatively,
when the user is not on the cushion (for example, based on a
timer)); and/or disclosed embodiments may provide superior
comfort/support. The disclosed embodiments may comprise cushions,
such as mattresses, which may be used in sleep systems.
Additionally, the disclosed embodiments may comprise cushions which
may be used in seating systems, where similar qualities and/or
functions may be desired for sleep systems and seating systems.
[0045] Embodiments of the disclosure typically include a cushion
system, which may be part of a sleeping system or a seating system,
for example. Such a cushion might comprise; a cover; and two or
more foam layers comprising: a sculpted foam layer comprising a
plurality of foam pillars (e.g. projecting out of at least one
(sculpted) surface); and at least one additional foam layer (e.g.
typically contacting either the lower or upper surface of the
sculpted foam layer. Such cushion embodiment typically would be
(metal) spring-free. In some cushion embodiments, the at least one
additional foam layer would comprise a base layer of foam (e.g.
underlying and in contact with the lower surface of the sculpted
foam layer) and/or a top layer of foam (e.g. atop and in contact
with the upper surface of the sculpted foam layer). Often, the
sculpted foam layer would be sandwiched between the base layer and
the top layer of foam (sometimes with other, intermediate (foam)
layers therebetween). In some embodiments, the sculpted foam layer
would have a single sculpted surface (e.g. with pillars of foam
projecting outward), and such sculpted foam surface could be
oriented either downward or upward (although typically if oriented
upward there would be at least one foam layer located above it to
provide a flat upper (e.g. sitting or sleeping) surface. So,
typically in cushions having only two foam layers (e.g. only one
additional foam layer in addition to the sculpted foam layer), if
the sculpted layer is underlain by a base layer then the sculpted
layer would be facing downward (e.g. with sculpted layer on the
lower surface having pillars projecting downward to contact the
base foam layer). In some cushion embodiments, the top and base
foam layers may be connected (e.g. formed of a single layer/sheet
of foam which has been bent/folded to enwrap the sculpted/middle
foam layer. Various exemplary embodiments of such disclosed
cushions will be described in more detail below, providing
additional, exemplary details (for example with respect to sleep
systems and/or seating systems).
[0046] Often, disclosed embodiment sleep systems might have the
cushion/mattress and foundation interact with each other (for
example, being in fluid communication), to provide one or more such
sleep benefits, as persons of skill will understand based on the
disclosure below. Typical foundation embodiments might comprise an
upper surface (of a cover) allowing airflow therethrough (and
typically having an air flow unit (such as a fan or air pump)
operable to direct air through the upper surface), while typical
mattress embodiments might comprise a bottom surface (of a cover)
(and in some embodiments a top surface of the cover) allowing
airflow therethrough (and often also including air pathways (such
as pinholes) vertically throughout the mattress). So, most
disclosed sleep system embodiments typically might have a
ventilation mattress atop a ventilation foundation, with airflow
therebetween.
[0047] Disclosed embodiments relate generally to mattress
ventilation sleep systems (and/or related foundations and/or
mattresses), which typically would include a mattress ventilation
foundation in conjunction with a mattress (for example, typically
located atop the foundation). Typically, the mattress ventilation
foundation might comprise a support structure (such as support
struts and structural frame, for example, which might be similar to
a conventional box spring foundation), operable to support a
mattress in a manner similar to a conventional mattress foundation
(and which typically might be hollow); an air flow unit (such as a
forced air supply unit (e.g. fan) operable to either blow air into
the supported mattress atop the foundation or suck air from the
supported mattress); and a cover (including an upper, support
surface upon which the mattress would lay), which would typically
include a means for airflow between the foundation (e.g. the air
flow unit) and the supported mattress (e.g. an air permeable
element/panel, such as one or more panels of high air flow mesh
fabric located in the upper surface of the foundation cover, for
example). In some embodiments, the air flow unit might include
filtration (such as a HEPA filter), which might for example be
located at the intake and/or outtake for the air flow unit. The air
flow unit might be housed within the support structure of the
foundation in some embodiments, while in other embodiments the air
flow unit might be external to (for example, mounted onto) the
support structure (for example, mounted onto the bottom surface of
the cover/support structure and in fluid communication with the
hollow cavity within the cover/support structure by an
opening).
[0048] Typically, the foundation cover would
surround/enclose/encompass the support structure on all sides, and
the foundation cover would be airtight/air impermeable (e.g. formed
of an airtight material such as fabric overtop a polyvinyl
substrate, for example) except for the attachment/fluid
communication port (e.g. inlet/outlet/opening) for the air flow
unit (which allows fluid communication between the external
environment and the hollow cavity within the foundation, for
example) and the means for airflow between the foundation and the
supported mattress (e.g. air permeable element/panel, such as high
airflow mesh panel(s)). For example, the bottom and side surfaces
of the foundation cover would typically be airtight (except for the
inlet/outlet/opening for the air flow unit), while the upper
surface of the foundation cover (which would typically support
and/or contact the bottom surface of the mattress) would include
the means for airflow between the foundation (e.g. the air flow
unit) and the supported mattress (e.g. at least one air permeable
element/panel, such as one or more panels of high air flow mesh
fabric located in the upper surface of the foundation cover, for
example). In some embodiments, the entire upper surface of the
foundation cover might be formed of high airflow mesh fabric, while
in other embodiments, the upper surface might include a plurality
of panels of such high airflow mesh fabric and/or other means for
allowing airflow between the foundation and the supported mattress
(such as air passageways).
[0049] Typically, air might flow through the hollow cavity of the
foundation to the upper surface of the foundation cover (as
directed by the air flow unit, for example), but alternatively,
there could be tubing or ducts leading from the air flow unit to
the upper surface of the foundation cover (e.g. to specific
locations on the upper surface of the foundation cover
corresponding to the pinholes in the supported mattress thereupon).
In such embodiments, it might not be necessary for the bottom and
sides of the foundation cover to be airtight.
[0050] Additionally, some embodiments of the air flow unit might
optionally comprise a climate control unit, which might cool and/or
heat air flowing through the air flow unit (for example, before the
air flows into the supported mattress atop the foundation). In some
embodiments, the climate control unit would be located within the
housing for the air flow unit, while in other embodiments, the
climate control unit might be located external to such housing
(e.g. it may be either separate or combined with the blower portion
of the air flow unit). Similarly, embodiments of the air flow unit
might optionally comprise an air ionizer (for electric
sterilization of air prior to entering the foundation) and/or an
ultraviolet germicidal irradiation light (for irradiating light
sufficiently to substantially destroy harmful microbes, such as
bacteria, prior to entering the foundation). As with the optional
climate control unit, the air ionizer and/or UV germicidal
irradiation light units could be located within the housing for the
air flow unit or (in other embodiments) located external to such
housing (e.g. each may be either separate or combined with the
blower portion of the air flow unit). Typically, the air flow unit
might be controlled/operated by a controller, which might be a
separate device and which might allow for remote control of the air
flow device (e.g. the blower and/or climate control unit). In some
embodiments, the controller and/or air flow unit may include a
timer, for example allowing the user to set the air flow unit for a
regular (for example daily or weekly) refresh cycle. And typically,
the air flow unit would be electrically powered (for example with a
plug allowing power to be drawn from a standard electrical wall
socket).
[0051] So typically in operation, air might be drawn into the
foundation (for example by the air flow unit, through the intake
opening/fluid communication port), and then forced out the upper
surface (for example through a high airflow mesh fabric upper
surface or panel(s)) and into the supported mattress. This may
allow for a supported mattress to be refreshed with clean air
and/or may enhance sleep comfort for a user lying atop the
mattress. Alternatively, air might be sucked out of the supported
mattress (for example by operating the air flow unit in reverse to
create suction), into the foundation (for example through the upper
surface of the cover of the foundation, perhaps through one or more
high air flow mesh panels), and out the air flow unit's outtake
opening/fluid communication port (which might be the same intake
opening if the air flow device is operated for blowing instead of
suction in some embodiments). In some embodiments, the air flow
unit might be operable to run in forward (e.g. blowing mode) and/or
reverse (e.g. suction mode). So in some embodiments, the air flow
unit might be run in reverse (for example, suction mode to suck air
from the supported mattress) to refresh the mattress (e.g. a
refresh cycle, which in some embodiments might be periodically
run), while the air flow unit might be run in forward (for example,
blowing mode to blow fresh (e.g. filtered) and/or climate
controlled (e.g. cooled or heated) and/or ionized and/or UV
sanitized air into the supported mattress) to enhance sleep comfort
atop the supported mattress (for example, improving allergy
conditions and/or temperature and/or airflow for the user atop the
supported mattress, perhaps while the user is actually lying
atop/sleeping on the mattress).
[0052] While it is possible that any sort of mattress might be used
to some advantage atop such a ventilation foundation, more
typically specialized air flow (e.g. ventilation) mattress
embodiments might be used in conjunction with the disclosed
foundation embodiments. For example, the mattress might comprise a
mattress cover having a bottom surface which includes a means for
airflow between the foundation and the supported mattress (e.g.
into and/or out of the mattress, for example at least one air
permeable element/panel). For example, in some embodiments the
bottom surface of the mattress cover might be formed of or include
one or more panels of high airflow mesh fabric (or alternatively,
the bottom surface of the mattress cover might include air
passageways, which might correspond to those of the upper surface
of the foundation cover). In some embodiments, the top surface of
the mattress cover might also comprise air permeable element/panel
or other means of airflow into/out of the mattress (e.g. high
airflow mesh or loosely woven fabric panel(s)). And in some
embodiments, the remainder of the mattress cover might be
(substantially) air impermeable. Furthermore, the mattress might
comprise one or more (and typically a plurality of) primarily
vertical air pathways (e.g. pin holes), operable to allow air flow
vertically throughout the mattress (for example from the bottom of
the mattress to the top of the mattress). In some embodiments, the
mattress might be an all-foam and/or spring-free mattress. For
example, the mattress might be formed entirely of layers of foam,
and each layer of foam might include vertical pin holes, at least
some of which align to provide continuous airflow
passages/pathways/pinholes vertically throughout the mattress.
[0053] Some such mattress embodiments might include one or more
foam layers having a sculpted surface with a plurality of foam
pillars. For example, some embodiments might have a base layer of
foam (e.g. the bottom layer of foam) with an upward facing sculpted
surface (e.g. the pillars of foam facing/projecting upward), and
another layer of foam (typically a middle foam layer, located
somewhere between the base foam layer and the uppermost (sleep
surface) layer of foam) with a downward facing sculpted surface
(e.g. the pillars of foam facing/projecting downward). Typically,
the sculpted foam layers would each have scoring (e.g. a series of
grooves/gaps) forming a grid on one surface (termed the sculpted
surface), with the grid pattern resulting in a plurality of foam
pillars projecting outward from a common, unified slab/base of foam
(e.g. the surface opposite the sculpted surface typically would be
flat, such that the foam pillars would all be joined together into
an integral whole layer at their bases/bottoms). The sculpted foam
layer(s) might effectively replace the support functionality of the
springs while also often providing added benefits. For example, a
sculpted foam surface (e.g. foam pillars) may provide more
flexibility in adjusting to various body contours than metal
springs, and therefore may be more effective in reducing pressure
points against the human body than traditional metal springs in
conventional mattresses. More specifically, the layer(s) of foam
with a sculpted surface would typically include a plurality of foam
pillars (or blocks), each of which is freestanding (e.g.
independent) with respect to the other pillars, but all of which
are joined together into a single integral base (which typically
has a flat exterior surface). So, the base portion of the pillars
are all joined together (e.g. a common base), while the remaining
freestanding portion of the layer of foam comprises a plurality of
independent pillars separated from one another by a gap or groove
on all sides. Stated another way, the sculpted layer(s) of foam may
comprise each a base portion (which typically is a uniform flat
sheet of foam) and a pillar portion (which typically comprises a
plurality of independent pillars or blocks of foam, each of which
is completely separate from the other pillars), with the pillar
portion being securely attached to a surface of the base portion
(so in effect the pillars project out from the flat base portion).
Thus, the sculpted surface of the sculpted layer of foam would
typically be the distal surface of the pillars (or pillar portion).
Typically, the sculpted layer of foam may be formed by cutting a
pattern of grooves in one surface (which would then become the
sculpted surface) of an initially uniform (e.g. flat sheet with
constant thickness) sheet of foam, thereby forming a plurality of
foam pillars which extend out from the base portion (with the
pillar portion and the base portion integrally forming a single
layer of foam having different shapes/characteristics on opposing
sides). Thus, the sculpted layer of foam might also be termed a
contour cut layer of foam in some embodiments (since in many
embodiments the layer of foam is sculpted via cutting, for example
contour cutting). In other embodiments, it may be possible to form
the sculpted layer of foam by molding (with the mold forming the
pillar portion projecting outward from the base portion).
Typically, the substantially one entire surface of the sculpted
foam layer (e.g. the entire sculpted surface) would be entirely
comprised of such pillars (e.g. substantially the entire sculpted
surface of the sculpted foam layer would be formed of pillars),
although in other embodiments the sculpted surface might have
pillars only on a portion of the sculpted surface.
[0054] Typical mattress embodiments might have vertical pin holes
passing through (at least) the base portion of the sculpted foam
layers, and such pin holes might typically be positioned to align
with the grooves/gaps between the foam pillars (so that air could
flow continuously through the vertical pin holes and the grooves to
pass from one surface of the sculpted foam layer all the way
through to the other surface of the sculpted foam layer). In some
embodiments, the base layer of foam would comprise a foam component
having a sculpted surface (typically with pillars facing upward)
surrounded by foam edge support perimeter rails (which typically
would be solid blocks of foam encompassing the sides of the base
foam component with sculpted surface, and typically having an
uncompressed height approximately equal to the uncompressed height
of the base foam component (e.g. the upper surface of the edge
support perimeter rails would typically be approximately the same
as the uncompressed height of (e.g. flush with) the upper surface
of the foam pillars of the base foam component with sculpted
surface).
[0055] Typically, mattress embodiments would have at least one
(foam) layer located between the base sculpted foam layer (which
typically would have the sculpted surface (e.g. foam pillars)
facing upward) and the middle sculpted foam layer (which typically
would have the sculpted surface (e.g. foam pillars) facing
downward), and would have at least one (foam) layer located above
the middle sculpted foam layer (e.g. a sleep surface layer
(typically of foam) would be located atop the middle sculpted foam
layer). In some embodiments, the foam pillars of the base sculpted
foam layer would be larger (e.g. the cross-section/footprint/outer
surface of the pillars would be larger) than the foam pillars of
the middle sculpted foam layer. And as mentioned above, typically
the various (foam) layers of the mattress would each have vertical
pin holes, at least some of which would align to provide continuous
airflow from the bottom to the top of the mattress. For example, in
some embodiments all (foam) layers located above the base layer of
foam might have vertical pinholes which entirely align, even though
the base foam layer might have less vertical pinholes spaced
further apart such that only some of the pinholes in the remaining
layers align with pinholes in the base layer. Although the base
layer in some embodiments may have fewer pinholes spaced further
apart than the other layers of foam, air may be operable in some
such embodiments to move through the grooves in the base portion
(e.g. since the pinholes in the base portion may be in fluid
communication with the grooves in the base portion) to the pinholes
in the upper layers of foam which are not aligned with the pinholes
in the base layer of foam.
[0056] Typically, the sculpted layer of foam would have a plurality
of foam pillars forming the sculpted surface, and the pillars would
be configured within the sculpted foam layer and the mattress as a
whole to essentially be limited to movement only (or in some
embodiments, primarily) in the vertical direction (e.g. without any
horizontal/sideways movement of the pillars during use of the
mattress). In other words, the configuration of the foam layers of
the mattress (for example, with the layers placed in contact in
such a way as to minimize shear or torsion in the pillars during
construction (e.g. essentially placing the pillars only in
compression) and with the layers perhaps laminated together) would
typically ensure that compression on the top (e.g. sleep surface)
of the mattress would be transmitted to the foam pillars entirely
as a vertical (e.g. compression) force (without, for example,
introducing any (e.g. substantial) horizontal, shear, or torsion
forces to the foam pillars) for each affected foam pillar.
Additionally, each pillar of foam in the sculpted layer would
typically be configured for essentially independent movement (e.g.
each pillar moves independent of the other surrounding/proximate
pillars). This independence might arise due to the contour cuts
(e.g. grooves/gaps) separating the foam pillars and/or the fact
that the base of the foam pillars would be linked by conformable
foam (e.g. in the form of an integrated base of foam linking all
pillars together). So, embodiments might have pillars of the
sculpted foam layer configured for essentially independent movement
and/or essentially only vertical movement during usage of the
mattress (e.g. by a user lying atop the mattress). Typical
embodiments might have the pillars configured for independent
movement essentially only in the vertical direction. For example,
each foam pillar might be operable to move vertically without
substantially imparting any vertical movement to
surrounding/proximate foam pillars in the sculpted foam layer.
Thus, movement by one foam pillar typically might not impart any
movement to other foam pillars in proximity within the sculpted
foam layer (such that each pillar movement would independently
relate to its own loading from the sleep surface above). So, each
foam pillar of an exemplary sculpted foam layer in a disclosed
mattress embodiment may be operable to only (or in some embodiments
primarily) carry/support compression forces from directly above the
foam pillar. Of course, Applicant does not intend to be bound by
theory, but rather simply notes that the presently disclosed
embodiments may perform/operate differently and/or better. Such
configuration of the sculpted foam layer (with regard to movement)
may be quite different from the typical movement allowed/provided
by conventional metal springs (e.g. coil springs in a mattress).
Conventional coil spring mattresses have a series of springs which
typically are linked by wire across their top surfaces. Thus, the
coil springs do not move independently (e.g. movement by one coil
spring necessarily affects the surrounding coil springs due to the
rigid nature of the linking wire frame) and the linking wire frame
at the top of the coil springs may typically introduce non-vertical
(e.g. non-compression) forces into the springs (such that the coil
springs may flex and move horizontally and/or torsionally, for
example, in response to a user atop the mattress sleep surface).
Thus, the disclosed embodiments (with foam pillars in a spring-less
mattress) may perform quite differently in operation than a
conventional spring mattress. Applicant notes that disclosed
mattress embodiments typically do not include traditional springs,
but for example might be termed all-foam mattresses (e.g. all the
cushion/support elements are foam) and/or (metal/coil) spring-free
mattresses (e.g. no springs, even if the mattress embodiment may
include some other cushion/support element(s) in addition to or
instead of one or more foam elements).
[0057] While typical sleep system embodiments would comprise a
mattress embodiment atop a foundation embodiment, other embodiments
might be focused on only the mattress or only the foundation. In
other words, disclosed mattress embodiments could alternatively be
used with conventional foundation elements (or even
separately/alone), and disclosed foundation embodiments could
alternatively be used with conventional mattress elements (although
doing so might reduce potential benefits available through the
joint use of disclosed mattress embodiment(s) with disclosed
foundation embodiment(s), since the joint use of ventilation
mattress atop ventilation foundation may provide for improved fluid
communication therebetween). A preferred embodiment, however, would
typically place a mattress configured to allow airflow/air transfer
(e.g. airflow) through its bottom surface (and perhaps also
typically having some means of air distribution throughout the
mattress (e.g. pinholes) for air passing through the bottom surface
of the mattress) atop a foundation configured to provide
airflow/air transfer (for example, forced airflow, which might be
suction and/or blowing) through its upper surface.
[0058] Turning now to the figures for specific exemplary
embodiments, FIG. 1A illustrates exemplary embodiment(s) of a
ventilated sleep system 100 (typically comprising a mattress and a
foundation), with a ventilated mattress 140 used in conjunction
with (typically directly atop) a ventilation foundation (such as
either 120a or 120b, which basically differ regarding the location
of the air flow unit 130a). The mattress 140 has a bottom surface
142 which allows airflow into and/or out of the mattress 140. For
example, the bottom surface 142 of the mattress 140 cover might be
formed of or comprise high airflow mesh fabric (for example 150 gsm
100% polyester spacer mesh fabric restricting airflow CFM less than
about 35% at 3 PSI). In some embodiments, the upper surface of the
mattress 140 might also allow airflow into/out of the mattress 140
(for example, with the upper surface of the mattress 140 cover
being formed of or comprising high airflow mesh fabric, similar to
that used for the bottom surface 142 of the mattress cover as
described above).
[0059] Either foundation 120a (with an air flow unit 130a external
to the support structure of the foundation and/or cover of the
foundation, for example externally mounted on the foundation,
perhaps underneath the foundation at or near the foot end of the
bed, for example centered from side to side, and in fluid
communication with the foundation hollow cavity via
inlet/intake/opening 132a) or 120b (with air flow unit 130b located
within the foundation support structure and/or cover, for example
mounted internally on the bottom/base panel of the foundation,
perhaps within the foundation at or near the foot end of the bed,
for example on the left side when looking at the foundation from
the foot, and in fluid communication with the external environment
via inlet/intake/opening 132b) might optionally be used with the
mattress 140, with the mattress 140 being located atop either
foundation 120a or 120b to form the ventilated sleep system 100. In
both foundation 120a and 120b, the upper surface 122a or 122b,
respectively, of the foundation 120a/b would be configured to allow
airflow out of the foundation (for example, into a mattress 140
directly atop (and in contact with) the foundation. So for example,
the upper surface 122a or 122b of the foundation cover might be
formed of or comprise high airflow mesh fabric (similar to that
described above with respect to the bottom surface 142 of the
mattress cover, for example, to allow airflow communication between
the foundation and the mattress 140, for example). And typically,
the foundation might be held above the floor by a frame or legs
111a,b (which might be similar to conventional bed frames used for
conventional box springs, for example, and which might provide
sufficient clearance from the floor to allow the required airflow
for operation of the ventilation mattress system). Typically, the
frame would not interfere with or block the inlet/intake/opening
132a/b for the air flow unit 130a,b.
[0060] So in FIG. 1A, air might pass into the foundation 120a,b,
for example through a filter such as a HEPA filter and/or through a
climate control unit (which might, for example, be operable to cool
and/or heat the air) via an air flow unit 130a,b, passing through
the foundation 120a/b (e.g. hollow cavity) to exit through the
upper surface 122a,b of the foundation 120a/b and enter the bottom
surface 142 of the mattress 140 in order to pass (vertically)
through at least a portion of the mattress 140. In such a system,
the air flow unit 130a,b might pump air into the mattress 140
through the foundation 120a/b. Alternatively, air might flow
through the system in reverse, with the air flow unit 130a,b
sucking air out of the mattress 140 and into the foundation 120a/b
(and then out to the external environment). The air flow unit
130a,b typically might displace about 100-300 CFM, and typically
might operate at less than about 6 dB. In some embodiments, the
upper surface of the mattress 140 might also allow for airflow (for
example, being formed of or comprising high airflow mesh or loosely
woven fabric panels, similar to those previously described). In
some embodiments, the high airflow fabric panels throughout the
sleep system (or at least for the upper foundation cover surface
and lower mattress cover surface) might all be similar and/or
formed of the same material. In some embodiments, the air flow unit
130a,b might be configured to allow for forward and reverse
operation (e.g. operable to allow air to be blown into or sucked
out of the mattress 140 by the foundation 120a/b). The arrows in
FIG. 1A illustrate potential airflow in the system, as persons of
skill would understand.
[0061] Typically, the foundation(s) 120a,b of FIG. 1A would
comprise a hollow structure (formed for example by support struts
and a structural frame), and air would be pumped into/out of the
hollow structure cavity (for example by the air flow unit 130a,b).
In other words, in such embodiments, air would simply flow through
the hollow cavity of the foundation 120a/b as it interacts with the
mattress 140 and the outside environment. So for example, external
air might be drawn into the hollow cavity of the foundation 120a/b
through the inlet/intake/opening 132a,b, flow through the hollow
cavity to the upper surface of the foundation 120a,b, flow out of
the foundation 120a/b through the upper surface 122a,b and into the
mattress 140 through the mattress bottom surface 142, and then pass
through at least a portion of the mattress 140 (and in some
embodiments, air might flow all the way through the mattress 140
and optionally might flow out the upper surface of the mattress
140). Alternatively, air might flow into the hollow cavity of the
foundation 120a,b through the upper surface 122a,b (for example,
sucking air from the mattress 140 through the bottom surface 142 of
the mattress 140), through the hollow cavity of the foundation
120a,b, and out of the foundation 120a,b via an inlet/intake (which
in the case would actually serve as an outtake) and/or opening
132a,b to the external environment.
[0062] FIG. 1B illustrates an alternative embodiment sleep/bedding
system, similar to that of FIG. 1A. One version of the foundation
120b of FIG. 1B may have an access panel, which for example might
allow for easy access to change the HEPA filter and/or to provide
maintenance or repair to the air flow unit 130b. FIGS. 1Ca, 1Cb and
1Cc illustrate in more detail an exemplary sleep/bedding system
embodiment similar to FIG. 1B, having an internal (e.g.
mounted/located within the foundation frame/cover) air flow unit
130b, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view of the foot of the bed, and FIG. 1Cc showing a top view.
Typically, in the embodiment of FIGS. 1Ca, 1Cb and 1Cc the air flow
unit 130b might be located at (e.g. in proximity to) the foot of
the bed within the foundation. For example, the optional HEPA
filter might be located over the air intake, with air then flowing
through the blower to be expelled into the hollow cavity of the
foundation 120b. In some embodiments, there may be an access panel,
for example located on the upper surface of the foundation 120b
above the HEPA filter or air intake or air flow unit 130b. The
access panel might be a hinged section (for example, operable to
open by pivoting upward) of the upper foundation surface (although
in some embodiments, the access panel portion of the upper
foundation 120b cover might not be air permeable, for example to
help direct air through the blower and into the foundation).
[0063] FIGS. 1Da, 1Db and 1Dc illustrate in more detail an
exemplary sleep/bedding system embodiment similar to FIG. 1B,
having an external (e.g. mounted/located outside the foundation
120b frame/cover, for example mounted beneath the foundation 120b)
air flow unit 130a (shown in FIG. 1B), with FIG. 1Da showing a side
view, FIG. 1Db showing an end view of the foot of the bed, and FIG.
1Dc showing a top view. Typically, the air flow unit 130a of FIGS.
1Da-1Dc might be mounted to the bottom surface of the foundation at
or in proximity to the foot of the bed (perhaps located towards the
center between the sides). And again, there may be an access panel,
which for example might typically be located on the housing of the
air flow unit to allow access to the HEPA filter and/or blower.
FIG. 1E illustrates an exemplary sleep/bedding system in 3D
perspective view, showing that externally the sleep/bedding system
would resemble a conventional mattress atop a conventional
box-spring foundation unit (e.g. a typical conventional bed).
[0064] FIGS. 2A1 and 2A2 illustrate an exemplary ventilation
mattress 240A, which is an all-foam (or spring-free) mattress
formed of a plurality of foam layers (with the base layer being a
sculpted foam layer having the sculpted surface (with foam pillars)
facing upward, a middle sculpted foam layer having the sculpted
surface (with foam pillars) facing downward, a sleep surface layer,
at least one foam layer (e.g. transition layer) between the middle
sculpted foam layer and the base sculpted foam layer, and/or a foam
layer located between the sleep surface layer and the middle
sculpted foam layer). While FIG. 2A1 shows the foam components of
the mattress (e.g. with the cover removed) in perspective view,
FIG. 2A2 shows a side cross-section view of the same mattress.
FIGS. 2B1 and 2B2 illustrate a similar all foam mattress (e.g. with
the foam components removed from the cover), and differs primarily
in the particular foam material selected (with the embodiment of
FIG. 2A1 being formed of conventional high density foam (e.g. all
component foam layers are formed of conventional high density
foam), and the embodiment of FIG. 2B1 having the top two layers
formed of memory foam, for example gel memory foam, while the
remaining layers are formed of conventional high density foam). And
in some embodiments, all such foam layers would be adhered into an
integrated whole (e.g. laminated) and/or enclosed/encased in a
cover, thereby forming an integrated mattress.
[0065] So in FIG. 2A1, the mattress 240A comprises a base layer of
foam 242 (which comprises a sculpted foam element 243 with the
sculpted surface (e.g. the foam pillars) facing/extending upward)
located as the bottom layer of foam in the mattress 240A, a middle
sculpted foam layer 250 with the sculpted surface (e.g. foam
pillars) facing/projecting downward and located above the base
layer (although typically not directly above or in contact with the
base layer), a transition foam layer 260 located between (and
typically in contact with) the base layer of sculpted foam 242 and
the middle layer of sculpted foam 250, a top (sleep surface) foam
layer 270 (typically located as the uppermost foam layer 250 in the
mattress 240A), and (optionally) a second (e.g. penultimate) layer
of foam 280 located between the top (sleep surface) foam layer 270
and the middle sculpted foam layer 250. FIG. 2A1 shows the foam
layers of the mattress 240A without the cover (not shown),
illustrating the order and orientation of the foam layers in this
mattress embodiment. Typically, the foam layers are arranged one
atop another in the order described above, with proximate layers
contacting one another (e.g. the base foam layer 242 is the bottom
layer, the transition foam layer 260 is located atop and in contact
with the base layer 242, the middle sculpted foam layer 250 is
located atop and in contact with the transition layer, the second
(penultimate) foam layer 280 is located atop and in contact with
the middle sculpted foam layer 250, and the top (sleep surface)
foam layer 270 is located atop and in contact with the second
(penultimate) foam layer 280 and forms the upper foam layer of the
mattress 240A). Typically, the layers would all be encased within a
cover (not shown here), and typically the cover would have a bottom
surface with means for airflow (for example, one or more panels of
high airflow mesh fabric). Also, in some embodiments, the upper
surface of the cover might include means for airflow (for example,
an air permeable element, such as one or more panels of high
airflow mesh fabric).
[0066] In FIG. 2A1, the base layer 242 comprises a sculpted foam
element/layer 243 with upward facing sculpted surface (e.g. foam
pillars 248 projecting upward and separated by a series (e.g. grid)
of gaps or grooves or cuts 247), and edge support perimeter rails
of foam 244 which surround/encase the sculpted foam element 243 on
all sides (e.g. about/around the perimeter of the sculpted foam
element 243). Typically, the edge support perimeter rails 244 might
be formed of the same foam as the base layer sculpted foam element
243 and/or might have the same uncompressed height as the sculpted
foam element 243 (e.g. the upper surface of the edge support
perimeter rails 244 might be approximately level with the upper
surface of the foam pillars 248 of the sculpted foam element 243
when both are uncompressed). In the embodiment of FIG. 2A1, the
foam pillars 248 would typically have a square rectangular outer
surface (and/or cross-section) of about 4 inches by 4 inches, and
the gaps/grooves 247 forming the grid resulting in the foam pillars
248 might typically have a width of about 0.75 inches and a depth
of about 3 inches. So for example, the gaps/grooves 247 in the base
layer sculpted foam element 243 might typically have a depth
ranging from about 1/2 to 2/3 the total height for the base layer
242, for example about 60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars 248 of the sculpted
foam element 243 typically would have a plurality of pinholes (e.g.
essentially vertical air passageways), as will be described in
greater detail below. In alternate embodiments, the pinholes might
pass through both the base portion and the pillar portion of one or
more of the sculpted foam layers.
[0067] In FIG. 2A1, the transition layer of foam 260 would
typically be a flat sheet of foam with a plurality of pinholes 265
(e.g. essentially vertical air passageways). In the embodiment of
FIG. 2A1, the transition foam layer 260 would typically have the
same width and length dimensions (e.g. depending on whether the
mattress 240A is a twin, full/double, queen, king, etc.) as the
base foam layer 242 (e.g. including both the sculpted foam element
243 and the surrounding edge support perimeter rails 244), although
in other embodiments (in which the foam pillars 248 are lower than
the surrounding edge support perimeter rails 244, for example by a
height approximately equal to the thickness of the transition
layer, the transition foam layer 260 might be sized to fit over
just the sculpted foam element 243 of the base foam layer 242 (e.g.
so that it would be located within the edge support perimeter rails
244 as well).
[0068] The middle sculpted foam layer 250 of FIG. 2A1 would
typically be sized (e.g. width and length) approximately the same
as the base foam layer 242 and/or the transition foam layer 260
(and typically the same as the layers atop it as well), and would
be oriented with the sculpted surface (e.g. foam pillars 258)
facing/projecting downward. In the embodiment of FIG. 2A1, the foam
pillars 258 would typically have a square rectangular outer surface
(and/or cross-section) of about 2 inches by 2 inches, and the
gaps/grooves 257 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. So for example, the gaps/grooves 257 in the
middle sculpted foam layer 250 might typically have a depth ranging
from about 1/2 to 2/3 the total height for the middle sculpted
layer, for example about 55-60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars 258 of the middle
sculpted foam layer 250 typically would have a plurality of
pinholes 255 (e.g. essentially vertical air passageways), as will
be described in greater detail below. Typically, the pinholes 255
of the middle sculpted foam layer 250 would be spaced and/or
oriented/located the same (identically) as the pinholes 265 in the
transition foam layer 260 (and typically also the same as the
layers located above it), with the pinholes 255 aligning vertically
with the pinholes 265. And typically, at least some of the pinholes
255/265 would also align with the pinholes 245 in the base foam
layer 242 (e.g. the sculpted foam element 243 of the base layer
foam 242). For example, every other pinhole 255/265 might align
with a pinhole 245 (and groove/gap 247) in the sculpted foam
element of the base layer.
[0069] The second (penultimate) foam layer 280 and the top (sleep
surface) foam layer 270 would typically each be a flat sheet of
foam with a plurality of pinholes 285, 275 respectively (e.g.
essentially vertical air passageways). In the embodiment of FIG.
2A1, both the second (penultimate) foam layer 280 and the top
(sleep surface) foam layer 270 would typically have the same width
and length dimensions (e.g. depending on whether the mattress 240A
is a twin, full/double, queen, king, etc.) as the base foam layer
242, the transition foam layer 260, and/or the middle sculpted foam
layer 250. And, the pinholes 285, 275 of the second (penultimate)
foam layer 280 and the top (sleep surface) foam layer 270
respectively would typically be spaced and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer
260 and the pinholes 255 in the middle sculpted foam layer 250,
with the pinholes 285, 275 aligning vertically with the pinholes
265, 255. Thus, the pinholes 265, 255, 285, and 275 of FIG. 2A1
would typically align to form continuous airflow pathways from the
upper surface of the base foam layer 242 upward to the upper
surface of the mattress 240A (although in other embodiments, only
some of the pinholes might align). And typically, at least some of
the pinholes 285,275 would also align with the pinholes 245 in the
base foam layer 242 (e.g. the sculpted foam element 243 of the base
foam layer 242). For example, every other pinhole 285,275 might
align with a pinhole 245 (and groove/gap 247) in the sculpted foam
element 243 of the base foam layer 242. In other embodiments, the
pinholes 265, 255, 285, and 275 might all align with the pinholes
245 in the base foam layer 242 (e.g. the pinholes in all the layers
could be spaced equally so they all align to form continuous air
flow pathways from the bottom surface of the mattress to the upper
surface of the mattress 240A).
[0070] Similarly, FIG. 2A2 shows a cross-section view of the foam
elements of the mattress 240A shown in FIG. 2A1. In this
embodiment, the base foam layer 242 typically would have an
uncompressed height of about 5 inches, the transition foam layer
260 typically would have an uncompressed height of about 1.25
inches, the middle sculpted foam layer 250 typically would have an
uncompressed height of about 3 inches, the second (penultimate)
foam layer 280 typically would have an uncompressed height of about
1.75 inches, and the top (sleep surface) foam layer 270 typically
would have an uncompressed height of about 1.25 inches. In FIG.
2A2, the middle sculpted foam layers 250 would typically vary in
firmness, from softest at the top to hardest/firmest at the bottom.
For example, the top (sleep surface) foam layer 270 would typically
be the softest layer of foam (for example, IFD of about 14), the
second (penultimate) foam layer 280 would typically be somewhat
firmer that the top layer (for example, IFD of about 20), the
middle sculpted foam layer 250 would typically be somewhat firmer
than the second (penultimate) foam layer 280 (for example, IFD of
about 35), the transition foam layer 260 typically would be
somewhat firmer than the middle sculpted layer (for example, IFD of
about 45), while the base foam layer 242 might typically have the
same firmness as the transition foam layer 260 (for example, IFD of
about 45). In other embodiments, the base layer 242 might be
somewhat firmer than the transition layer 260. Typically, the edge
support perimeter rails 244 would have the same firmness (e.g. IFD)
and/or be formed of the same foam as the sculpted foam element 243
of the base layer. In other embodiments, the firmness of the
various layers may differ and/or may vary differently from the
descriptions above. And in FIG. 2A2, the thickness (e.g. lateral
width) of the edge support perimeter rails typically would be about
4 inches (or in other embodiments, about the same size as one of
the foam pillar's 248 square rectangular outer surface (and/or
cross-section) sides).
[0071] FIG. 2A2 also shows the alignment of the pinholes 265, 255
(and gap 257), 285, and 275, and the fact that every other pinhole
265, 255, 285, 275 aligns with a pinhole 245 (and gap 247) of the
base foam layer 242 in this embodiment. The alignment of pinholes
may allow continuous airflow upward from the bottom surface of the
mattress 240A to the upper surface of the mattress 240A and/or
downward from the upper surface of the mattress 240A to the bottom
surface of the mattress 240A, as illustrated by the exemplary
airflow arrows (except along the perimeter edges where the edge
support perimeter rails 244 may not have pinholes, in some
embodiments). In some embodiments, the pinholes may be hole-punched
into the foam sheets/layers, while in other embodiments the
pinholes might be formed for example by molding of the foam
sheets/layers). And in some embodiments, the gaps/grooves 247, 257
might be cut/scored into the foam to form the sculpted surface(s),
while in other embodiments the gaps/grooves 247, 257 might be
formed for example by molding (e.g. due to the shape of the foam
mold forming the layer(s)). The upper surface of the top (sleep
surface) foam layer 270 forms the sleep surface 272 (although
typically there would be a cover, not shown here, lying
atop/encasing the foam).
[0072] So in some embodiments, the mattress might comprise at least
two sculpted foam layers (with each having a sculpted surface with
a plurality of pillars) with a transition foam layer (and typically
only one such transition foam layer) therebetween. The upper
sculpted foam layer would typically be oriented with its sculpted
surface facing downward (although in other embodiments, it could
face upward and/or there might not be a foam (transition) layer
between the two sculpted foam layers), while the lower/bottom
sculpted foam layer (e.g. the base layer) would typically be
oriented with its sculpted surface facing upward. And typically
(although optionally), there would be one or more foam layers
located above the uppermost sculpted foam layer (e.g. the middle
sculpted foam layer), with these top foam layers having a softer
IFD than that of the middle sculpted foam layer. A series of
pinholes in the foam layers (perhaps in conjunction with the
gaps/grooves forming the sculpted surface of the sculpted foam
layers) would allow for airflow vertically throughout the mattress
(or at least through a plurality of foam layers of the mattress).
And typically, the foam layers would be enclosed/encased within a
cover, which typically would have a bottom/lower surface which is
air permeable (for example, formed of or comprising high airflow
mesh fabric, typically allowing airflow comparable to the upper/top
surface of the ventilation foundation upon which such a mattress
would typically operate). So as discussed above, the mattress
embodiment would typically have a bottom cover surface allowing
airflow therethrough (e.g. one or more panels restricting airflow
cubic feet per minute less than about 35% at 3 PSI), and the
ventilation foundation (upon/atop which the mattress embodiment
would typically be used) typically would also have an upper/top
cover surface allowing airflow therethrough (for example, similar
to the airflow allowed by the bottom surface of the cover of the
mattress), such that the joint mattress-foundation sleep/bedding
system embodiment typically would effectively allow airflow between
the foundation and the mattress (for example, based on an airflow
unit in or on the foundation).
[0073] FIGS. 2B1 and 2B2 show a similar foam mattress 240B formed
of multiple layers of foam (typically within a cover (not shown)).
The embodiment of FIGS. 2B1 and 2B2 is substantially the same in
structure as the embodiment of FIGS. 2A1 and 2A2, primarily
differing in the foam material used. For example, in FIG. 2B1, the
top two layers might be memory foam (for example, gel memory foam).
Persons of skill will understand that the foam materials and/or
characteristics of the layers of foam for such exemplary mattresses
may differ, for example being selected based on the specific needs
of the particular mattress.
[0074] FIG. 3 illustrates an exemplary base foam layer 242 (similar
to that of FIG. 2A1, for example), showing the sculpted surface
(e.g. upper surface) of the sculpted foam element 243 (with foam
pillars 248 separated by gaps/grooves 247 in a grid) and the edge
support perimeter rails 244 in plan view (of the upper, sculpted
surface). As noted above, the foam edge support perimeter rails 244
surround and abut all four sides of the sculpted foam element 243,
and they each may typically have a width (e.g. lateral dimension)
approximately equal to one of the sides of the square rectangular
outer surface (and/or cross-section) of the foam pillars 248.
Typically (as shown in FIG. 3), all of the foam pillars 248 would
be equally sized (for example, they might all be equally sized with
a square cross-section, as for example formed by a grid of
gaps/grooves 247 in which the longitudinal grooves/gaps 247 are
equally spaced, and the lateral gaps/grooves 247 are also equally
spaced apart by the same amount as the longitudinal gaps, for
example forming a grid that resembles a checkerboard). So for
example in the embodiment of FIG. 3, the foam pillars 248 would
typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars 248 might
typically have a width of about 0.75 inches and a depth of about 3
inches.
[0075] FIG. 3 also shows the pinholes 245 in the base foam layer
242, which are typically located in the joined base portion of the
foam pillars 248 of the base foam layer 242 so that they exit into
the gaps/grooves 247 separating the foam pillars 248. In other
words, the pinholes 245 typically do not pass through the
projecting foam pillar 248 portion of the base foam layer 242
sculpted foam element 243, but rather pass only though the integral
base portion of the sculpted foam element 243 (e.g. the bottom
portion where the foam pillars are joined together into an integral
whole) such that the pinholes 245 extend upward from the bottom of
the base foam layer 242 to exit within the gaps/grooves 247 between
the foam pillars 248. The pinholes 245 of FIG. 3 typically might
have a diameter of about 0.5 inches (and typically would all be
about the same size), and typically would be spaced apart
approximately 3.937 inches. So for example, the pinholes 245
typically might be located within the gaps/grooves 247 at locations
in proximity to the corners of each foam pillar 248 of the base
foam layer 242 (e.g. at the grid groove intersections).
[0076] Similarly, FIG. 4 illustrates an exemplary middle sculpted
foam layer 250 (similar to that of FIG. 2A1, for example), showing
the sculpted surface (e.g. the bottom surface) (with foam pillars
258 separated by gaps/grooves 257 in a grid) in plan view (of the
sculpted surface). Typically (as shown in FIG. 4), all of the foam
pillars 258 would be equally sized (for example, they might all be
equally sized with a square cross-section, as for example formed by
a grid of gaps/grooves 257 in which the longitudinal gaps/grooves
257 are equally spaced, and the lateral gaps/grooves are also
equally spaced apart by the same amount as the longitudinal gaps,
for example forming a grid that resembles a checkerboard). So for
example in the embodiment of FIG. 4, the foam pillars 258 would
typically have a square rectangular outer surface (and/or
cross-section) of about 2 inches by 2 inches, and the gaps/grooves
257 forming the grid resulting in the foam pillars 258 might
typically have a width of about 0.375 inches and a depth of about
1.75 inches. While the embodiment of FIG. 2A1, for example, has the
foam pillars 258 of the middle sculpted foam layer sized to be
about 1/4 the size of the foam pillars 248 of the base layer (e.g.
2 inches by 2 inches versus 4 inches by 4 inches, such that each
4.times.4 pillar in the base layer of FIG. 2A1, for example, might
have four 2.times.2 pillars in the middle sculpted layer located
above it); in other embodiments, the ratio of the foam pillar
sizing may vary (for example, the foam pillars 258 could be the
same size as the foam pillars 248 in some embodiments, or the foam
pillars 258 might be 1/2, 1/3, 1/8, or 1/16 the size of the foam
pillars 248 in other embodiments). Typically, the sizing ratio
would be such that at least some of the gaps/grooves 257 in the
middle sculpted foam layer would align with at least some of the
gaps/grooves 247 of the base layer (since that may be important to
aid in alignment of pinholes in some embodiments, as well as
perhaps providing consistent support and/or comfort
characteristics).
[0077] FIG. 4 also shows the pinholes 255 in the middle sculpted
foam layer 250, which are typically located in the joined base
portion of the foam pillars 258 of the middle sculpted foam layer
250 so that they exit into the gaps/grooves 257 separating the foam
pillars 258. In other words, the pinholes 255 typically do not pass
through the projecting foam pillar 258 portion of the middle
sculpted foam layer 250, but rather pass only though the integral
base portion of the middle sculpted foam layer 250 (e.g. the bottom
portion where the foam pillars 258 are joined together into an
integral whole) such that the pinholes 255 extend downward from the
top of the middle sculpted foam layer 250 to exit within the
gaps/grooves 257 between the foam pillars 258. The pinholes 255 of
FIG. 4 typically might have a diameter of about 0.25 inches (and
typically would all be about the same size), and typically would be
spaced apart approximately 1.9685 inches. So for example, the
pinholes 255 typically might be located within the gaps/grooves 257
at locations in proximity to the corners of each foam pillar 258 in
the middle sculpted foam layer 250 (e.g. at the grid groove
intersections). As discussed above, the pinholes in the foam layers
(of an exemplary mattress) above the middle sculpted foam layer 250
(as well as perhaps an underlying transition layer) typically would
be sized and spaced (e.g. located) identical to those in the middle
sculpted foam layer 250, in order to form continuous airflow
pathways upward.
[0078] FIG. 5A illustrates an exemplary ventilation mattress 540,
which is an all-foam (or spring-free) mattress formed of a
plurality of foam layers (with the base layer being a sculpted foam
layer having the sculpted surface (with foam pillars) facing
upward, a middle sculpted foam layer having the sculpted surface
(with foam pillars) facing downward, a sleep surface layer, at
least one foam layer (e.g. transition layer) between the middle
sculpted foam layer and the base sculpted foam layer, and/or a foam
layer located between the sleep surface layer and the middle
sculpted foam layer). FIG. 5B illustrates a similar all foam
mattress (e.g. with the foam components removed from the cover),
and differs primarily in the middle layer construction. In some
embodiments, all such foam layers would be adhered into an
integrated whole (e.g. laminated) and/or enclosed/encased in a
cover, thereby forming an integrated mattress.
[0079] So in FIG. 5A, the mattress 540 comprises a base layer of
foam 242 (which comprises a sculpted foam element with the sculpted
surface (e.g. the foam pillars) facing/extending upward) located as
the bottom layer of foam in the mattress 540 (wherein the base foam
layer 242 may be similar to the base foam layer 242 described
above), a middle sculpted foam layer 550 with the sculpted surface
(e.g. foam pillars) facing/projecting downward and located above
the base foam layer 242 (although typically not directly above or
in contact with the base foam layer 242), a transition foam layer
260 located between (and typically in contact with) the base layer
of sculpted foam 242 and the middle layer of sculpted foam 550
(wherein the transition foam layer 260 may be similar to the
transition foam layer 260 described above), a top (sleep surface)
foam layer 270 (typically located as the uppermost foam layer in
the mattress, wherein the top (sleep surface) foam layer 270 may be
similar to the top (sleep surface) foam layer 270 described above),
and (optionally) a second (e.g. penultimate) foam layer 280 located
between the top (sleep surface) foam layer 270 and the middle
sculpted foam layer 550 (wherein the second foam layer 280 may be
similar to the second foam layer 280 described above).
[0080] FIG. 5A shows the layers foam of the mattress 540 without
the cover (not shown), illustrating the order and orientation of
the foam layers in this mattress embodiment. Typically, the foam
layers are arranged one atop another in the order described above,
with proximate layers contacting one another (e.g. the base foam
layer 242 is the bottom layer, the transition foam layer 260 is
located atop and in contact with the base layer, the middle
sculpted foam layer 550 is located atop and in contact with the
transition foam layer 260, the second (penultimate) foam layer 280
is located atop and in contact with the middle sculpted foam layer
550, and the top (sleep surface) foam layer 270 is located atop and
in contact with the second (penultimate) foam layer 280 and forms
the upper foam layer of the mattress 540). Typically, the layers
would all be encased within a cover (not shown here), and typically
the cover would have a bottom surface with means for airflow (for
example, one or more panels of high airflow mesh fabric). Also, in
some embodiments, the upper surface of the cover might include
means for airflow (for example, an air permeable element, such as
one or more panels of high airflow mesh fabric).
[0081] In FIG. 5A, the base foam layer 242 comprises a sculpted
foam element/layer 243 with upward facing sculpted surface (e.g.
foam pillars 248 projecting upward and separated by a series (e.g.
grid) of gaps or grooves or cuts 247), and edge support perimeter
rails 244 of the foam which surround/encase the sculpted foam
element 243 on all sides (e.g. about/around the perimeter of the
sculpted foam element 243). Typically, the edge support perimeter
rails 244 might be formed of the same foam as the base layer
sculpted foam element 243 and/or might have the same uncompressed
height as the sculpted foam element 243 (e.g. the upper surface of
the edge support perimeter rails 244 might be approximately level
with the upper surface of the foam pillars 248 of the sculpted foam
element 243 when both are uncompressed).
[0082] In the embodiment of FIG. 5A, the foam pillars 248 would
typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars might typically
have a width of about 0.75 inches and a depth of about 3 inches. So
for example, the gaps/grooves 247 in the base layer might typically
have a depth ranging from about 1/2 to 2/3 the total height for the
base layer, for example about 60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the sculpted foam
element 243 typically would have a plurality of pinholes 265 (e.g.
essentially vertical air passageways), as will be described in
greater detail below. In alternate embodiments, the pinholes might
pass through both the base portion and the pillar portion of one or
more of the sculpted foam layers.
[0083] In FIG. 5A, the transition foam layer of foam 260 would
typically be a flat sheet of foam with a plurality of pinholes 265
(e.g. essentially vertical air passageways). In the embodiment of
FIG. 5A, the transition foam layer 260 would typically have the
same width and length dimensions (e.g. depending on whether the
mattress is a twin, full/double, queen, king, etc.) as the base
foam layer 242 (e.g. including both the sculpted foam element 243
and the surrounding edge support perimeter rails 244), although in
other embodiments (in which the foam pillars are lower than the
surrounding edge support perimeter rails, for example by a height
approximately equal to the thickness of the transition layer, the
transition foam layer 260 might be sized to fit over just the
sculpted foam element 243 of the base foam layer 242 (e.g. so that
it would be located within the edge support perimeter rails 244 as
well).
[0084] The middle sculpted foam layer 550 of FIG. 5A would
typically be sized (e.g. width and length) approximately the same
as the base foam layer 242 and/or the transition foam layer 260
(and typically the same as the layers atop it as well), and would
be oriented with the sculpted surface (e.g. foam pillars 554)
facing/projecting downward. In the embodiment of FIG. 5A, the foam
pillars 554 would typically have a square/rectangular outer surface
(and/or cross-section) of about 4 inches by 4 inches, and the
gaps/grooves 557 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. So for example, the gaps/grooves 557 in the
middle sculpted foam layer 550 might typically have a depth ranging
from about 1/2 to 2/3 the total height for the middle sculpted foam
layer 550, for example about 55-60% in some exemplary embodiments.
In addition, the joined bases of the foam pillars of the middle
sculpted foam layer 550 typically would have a plurality of
pinholes 555 (e.g. essentially vertical air passageways), as will
be described in greater detail below.
[0085] In the embodiment shown in FIG. 5A, the pinholes 555 of the
middle sculpted foam layer 550 may be spaced and/or
oriented/located the same (identically) as the pinholes 245 of the
base foam layer 242. And typically, at least some of the pinholes
555 may align with the pinholes 265 in the transition foam layer
260 (as well as the layers located above it), with some of the
pinholes 265 aligning with the pinholes 555. For example, every
other pinhole 265 might align with a pinhole 255 in the middle
sculpted foam layer 550.
[0086] The middle sculpted foam layer 550 may also comprise an
additional set of pillars 552 located on the top surface of the
middle sculpted foam layer 550. In the embodiment of FIG. 5A, the
top pillars 552 may be sized differently than the bottom foam
pillars 554 (for example, the top pillar 552 might be 1/4 the
(cross-section) size of the bottom foam pillars 554, with four top
pillars 552 for each corresponding bottom pillar, although in other
embodiments the top and bottom foam pillars 552,554 could be the
same size). In the embodiment of FIG. 5A, the pinholes 555 may
align with every groove 557 in the bottom foam pillars 554, while
the pinholes 555 may align with every other groove 553 in the top
pillars 552. In some embodiments, the grooves 553 of the top
pillars 552 may align with the pinholes 275, 285 of the top (sleep
surface) foam layer 270 and second (penultimate) foam layer
280.
[0087] The second (penultimate) foam layer 280 and the upper (sleep
surface) foam layer 270 would typically each be a flat sheet of
foam with a plurality of pinholes 285, 275 respectively (e.g.
essentially vertical air passageways). In the embodiment of FIG.
5A, both the second (penultimate) foam layer 280 and the upper
(sleep surface) foam layer 270 would typically have the same width
and length dimensions (e.g. depending on whether the mattress is a
twin, full/double, queen, king, etc.) as the base foam layer 242,
the transition foam layer 260, and/or the middle sculpted foam
layer 550. And, the pinholes 285, 275 of the second (penultimate)
foam layer 280 and the top (sleep surface) foam layer 270
respectively would typically be spaced and/or oriented/located the
same (identically) as the pinholes 265 in the transition foam layer
260 and optionally the pinholes 555 in the middle sculpted foam
layer 550, with the pinholes 285, 275 aligning vertically with the
pinholes 265, 555. Thus, the pinholes 265, 555, 285, and 275 of
FIG. 5A would typically align to form continuous airflow pathways
from the upper surface of the base foam layer 242 upward to the
upper surface of the mattress (although in other embodiments, only
some of the pinholes might align). And typically, at least some of
the pinholes 285/275 would also align with the pinholes 245 in the
base foam layer 242 (e.g. the sculpted foam element 243 of the base
layer). For example, every other pinhole 285, 275 might align with
a pinhole 245 (and groove/gap 247) in the sculpted foam element 243
of the base foam layer 242. In other embodiments, the pinholes 265,
555, 285, and 275 might all align with the pinholes 245 in the base
foam layer 242 (e.g. the pinholes in all the layers could be spaced
equally so they all align to form continuous air flow pathways from
the bottom surface of the mattress to the upper surface of the
mattress).
[0088] In FIG. 5A, the foam layers would typically vary in
firmness, from softest at the top to hardest/firmest at the bottom.
For example, the top (sleep surface) foam layer 270 would typically
be the softest layer of foam (for example, IFD of about 14), the
second (penultimate) foam layer 280 would typically be somewhat
firmer that the top layer (for example, IFD of about 20), the
middle sculpted foam layer 550 would typically be somewhat firmer
than the second (penultimate) layer 280 (for example, IFD of about
35), the transition foam layer 260 typically would be somewhat
firmer than the middle sculpted foam layer 550 (for example, IFD of
about 45), while the base foam layer 242 might typically have the
same firmness as the transition foam layer 260 (for example, IFD of
about 45). In other embodiments, the base foam layer 242 might be
somewhat firmer than the transition foam layer 260. Typically, the
edge support perimeter rails 244 would have the same firmness (e.g.
IFD) and/or be formed of the same foam as the sculpted foam element
243 of the base foam layer 242. In other embodiments, the firmness
of the various layers may differ and/or may vary differently from
the descriptions above. In some embodiments, the thickness (e.g.
lateral width) of the edge support perimeter rails 244 typically
would be about 4 inches (or in other embodiments, about the same
size as one of the foam pillar 248 square rectangular outer surface
(and/or cross-section) sides).
[0089] The alignment of pinholes may allow continuous airflow
upward from the bottom surface of the mattress to the upper surface
of the mattress 540 and/or downward from the upper surface of the
mattress to the bottom surface of the mattress 540 (except along
the perimeter edges where the edge support perimeter rails may not
have pinholes, in some embodiments). In some embodiments, the
pinholes may be hole-punched into the foam sheets/layers, while in
other embodiments the pinholes might be formed for example by
molding of the foam sheets/layers).
[0090] So in some embodiments, the mattress might comprise at least
two sculpted foam layers (with each having a sculpted surface with
a plurality of pillars) with a transition foam layer (and typically
only one such transition foam layer) therebetween. The upper
sculpted foam layer would typically be oriented with its sculpted
surface facing downward (although in other embodiments, it could
face upward and/or there might not be a foam (transition) layer
between the two sculpted foam layers and/or the upper sculpted foam
layer might have both an upper and lower sculpted surface), while
the lower/bottom sculpted foam layer (e.g. the base layer) would
typically be oriented with its sculpted surface facing upward. And
typically (although optionally), there would be one or more foam
layers located above the uppermost sculpted foam layer (e.g. the
middle sculpted foam layer), with these top foam layers having a
softer IFD than that of the middle sculpted foam layer. A series of
pinholes in the foam layers (perhaps in conjunction with the
gaps/grooves forming the sculpted surface of the sculpted foam
layers) would allow for airflow vertically throughout the mattress
(or at least through a plurality of foam layers of the mattress).
And typically, the foam layers would be enclosed/encased within a
cover, which typically would have a bottom/lower surface which is
air permeable (for example, formed of or comprising high airflow
mesh fabric, typically allowing airflow comparable to the upper/top
surface of the ventilation foundation upon which such a mattress
would typically operate). So as discussed above, the mattress
embodiment would typically have a bottom cover surface allowing
airflow therethrough (e.g. one or more panels restricting airflow
cubic feet per minute less than about 35% at 3 PSI), and the
ventilation foundation (upon/atop which the mattress embodiment
would typically be used) typically would also have an upper/top
cover surface allowing airflow therethrough (for example, similar
to the airflow allowed by the bottom surface of the cover of the
mattress), such that the joint mattress-foundation sleep/bedding
system embodiment typically would effectively allow airflow between
the foundation and the mattress (for example, based on an airflow
unit in or on the foundation).
[0091] FIG. 5B shows a similar foam mattress 542 formed of multiple
layers of foam (typically within a cover (not shown). The
embodiment of FIG. 5B is substantially the same in structure as the
embodiment of FIG. 5A, primarily differing in the construction of
the middle sculpted foam layer 560. In the embodiment of FIG. 5B
the middle sculpted foam layer 560 would typically be sized (e.g.
width and length) approximately the same as the base foam layer 242
and/or the transition foam layer 260 (and typically the same as the
layers atop it as well), and would be oriented with the sculpted
surface (e.g. foam pillars 556) facing/projecting downward. In the
embodiment of FIG. 5A, the foam pillars 554 would typically have a
square rectangular outer surface (and/or cross-section) of about 2
inches by 2 inches, and the gaps/grooves 557 forming the grid
resulting in the foam pillars might typically have a width of about
0.375 inches and a depth of about 1.75 inches. So for example, the
gaps/grooves in the middle sculpted layer might typically have a
depth ranging from about 1/2 to 2/3 the total height for the middle
sculpted layer, for example about 55-60% in some exemplary
embodiments. In addition, the joined bases of the foam pillars of
the middle sculpted foam layer 560 typically would have a plurality
of pinholes 555 (e.g. essentially vertical air passageways), as
will be described in greater detail below. Typically, the pinholes
555 of the middle sculpted foam layer 560 would be spaced and/or
oriented/located the same (identically) as the pinholes 265 in the
transition foam layer 260 (and typically also the same as the
layers located above it), with the pinholes 555 aligning vertically
with the pinholes 265. And typically, at least some of the pinholes
555/265 would also align with pinholes in the base foam layer 242
(e.g. the sculpted foam element 243 of the base layer). For
example, every other pinhole 555, 265 might align with a pinhole
(and groove/gap 247) in the sculpted foam element 243 of the base
foam layer 242.
[0092] The middle sculpted foam layer 560 may also comprise an
additional set of pillars 552 located on the top surface of the
middle sculpted foam layer 560. In the embodiment of FIG. 5A, the
top pillars 552 may be sized the same (identical) as the bottom
foam pillars 554. In the embodiment of FIG. 5A, the pinholes 555
may align with every groove 557 in the bottom foam pillars 554, and
the pinholes 555 may align with every groove 553 in the top pillars
552.
[0093] FIGS. 6A-6B illustrate detailed views of the middle sculpted
foam layers 550 and 560. The middle sculpted foam layer 550 of FIG.
6A may comprise top pillars 552 and bottom pillars 554 that differ
in size. For example, the top pillars 552 may typically have a
square rectangular outer surface (and/or cross-section) of about 2
inches by 2 inches, while the bottom pillars 554 may typically have
a square rectangular outer surface (and/or cross-section) of about
4 inches by 4 inches. The middle sculpted foam layer 560 of FIG. 6B
may comprise top pillars 552 and bottom pillars 556 that are the
same in size. For example, the top pillars 552 may typically have a
square rectangular outer surface (and/or cross-section) of about 2
inches by 2 inches, and the bottom pillars 556 may also typically
have a square rectangular outer surface (and/or cross-section) of
about 2 inches by 2 inches. Typically, the foam pillars of the
middle sculpted foam layer would be sized with respect to the
pillars of the base layer of foam within a range including
1-to-1-4-to-1 with respect to cross-section (such that the foam
pillars of the middle sculpted foam layer each range in size from
being equally sized to the base layer pillars down to being a
quarter the size of the base layer pillars (i.e. four middle
sculpted layer pillars per one base layer pillar)), with each top
foam pillar of the middle sculpted foam layer often being equally
sized and each bottom foam pillar of the middle sculpted foam layer
often being equally sized. So for example, the base layer foam
pillars might be 4.times.4 inches in cross-section, and the middle
sculpted foam layer might have pillars that are 4.times.4 inches or
2.times.2 inches (for example, the bottom pillars of the middle
sculpted foam layer could be 4.times.4 inches or 2.times.2 inches,
while the top pillars of the middle sculpted foam layer could be
2.times.2 inches (or 4.times.4 inches)).
[0094] Additionally, the pinholes 555 in the middle sculpted foam
layers 550 and 560 may align with the grooves 557 in the bottom
foam pillars 554,556 in both embodiments. Therefore, the pinholes
555 of the middle sculpted foam layer 550 of FIG. 6A may be fewer
in number and spaced differently than the pinholes 555 of the
middle sculpted foam layer 560 of FIG. 6B.
[0095] In the embodiment shown in FIG. 6A, the middle sculpted foam
layer 550 may be formed of one piece of foam, wherein the pillars
552/554 and pinholes 555 may be formed by sculpting and/or molding
a single piece of foam. In the embodiment shown in FIG. 6B, the
middle sculpted foam layer 560 may be formed of one piece of foam,
wherein the pillars 552/556 and pinholes 555 may be formed by
sculpting and/or molding a single piece of foam.
[0096] FIGS. 7A-7B illustrate alternative detailed views of the
middle sculpted foam layers 550 and 560. In FIGS. 7A-7B, the middle
layers 550 and 560 may comprise two different types of foam joined
together using adhesive. The middle layers 550 and 560 may be
similar to those described in FIGS. 6A-6B, except that the layers
may be formed of two pieces of foam instead of one.
[0097] In the embodiment shown in FIG. 7A, the middle sculpted foam
layer 550 may be formed of two pieces of foam, wherein the pillars
552 and partial pinholes 555 may be formed by sculpting and/or
molding a first piece of foam 720, and the pillars 554 and partial
pinholes 555 may be formed by sculpting and/or molding a second
piece of foam 722. Then, the two pieces of foam 720 and 722 may be
joined together and laminated to form the middle sculpted foam
layer 550.
[0098] In the embodiment shown in FIG. 7B, the middle sculpted foam
layer 560 may be formed of two pieces of foam, wherein the pillars
552 and partial pinholes 555 may be formed by sculpting and/or
molding a first piece of foam 720, and the pillars 556 and partial
pinholes 555 may be formed by sculpting and/or molding a second
piece of foam 724. Then, the two pieces of foam 720 and 724 may be
joined together and laminated to form the middle sculpted foam
layer 560.
[0099] FIG. 8 illustrates an exemplary base foam layer 242 similar
to that shown and described in FIG. 3.
[0100] Further embodiments of the disclosure may include similar
cushion embodiments that may be used in seating support systems.
Such a cushion may comprise similar foam materials, similar support
features, and similar layers to the previously disclosed
embodiments. The density of the foam material of the various layers
of the cushion may be similar to the foam materials of the
previously described embodiments. Additionally, the IFD of the foam
material of the various layers of the cushion may be similar to the
IFD of the foam materials of the previously described embodiments.
A seating support system may comprise a cushion for use in a chair,
a sofa, a vehicle seat, a supplemental seat cushion, or any other
seating system. Thus, the disclosed seating cushion embodiments may
be configured for use upon a support element (including a frame)
for a chair, sofa, etc. (which may include a back support/frame
and/or back cushion in some embodiments, in addition to a seating
support frame).
[0101] FIG. 9A illustrates a general diagram of an exemplary
cushion 900, which may be part of a seating cushion support system,
and which is an all-foam (or spring-free) cushion formed of a
plurality of foam layers with at least one layer being a sculpted
foam layer having the sculpted surface (with foam pillars 958)
facing upward and/or downward. The foam pillars 958 may be similar
to the foam pillars described in previous embodiments.
[0102] FIG. 9B illustrates a cover 910 that may be installed over
the foam layers of the cushion 900. FIG. 9A shows the foam
components of the cushion (e.g. with the cover 910 removed) in
perspective view. In some embodiments, all such foam layers would
be adhered into an integrated whole (e.g. laminated) and/or
enclosed/encased in the cover 910, thereby forming an integrated
cushion. FIGS. 10-17 illustrate different exemplary embodiments of
such all foam cushion (e.g. with the foam components removed from
the cover 910).
[0103] As shown in FIG. 9A, the cushion 900 comprises a base foam
layer 940 located as the bottom layer of foam in the cushion 900, a
middle sculpted foam layer 950 with a sculpted surface (e.g. foam
pillars 958 separated by gaps/grooves 957) facing/projecting upward
and/or downward and located above the base foam layer 940, a top
foam layer 960 (typically located as the uppermost foam layer 260
in the cushion 900), and an outer wrap 902 configured to wrap
around at least a portion of the assembled layers 940, 950, and 960
of the cushion 900. The top foam layer 960 may form a top "sitting"
surface 904, where a user may sit upon the cushion 900. FIG. 9
shows the layers foam of the cushion 900 without the cover (not
shown), illustrating the order and orientation of the foam layers
in this cushion embodiment. Typically, the foam layers are arranged
one atop another in the order described above, with proximate
layers contacting one another, e.g. the base layer 940 is the
bottom layer, the middle sculpted foam layer 950 is located atop
and in contact with the base layer 940, and the top layer 960 is
located atop and in contact with the middle sculpted foam layer 950
and forms the upper foam layer of the cushion 900), with the outer
wrap 902 covering a bottom surface of the base foam layer 940 and
covering a top surface of the top foam layer 960, such that the
middle sculpted foam layer 950 typically could be sandwiched
between and in (direct) contact with the top layer 960 and the
bottom layer 940.
[0104] In some embodiments, the middle sculpted foam layer 950 may
also be called an independent foam spring component, where the foam
pillars 958 may also be called "foam springs" separated by the
gaps/grooves 957. As shown in FIG. 9A, the foam pillars 958 may
comprise a rectangular shape (or more specifically an approximately
square shape). However, the foam pillars 958 may comprise any
shape, such as a circular (cross-section) shape (or cylindrical
shape for the overall foam pillar/spring), a triangular shape, a
rounded shape, a rectangular shape with rounded edges, or any other
shape that may be defined by gaps/grooves 957 in the material of
the middle sculpted foam layer 950.
[0105] The outer wrap 902 may typically comprise a synthetic fiber
material configured to provide protection for the foam layers of
the cushion 900 (e.g., from damage by fluids, sharp objects, and/or
other substances). In some embodiments, the outer wrap 902 may
comprise a material configured to reduce friction between the outer
wrap 902 and the cover 910 that may be installed over the cushion
900. The reduced friction provided by the outer wrap 902 may allow
the cushion 900 to move within the cover 910 to return to an
original position within the cover 910, for example after a user
has sat upon the cushion 900. For example, in some embodiments, the
outer wrap 902 may comprise polyethylene terephthalate (PET), i.e.
polyester or the brand name Dacron.
[0106] Typically, as shown in FIG. 9B, the layers would all be
encased within the cover 910, and the cover 910 may have a bottom
surface with means for airflow (for example, one or more panels of
high airflow mesh fabric) in some embodiments. Also, in some
embodiments, the upper surface of the cover 910 might include means
for airflow (for example, an air permeable element, such as one or
more panels of high airflow mesh fabric). The cover 910 may
comprise a zipper 912 located on a "back" portion of the cushion
900 and cover 910 (e.g. facing the back portion of the seating
unit/frame). Additionally, the cover 910 may comprise an air
permeable element 914 in one or more surfaces of the cover 910,
wherein the air permeable element 914 may facilitate airflow into
and out of the foam layers of the cushion 900. In some embodiments,
the air permeable element 914 may comprise a mesh material.
Regardless, the cover typically would be configured to be
sufficiently durable for a seating surface (e.g. to endure friction
caused by user interaction with the seating surface, for
example).
[0107] FIG. 10 shows a side cross-section view of an exemplary
embodiment of the cushion 900. In FIG. 10, the base layer 1040
comprises a solid layer of foam and the top layer 1060 comprises a
solid layer of foam. The middle sculpted foam layer 1050 of FIG. 9
would typically be sized (e.g. width and length) approximately the
same as the base layer 1040 and/or the top layer (and typically the
same as the layers atop it as well), and would be oriented with the
sculpted surface (e.g. foam pillars 1058) facing/projecting
downward. In some embodiments, the foam pillars 1058 may typically
have a square rectangular outer surface (and/or cross-section) of
about 2 inches by 2 inches. In another embodiment, the foam pillars
1058 may have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches.
[0108] In some embodiments, the height (or thickness) 1052 of the
middle sculpted foam layer 1050 may be approximately 3 inches, and
the gaps/grooves 1057 forming the grid resulting in the foam
pillars might typically have a width of about 0.375 inches and a
depth of about 1.75 inches. So for example, the gaps/grooves 1057
in the middle sculpted foam layer 1050 might typically have a depth
ranging from about 1/2 to 2/3 the total height for the middle
sculpted foam layer 1050, for example about 55-60% in some
exemplary embodiments.
[0109] The top layer 1060 may comprise a height (or thickness) 1062
of between approximately 1 to 4 inches. The base layer 1040 may
comprise a height (or thickness) 1042 of between approximately 1 to
4 inches. The total thickness of the cushion 900 (including the
outer wrap 902) may be between approximately 5 inches and 8
inches.
[0110] In some embodiments, the cushion 900 may comprise "front"
section 1010 of the cushion 900 where the middle sculpted foam
layer 1050 is solid, without any foam pillars 1058 or gaps/grooves
1057 (e.g. a wider area of sold foam without gaps or grooves of the
sort that might form intermediate foam pillars/springs). This front
section 1010 may be configured to support a front edge of the
cushion 900 when a user is sitting on the cushion 900, where the
front section 1010 may be configured to be located such that a user
might sit on the cushion 900 with their knees located proximate to
the front section 1010 of the cushion 900. The front section 1010
may optionally be configured to provide increased rigidity in this
specific portion of the cushion 900, which may provide improved
support based on how a user sits upon the cushion 900 (e.g. to
prevent edge collapse). In some embodiments, the front section 1010
may extend approximately 4 inches from the outer edge of the
cushion 900 toward the middle of the cushion 900. In some
embodiments, the front section 1010 may extend less than
approximately 4 inches from the outer edge of the cushion 900
toward the middle of the cushion 900.
[0111] In some embodiments, the "front" section described above may
be part of solid edge portion (i.e., forming the front section
1010) of the middle sculpted foam layer 1050 that extends around
the entire outer edge of the middle sculpted foam layer 1050. For
example, the cushion 900 may comprise a front edge (i.e., the front
section 1010), a back edge, and two side edges, where the solid
edge portion may create a border including the front edge, the back
edge, and the two side edges of the middle sculpted foam layer
1050. In some embodiments, the solid edge portion may extend
approximately 4 inches from the outer edge of the cushion 900
toward the middle of the cushion 900. In some embodiments, the
solid edge portion may extend less than approximately 4 inches from
the outer edge of the cushion 900 toward the middle of the cushion
900. In other embodiments, such solid edge portion might only be
located on front and back sides of the cushion (e.g. allowing the
cushion to be flipped for increased life without impacting the edge
collapse performance)
[0112] In some embodiments, the top layer 1060 may comprise a high
resiliency foam material with an IFD between approximately 25 and
35. In some embodiments, the base layer 1040 may comprise a high
resiliency foam material with an IFD between approximately 25 and
35. In some embodiments, the foam materials of the top layer 1060
and the base layer 1040 may be similar. In some embodiments, the
middle sculpted foam layer 1050 may comprise an IFD between
approximately 50 and 60. In other words, the middle sculpted foam
layer 1050 may comprise a foam material that is more firm than the
foam material of the top layer 1060 and/or the base layer 1040.
[0113] FIG. 11 shows a side cross-section view of another similar
exemplary embodiment of the cushion 900, where the top layer 1160
and the base layer 1140 may be formed by a single foam piece 1170
that has been folded around the middle sculpted foam layer 1050
(e.g. bracketing/enclosing the sculpted layer on the bottom, top,
and front sides). The base layer 1140 may contact the foam pillars
1058 separated by gaps/grooves 1057 and may be formed by a base
portion of the single foam piece 1170. The top layer 1160 may form
the top "sitting" surface of the cushion 900 and may be formed by a
top portion of the single foam piece 1170. In the embodiment shown
in FIG. 11, a folded portion 1172 of the single foam piece 1170
(e.g., located between the base layer 1140 and the top layer 1160)
may be positioned to form the front section 1010 of the cushion 900
(as described in FIG. 10). The folded portion 1172 may provide
optional increased rigidity for the front section 1010 of the
cushion 900. Additionally, the middle sculpted foam layer 1050 may
not extend all the way through the front section 1010 of the
cushion, due to the folded portion 1172.
[0114] FIG. 12 shows a side cross-section view of another similar
exemplary embodiment of the cushion 900, where the thickness 1242
of the base layer 1240 may be more than the thickness 1262 of the
top layer 1260. As an example, the thickness 1262 of the top layer
1260 may be approximately half of the thickness 1242 of the base
layer 1240.
[0115] FIG. 13 shows a side cross-section view of another similar
exemplary embodiment of the cushion 900, where the middle sculpted
foam layer 1350 may comprise the row of foam pillars 1358 separated
by gaps/grooves 1357 on the bottom surface of the middle sculpted
foam layer 1350 and may comprise additional foam pillars 1354
separated by gaps/grooves 1353 on the top surface of the middle
sculpted foam layer 1350. In some embodiments, the middle sculpted
foam layer 1350 may also be called a dual independent foam spring
component, where the foam pillars 1358 and 1354 may also be called
"foam springs" separated by the gaps/grooves 1357 and 1353.
[0116] Typically, the sizing ratio would be such that at least some
of the gaps/grooves 1357 on the bottom surface of the middle
sculpted foam layer 1350 would align with at least some of the
gaps/grooves 1353 of the top surface of the middle sculpted foam
layer 1350 (since that may be important to provide consistent
support and/or comfort characteristics). In some embodiments, the
foam pillars 1358 and the foam pillars 1354 may comprise similar
sizes and/or shapes and/or alignment/orientation, while in other
embodiments the foam pillars 1358 and the foam pillars 1354 may
comprise different sizes and/or shapes and/or
alignment/orientation.
[0117] In the embodiment shown in FIG. 13, the thickness 1352 of
the middle sculpted foam layer 1350 may be larger than the
thickness 1362 of the top layer 1360 and/or the thickness 1342 of
the base layer 1340. In other words, with the addition of the foam
pillars 1354 to the top surface of the middle sculpted foam layer
1350, the thickness 1352 of the middle sculpted foam layer 1350 may
comprise at least half of the total thickness of the cushion 900.
As shown in FIGS. 12 and 13, the cushion 900 may or may not
comprise a defined "front" section 1010 (or solid edge portion) as
described in FIGS. 10 and 11.
[0118] In some seating cushion embodiments, one or more of the foam
layers of the cushion may comprise pinholes (e.g. (vertical) air
passageways). FIG. 14 shows a side cross-section view of another
exemplary embodiment of the cushion 900 that may be similar to the
above described embodiments, but may comprise a plurality of
pinholes through one or more of the layers of the cushion 900. The
pinholes may be similar to those described in previous embodiments.
As shown in FIG. 14, the components of the cushion 900 may be
similar to those described with respect to FIG. 10, where each of
the layers may comprise a plurality of pinholes through the layers.
For example, the top layer 1460 may be similar to the top layer
1060, but may further comprise pinholes 1465 (e.g. essentially
vertical air passageways), as will be described in greater detail
below. Additionally, the base layer 1440 may be similar to the base
layer 1040, but may further comprise pinholes 1445, and the middle
sculpted foam layer 1450 may be similar to the middle sculpted foam
layer 1050, but may further comprise pinholes 1455 through the
joined bases of the foam pillars 1458 which may align with the
gaps/grooves 1457.
[0119] Typically, the pinholes 1455 of the middle sculpted foam
layer 1450 would be spaced and/or oriented/located the same
(identically) as the pinholes 1465 in the top layer 1460, with the
pinholes 1455 aligning vertically with the pinholes 1465. And
typically, at least some of the pinholes 1455/1465 would also align
with the pinholes 1445 in the base layer 1440. Thus, the pinholes
1445, 1455, and 1465 of FIG. 14 would typically align to form
continuous airflow pathways from the bottom surface of the base
layer 1440 upward to the upper surface of the cushion 900 (although
in other embodiments, only some of the pinholes might align).
[0120] In some embodiments, the cushion 900 may comprise "front"
section 1410 of the cushion 900 where the middle sculpted foam
layer 1450 is solid, without any foam pillars 1458 or gaps/grooves
1457. This front section 1410 may be configured to support a front
edge of the cushion 900 when a user is sitting on the cushion 900,
where the front section 1410 may be configured to be located such
that a user might sit on the cushion 900 with their knees located
proximate to the front section 1410 of the cushion 900. The front
section 1410 may optionally be configured to provide increased
rigidity in this specific portion of the cushion 900, which may
provide improved support based on how a user sits upon the cushion
900.
[0121] In some embodiments, the height (or thickness) 1452 of the
middle sculpted foam layer 1450 may be between approximately 1 to 4
inches. The top layer 1460 may comprise a height (or thickness)
1462 of between approximately 1 to 4 inches. The base layer 1440
may comprise a height (or thickness) 1442 of between approximately
1 to 4 inches. The total thickness of the cushion 900 (including
the outer wrap 902) may be between approximately 3 inches and 12
inches. In some embodiments, the total thickness of the cushion 900
(including the outer wrap 902) may be between approximately 5
inches and 8 inches.
[0122] FIG. 15 shows a side cross-section view of another exemplary
embodiment of the cushion 900 that may be similar to above
described embodiments, and may comprise a plurality of pinholes
through one or more of the layers of the cushion 900. As shown in
FIG. 15, the components of the cushion 900 may be similar to those
described with respect to FIG. 11, where each of the layers may
comprise a plurality of pinholes through the layers. For example,
the top layer 1560 may be similar to the top layer 1160, but may
further comprise pinholes 1565 (e.g. essentially vertical air
passageways), as will be described in greater detail below.
Additionally, the base layer 1540 may be similar to the base layer
1140, but may further comprise pinholes 1545, and the middle
sculpted foam layer 1450 may be similar to the middle sculpted foam
layer 1050, but may further comprise pinholes 1455 through the
joined bases of the foam pillars 1458 which may align with the
gaps/grooves 1457.
[0123] The top layer 1560 and the base layer 1540 may be formed by
a single foam piece 1570 that has been folded around the middle
sculpted foam layer 1450. The base layer 1540 may contact the foam
pillars 1558 separated by gaps/grooves 1557 and may be formed by a
base portion of the single foam piece 1570. The top layer 1560 may
form the top "sitting" surface of the cushion 900 and may be formed
by a top portion of the single foam piece 1170. In the embodiment
shown in FIG. 15, a folded portion 1572 of the single foam piece
1570 (e.g., located between the base layer 1540 and the top layer
1560) may be positioned to form the front section 1410 of the
cushion 900 (as described in FIG. 10). The folded portion 1172 may
provide optional increased rigidity for the front section 1410 of
the cushion 900. Additionally, the middle sculpted foam layer 1450
may not extend all the way through the front section 1410 of the
cushion, due to the folded portion 1572.
[0124] As shown in FIG. 15, the single foam piece 1570 may comprise
a plurality of pinholes 1545 positioned within the base layer 1540
and may comprise a plurality of pinholes 1565 positioned within the
top layer 1560. The pinholes 1545 and 1565 may or may not continue
into the folded portion 1572 of the single foam piece 1570.
[0125] FIG. 16 shows a side cross-section view of another exemplary
embodiment of the cushion 900 that may be similar to the above
described embodiments, and may comprise a plurality of pinholes
through one or more of the layers of the cushion 900. As shown in
FIG. 16, the components of the cushion 900 may be similar to those
described with respect to FIG. 12, where each of the layers may
comprise a plurality of pinholes through the layers. For example,
the top layer 1660 may be similar to the top layer 1260, but may
further comprise pinholes 1665. Additionally, the base layer 1640
may be similar to the base layer 1240, but may further comprise
pinholes 1645, and the middle sculpted foam layer 1450 may be
similar to the middle sculpted foam layer 1050, but may further
comprise pinholes 1455 through the joined bases of the foam pillars
1458 which may align with the gaps/grooves 1457.
[0126] FIG. 16 shows a side cross-section view of another exemplary
embodiment of the cushion 900, where the thickness 1642 of the base
layer 1640 may be more than the thickness 1662 of the top layer
1660. As an example, the thickness 1662 of the top layer 1660 may
be approximately half of the thickness 1642 of the base layer
1640.
[0127] FIG. 17 shows a side cross-section view of another exemplary
embodiment of the cushion 900 that may be similar to the above
described embodiments, and may comprise a plurality of pinholes
through one or more of the layers of the cushion 900. As shown in
FIG. 17, the components of the cushion 900 may be similar to those
described with respect to FIG. 13, where each of the layers may
comprise a plurality of pinholes through the layers. For example,
the top layer 1760 may be similar to the top layer 1360, but may
further comprise pinholes 1765. Additionally, the base layer 1740
may be similar to the base layer 1340, but may further comprise
pinholes 1745, and the middle sculpted foam layer 1750 may be
similar to the middle sculpted foam layer 1350, but may further
comprise pinholes 1755 through the joined bases of the foam pillars
1758 and 1754 where the pinholes 1755 may align with the
gaps/grooves 1757 and 1753.
[0128] As shown in FIG. 17, the middle sculpted layer 1750 may
comprise a row of foam pillars 1758 separated by gaps/grooves 1757
on the bottom surface of the middle sculpted layer 1750 and may
comprise additional foam pillars 1754 separated by gaps/grooves
1753 on the top surface of the middle sculpted layer 1750.
Typically, the sizing ratio would be such that at least some of the
gaps/grooves 1757 on the bottom surface of the middle sculpted foam
layer 1750 would align with at least some of the gaps/grooves 1753
of the top surface of the middle sculpted foam layer 1750 (since
that may be important to provide consistent support and/or comfort
characteristics). In the embodiment shown in FIG. 17, the thickness
1752 of the middle sculpted foam layer 1750 may be larger than the
thickness 1762 of the top layer 1760 and/or the thickness 1742 of
the base layer 1740. In other words, with the addition of the foam
pillars 1754 to the top surface of the middle sculpted foam layer
1750, the thickness 1752 of the middle sculpted foam layer 1750 may
comprise at least half of the total thickness of the cushion
900.
[0129] FIG. 18 illustrates an exploded view of the foam layers of
the cushion 900 shown in FIG. 14, where the middle sculpted foam
layer 1450 may comprise a plurality of foam pillars 1458 directed
toward the bottom surface of the cushion (i.e., adjacent to the
base layer 1440).
[0130] FIG. 19 illustrates another exploded view of the foam layers
of the cushion 900 shown in FIG. 14, where the middle sculpted foam
layer 1450 may be positioned with the foam pillars 1458 directed
toward the top surface of the cushion (i.e., adjacent to the top
layer 1460) instead of the bottom surface of the cushion (as shown
in FIG. 18). The middle sculpted foam layer 1450 may be used in
either configuration within the cushion 900.
[0131] FIG. 20 illustrates an exploded view of the foam layers of
the cushion 900 shown in FIG. 17, where the middle sculpted foam
layer 1750 may comprise a plurality of foam pillars 1758 directed
toward the bottom surface of the cushion (i.e., adjacent to the
base layer 1740) and may comprise a plurality of foam pillars
directed toward the top surface of the cushion (i.e., adjacent to
the top layer 1760).
[0132] It should be recognized that in some embodiments, seating
cushions similar to those described in FIGS. 9A, B-20 might only
have one additional foam layer in addition to the sculpted (e.g.
independent foam spring) layer. This might be the case for thinner
cushions, for example (e.g. cushions less than approximately 5
inches in thickness). And in various embodiments, the sculpted foam
(e.g. independent foam spring) layer may be oriented downward or
upward (or have pillars on both the top and bottom surfaces). Most
typically, when only having two foam layers, the foam pillars would
project downward and be underlain by a base layer of foam, while
the seating surface would be flat.
[0133] For additional details that may be relevant for some
embodiments (particularly some mattress embodiments and/or systems
having mattress embodiments), U.S. patent application Ser. No.
14/681,278 (entitled "Independent Foam Spring Mattress" and filed
Apr. 8, 2015, along with related provisional patent application No.
61/977,989 entitled "Independent Foam Spring Mattress" and filed
Apr. 10, 2014) is hereby incorporated by reference for all purposes
as if reproduced in its entirety to the extent that it is
compatible (e.g. not inconsistent) with and/or does not directly
contradict disclosure herein (e.g. the explicit disclosure herein
would always govern/trump in instances of contradiction,
inconsistency, or incompatibility). Specifically, details about the
foam layers and/or formation of the foam layers from the
incorporated by reference U.S. patent applications might be used in
some embodiments (for example, within a mattress cover as described
herein).
[0134] While various embodiments in accordance with the principles
disclosed herein have been shown and described above, modifications
thereof may be made by one skilled in the art without departing
from the spirit and the teachings of the disclosure. The
embodiments described herein are representative only and are not
intended to be limiting. Many variations, combinations, and
modifications are possible and are within the scope of the
disclosure. Alternative embodiments that result from combining,
integrating, and/or omitting features of the embodiment(s) are also
within the scope of the disclosure. Accordingly, the scope of
protection is not limited by the description set out above, but is
defined by the claims which follow, that scope including all
equivalents of the subject matter of the claims. Each and every
claim is incorporated as further disclosure into the specification
and the claims are embodiment(s) of the present invention(s).
Furthermore, any advantages and features described above may relate
to specific embodiments, but shall not limit the application of
such issued claims to processes and structures accomplishing any or
all of the above advantages or having any or all of the above
features.
[0135] Additionally, the section headings used herein are provided
for consistency with the suggestions under 37 C.F.R. 1.77 or to
otherwise provide organizational cues. These headings shall not
limit or characterize the invention(s) set out in any claims that
may issue from this disclosure. Specifically and by way of example,
although the headings might refer to a "Field," the claims should
not be limited by the language chosen under this heading to
describe the so-called field. Further, a description of a
technology in the "Background" is not to be construed as an
admission that certain technology is prior art to any invention(s)
in this disclosure. Neither is the "Summary" to be considered as a
limiting characterization of the invention(s) set forth in issued
claims. Furthermore, any reference in this disclosure to
"invention" in the singular should not be used to argue that there
is only a single point of novelty in this disclosure. Multiple
inventions may be set forth according to the limitations of the
multiple claims issuing from this disclosure, and such claims
accordingly define the invention(s), and their equivalents, that
are protected thereby. In all instances, the scope of the claims
shall be considered on their own merits in light of this
disclosure, but should not be constrained by the headings set forth
herein.
[0136] Use of broader terms such as "comprises", "includes", and
"having" should be understood to provide support for narrower terms
such as "consisting of", "consisting essentially of", and
"comprised substantially of". Use of the terms "optionally," "may,"
"might," "possibly," and the like with respect to any element of an
embodiment means that the element is not required, or
alternatively, the element is required, both alternatives being
within the scope of the embodiment(s). Also, references to examples
are merely provided for illustrative purposes, and are not intended
to be exclusive.
[0137] While several embodiments have been provided in the present
disclosure, it should be understood that the disclosed systems and
methods may be embodied in many other specific forms without
departing from the spirit or scope of the present disclosure. The
present examples are to be considered as illustrative and not
restrictive, and the intention is not to be limited to the details
given herein. For example, the various elements or components may
be combined or integrated in another system or certain features may
be omitted or not implemented.
[0138] Also, techniques, systems, subsystems, and methods described
and illustrated in the various embodiments as discrete or separate
may be combined or integrated with other systems, modules,
techniques, or methods without departing from the scope of the
present disclosure. Other items shown or discussed as directly
coupled or communicating with each other may be indirectly coupled
or communicating through some interface, device, or intermediate
component, whether electrically, mechanically, or otherwise. Other
examples of changes, substitutions, and alterations are
ascertainable by one skilled in the art and could be made without
departing from the spirit and scope disclosed herein.
* * * * *