FOAM CUSHION HAVING REDUCED CROSS-SECTION AREA FOAM PROFILES FORMING HOLLOW PORTION(S) FOR DEFORMATION

[0001] The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/246,772, filed Sep. 29, 2009, titled “CLOSE CELL FOAM CUSHION,” which is incorporated herein by reference in its entirety.

[0002] The present application also claims priority to U.S. Provisional Patent Application Ser. No. 61/293,289, filed Jan. 8, 2010, titled “CLOSE CELL FOAM CUSHION,” which is incorporated herein by reference in its entirety.

[0003] 1. Field of the Disclosure

[0004] The technology of the disclosure relates to cushioning, which may be used, for example, in cushioning applications such as mattresses, seats, foot support, back support, and protection pads.

[0005] 2. Technical Background

[0006] Cushions and materials providing cushioning are used in numerous environments and applications, for example, in the home, hotels, transportation, hospitals, sport facilities, etc. In terms of cushion material and structure, metal spring and open cell polyurethane foam planks have been popularly employed. Convoluted open cell polyurethane foam, latex foam, and inversely convoluted foam cushion have also been employed in lieu of using metal springs. In comparison with open cell foam, close cell foam at the same density can show higher compression modulus. In other words, one may use much lighter weight close cell foam to reach similar firmness of open cell foam. This can reduce carbon release of a cushioning product, providing environmental protection and energy savings.

[0007] Open channel crossing a foam cushion has been widely used to improve cushioning performance. Cushion surfaces may have different indentation patterns for better touch, feel and appearance. In addition, a cushion can be made from various types of repeating units, such as half moon shapes and big bubbles as examples. However, in these examples, the cushion does not easy bend or curl for transportation or storage. One could provide a cushion pad that is more easily bent or curled by providing a thin cushion pad in which a foam pad is indented with spanned folding lines to provide bend lines for easier bending and curling of the pad. However, it may be desirable to provide a thicker cushion that can be easily bent or folded for transportation while still retaining the cushioning performance provided by the indentation patterns provided in the cushioning surface.

[0008] Embodiments disclosed in the detailed description include cushions, which may be used in mattresses, bedding, seats, and mats as non-limiting examples. Non-limiting features of these cushions are to effectively support a compression force with much less usage of material, to adapt to large deformations without bottoming out as seen for some spring coils, to curl up for easy shipping and storage, and/or to have light weight and good buoyancy.

[0009] In this regard, in one embodiment, a cushion is comprised of a plurality of foam profiles. Each of the plurality of foam profiles has a top surface and a bottom surface, and a geometry of reduced cross-section area from the top surface to the bottom surface in a vertical projection. The plurality of foam profiles are arranged such that the top surfaces of the plurality of foam profiles are disposed in or substantially in a first plane, and the bottom surfaces of the plurality of foam profiles are disposed in or substantially in a second plane parallel or substantially parallel to the first plane. In this manner, hollow portions can be formed between adjacent foam profiles. At least one sheet of material is affixed to at least one of the top surface and the bottom surface of the plurality of foam profiles. The sheet of material assists to maintain the integrity of the cushion and to distribute an imposed force to the plurality of foam profiles. When a compression force is imposed on the cushion, the hollow portions allow the plurality of foam profiles to change their shapes to adapt to the deformation. As the compression force is removed, the plurality of foam profiles can return to their original shapes. Further, by providing the hollow portions, the cushion can more easily be rolled or wrapped for transport or storage.

[0010] In another embodiment, a method of providing a cushion is provided. The method comprises providing a plurality of foam profiles each having a top surface and a bottom surface, and a geometry of reduced cross-section area from the top surface to the bottom surface in a vertical projection. The method also comprises arranging the plurality of foam profiles such that the top surfaces of the plurality of foam profiles are disposed in or substantially in a first plane, and the bottom of the plurality of foam profiles are disposed in or substantially in a second plane parallel or substantially parallel to the first plane. The method also comprises affixing at least one sheet of material to at least one of the top surface and the bottom surface of the plurality of foam profiles.

[0011] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description that follows, the claims, as well as the appended drawings.

[0012] For example, wherein the plurality of foam profiles can be comprised of foamed material comprised from the group consisting of polypropylene, polypropylene copolymer, polystyrene, polyethylene, ethylene vinyl acetate (EVA), polyolefin, metallocene catalyzed low density polyethylene, thermoplastic olefin (TPO), thermoplastic polyester, thermoplastic vulcanizates (TPVs), polyvinyl chlorides (PVCs), chlorinated polyethylene, styrene block copolymers, ethylene methyl acrylates (EMAs), ethylene butyl acrylates (EBAs), polyurethane, natural rubber, synthetic rubber, latex, silicone, ethylene propylene diene Monomer (M-class) rubber (EPDM), isoprene, chloroprene, neoprene, melamine-formaldehyde, and polyester. The foam can include closed cells, open cells, or a combination of both. Any density of the foam profiles is possible. Different zones of firmness can be provided in the cushion. The sheet of material can be comprised of either a woven or non-woven sheet of material. The cross-section shape of the plurality of foam profiles can be provided in a variety of shapes. Edges pieces can be disposed on ends of the plurality of foam profiles for the cushion. The plurality of foam profiles can include hollow sections that may or may not include filler material. The cushion can be used in any application desired, including but not limited to a mattress, a bed, a seat, furniture, a mat, a beach mat, a camping mat, an athletic mat, padding, and a protection pad.

[0013] It is to be understood that both the foregoing general description and the following detailed description present embodiments, and are intended to provide an overview or framework for understanding the nature and character of the disclosure. The accompanying drawings are included to provide a further understanding, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments, and together with the description serve to explain the principles and operation of the concepts disclosed.

[0028] The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the embodiments and illustrate the best mode of practicing the embodiments. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the embodiments and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.

[0029] Embodiments disclosed in the detailed description include cushions, which may be used in mattresses, bedding, seats, and mats as non-limiting examples. Non-limiting features of these cushions are to effectively support a compression force with much less usage of material, to adapt to large deformations without bottoming out as seen for some spring coils, to curl up for easy shipping and storage, and/or to have light weight and good buoyancy.

[0030] In this regard, in one embodiment, a cushion is comprised of a plurality of foam profiles. Each of the plurality of foam profiles has a top surface and a bottom surface, and a geometry of reduced cross-section area from the top surface to the bottom surface in a vertical projection. The plurality of foam profiles are arranged such that the top surfaces of the plurality of foam profiles are disposed in or substantially in a first plane, and the bottom surfaces of the plurality of foam profiles are disposed in or substantially in a second plane parallel or substantially parallel to the first plane. In this manner, hollow portions can be formed between adjacent foam profiles. At least one sheet of material is affixed to at least one of the top surface and the bottom surface of the plurality of foam profiles. The sheet of material assists to maintain the integrity of the cushion and to distribute an imposed force to the plurality of foam profiles. When a compression force is imposed on the cushion, the hollow portions allow the plurality of foam profiles to change their shapes to adapt to the deformation. As the compression force is removed, the plurality of foam profiles can return to their original shapes. Further, by providing the hollow portions, the cushion can more easily be rolled or wrapped for transport or storage.

[0031] FIG. 1 illustrates a side perspective view of an exemplary cushion 11 comprised of a plurality of adjacent exemplary foam profiles 12 having a geometry of reduced cross-section area from top to bottom in a vertical projection, with sheets 13 affixed to the plurality of foam profiles 12. As examples only, the cushion 11 may be used in any application desired, including but not limited to a mattress, a bed, a seat, furniture, a mat, a beach mat, a camping mat, an athletic mat, padding, and a protection pad. In this example, the plurality of foam profiles 12 includes multiple pieces of hollow, long, and specially shaped close cell foam. However, the plurality of foam profiles 12 could also be open cell, or a combination of both open and close cells.

[0032] In this embodiment, the plurality of foam profiles 12 each have a top surface 14 and a bottom surface or edge 15, and a geometry of reduced cross-section area from the top surface 14 to the bottom surface 15 in a vertical projection. In this example, the cross-section outskirt of plurality of foam profiles 12 is a triangle, which may be an isosceles triangle, but other geometries are possible that provide this reduced cross-section area feature. Non-limiting examples include circles, ellipses, other triangles, rectangles, trapezoids, and other polygons that have more than four (4) sides. In this example, each of the plurality of foam profiles 12 also contains a hollow portion 17 to allow for deformation when a force is imparted thereon, as described below in more detail.

[0033] In this embodiment, the plurality of foam profiles 12 are disposed between two sheets 13. The sheets 13 can serve to maintain the integrity of the cushion 11 when a force is imparted on the cushion 11. The sheets 13 are comprised of a material or materials. The plurality of foam profiles 12 are arranged such that the top surfaces 14 are disposed in or substantially in a first plane P₁, and the bottom surfaces 15 are disposed in or substantially in a second plane P₂ parallel or substantially parallel to the first plane P₁. The sheets 13 are affixed to the plurality of foam profiles 12 from its top surface 14 and bottom surface 15. In this manner, as discussed in more detail below, voids V are created between adjacent foam profiles 12 at the top surfaces 15 of the plurality of foam profiles 12 due to the reduced cross-section area disposed in the plurality of foam profiles 12 to allow for easy bending and rolling of the cushion 11.

[0034] The sheets 13 may be made from any material desired, and may be woven or non-woven. The sheets 13 may be affixed to the plurality of foam profiles 12 using an affixation means comprised from the group consisting of thermal welding and ultrasonic welding. Multiple levels, such as three (3) or more layers of sheets enclosing two (2) or more layers of foam profiles 12, may be provided. The sheets 13 could be pieced together instead of providing the sheets 13 as one single piece of material. The sheets 13 could be made of materials that are flexible or materials that do not stretch.

[0035] An edge piece 16 is a long rectangular piece of foam used to build an edge portion of cushion 11, and it is also bonded to non-woven sheets 13. There is a much larger bonding area between the plurality of foam profiles 12 and the non-woven sheet 13 on a top surface of the cushion 11 than that on a bottom surface of the cushion 11. Because of strong bonding of the plurality of foam profiles 12 as well as the edge pieces 16 with the non-woven sheets 13, the cushion 11 has good integrity.

[0036] As examples, the plurality of foam profiles 12 can be comprised of foamed material comprised from the group consisting of polypropylene, polypropylene copolymer, polystyrene, polyethylene, ethylene vinyl acetate (EVA), polyolefin, metallocene catalyzed low density polyethylene, thermoplastic olefin (TPO), thermoplastic polyester, thermoplastic vulcanizates (TPVs), polyvinyl chlorides (PVCs), chlorinated polyethylene, styrene block copolymers, ethylene methyl acrylates (EMAs), ethylene butyl acrylates (EBAs), polyurethane, natural rubber, synthetic rubber, latex, silicone, ethylene propylene diene Monomer (M-class) rubber (EPDM), isoprene, chloroprene, neoprene, melamine-formaldehyde, and polyester. The plurality of foam profiles 12 can include closed cells, open cells, or a combination of both. Any density of the plurality of foam profiles 12 is possible. The plurality of foam profiles 12 could be separated along the extrusion direction like blocks to provide independent movement in the extrusion direction.

[0037] The plurality of foam profiles 12 can be made of various foam materials such as cross-linked or non-cross-linked polyolefin, rubber, or other polymers which have a glass transition temperature below room temperature around 25 degrees C., as examples. The plurality of foam profiles 12 may have a density, for example, in a range of 8 kg/m³ to 100 kg/m³, preferably 16 kg/m³ to 48 kg/m³. The plurality of foam profiles 12 may have a cell size in a range of 0.01 mm to 10 mm, preferably 0.3 mm to 3 mm, as examples. The plurality of foam profiles 12 may have a close cell content of more than 80% as an example. The plurality of foam profiles 12 may also contain various additives such as a flame retardant, a smoke suppressant, an antimicrobial agent, a fragrance, a color, etc., as examples.

[0038] Also, because the sheet 13 is attached to the bottom surface 15 of the plurality of foam profiles 12, when a compression force is imposed on the cushion 11, the plurality of foam profiles 12 are deformed while the integrity of the cushion 11 is maintained. The sheet 13 also plays a role in keeping each individual foam profile 12 maintained into a proper position in the cushion 11. In this regard, FIG. 2A illustrates a side view of a foam profile 12 in FIG. 1 in an uncompressed state. FIG. 2B illustrates a side view of a foam profile 12 in FIG. 1 in a compressed state. More particularly, FIGS. 2A and 2B show schematically a change in cross-section of the plurality of foam profiles 12 before and after compression (e.g., 50% compression). Because the hollow portion 17 is disposed in the foam profile 12, the foam profile 12 is also capable of adapting to large deformation. Once a compression force is removed, the foam profile 12 can return to its original shape.

[0039] There could be many alternative shapes for the plurality of foam profiles 12. In this regard, FIGS. 3A-3F illustrate side views of exemplary alternative foam profiles 12 that can be employed in a cushion, including the cushion 11 in FIG. 1 as an example. As shown in FIGS. 3A and 3B, hollow foam profiles 10 and 18 can have concave and convex side surfaces. A hollow foam profile 19 can have an outskirt of isosceles trapezoid and inner elliptical channel as shown in FIG. 3C. A hollow foam profile 20 can represent an isosceles trapezoid with arc bottom as shown in FIG. 3D. The cross-section of a hollow foam profile 22 can have grooves on its top surface, as shown in FIG. 3E, to have better air convection on the profile surface. In order to speed up air flow in and out of a hollow foam profile, holes 21 can be drilled through the hollow foam profile wall, as shown in FIG. 3F.

[0040] FIGS. 4A-4C illustrate side views of exemplary foam profiles for building up the edge portion of a cushion, including the cushion 11 in FIG. 1 as an example. The cushion 11 can have the rectangular edge piece 16, as shown in FIGS. 1 and 4A as an example. As alternatives, a solid right angle trapezoid foam profile 23 and a hollow right angle trapezoid foam profile 24 can be used as shown in FIGS. 4B and 4C, as another example.

[0041] FIG. 5 illustrates a side view of the cushion 11 of FIG. 1 partially rolled up. Since the sheet 13 is soft and flexible, the cushion 11 can be bent as shown in FIG. 5. Also, the plurality of foam profiles 12 in this example are arranged in parallel and distanced from each other with a space or void V between them, which allows easy bending and curling of the cushion 11 as well. When the cushion 11 is bent or curled, the voids V formed in the cushion 11 between adjacent foam profiles 12 provide for the ability for the cushion 11 to be easily bent or curled. The voids V between the foam profiles 12 in the cushion 11 are reduced and eventually closed if the adjacent foam profiles 12 are brought together during bending or curling of the cushion 11. The greater the void V between adjacent foam profiles 12, the more the cushion 11 can be rolled with less radius.

[0042] It may also be desired to have greater firmness for the edge portion of the cushion 11 than the middle portion of the cushion 11. For example, in a mattress application, this may assist in preventing a person from falling off the mattress. Firmness in the edge portion can be intensified by inserting a short piece of solid foam into the end of a corresponding hollow foam profile. In this regard, FIG. 6A illustrates the foam profile 12 with the hollow portion 17 disposed therein. FIGS. 6B and 6C illustrate exemplary filler material 25 disposed in the hollow portion 17 of the foam profile 12 in the cushion 11 of FIG. 1. FIGS. 6D-6F illustrate side views of exemplary filler material 27 disposed in a hollow portion 40 of the hollow foam profile 19 that may be provided in a cushion, including the cushion 11 of FIG. 1 as an example. For example, as illustrated in FIGS. 6A-6C, the filter material 25 may be a triangle-shaped foam insert that can be put in the end of the hollow portion 17 of the foam profile 12 to form a combined profile 26. As another example, as illustrated in FIGS. 6D-6F, the filler material 27 in the form of an elliptical-shaped foam insert can be put in the end of the hollow foam profile 19 to form a combined profile 28.

[0043] FIG. 7 illustrates a top view of the cushion 11 of FIG. 1 which employs solid right angle trapezoid foam profiles 23 on ends of the cushion 11 to provide intensified firmness at edge portions of the cushion 11. FIG. 8 illustrates a side perspective view of the cushion 11 of FIG. 1 comprised of the plurality of adjacent exemplary foam profiles 12 melting down on the top surface 14 in a desired pattern, such as having islands 29 and grooves 30. The resulting cushion 11 may have a more rugged feel and appearance.

[0044] FIG. 9 illustrates a side perspective view of the cushion 11 of FIG. 1, modified by adding an open cell foam layer 31 on the top of the cushion 11. On the bottom surface of the cushion 11, strips of re-closable plastic fasteners can be used along the edge of the cushion 11 to lock the position of the bottom non-woven sheet 13 to a supporting surface, specifically using a pair of fasteners 32, which may be re-closeable, in a lateral direction and a pair of fasteners 33 in a longitudinal direction, as shown in FIG. 9. Matching parts of the pairs of fasteners 32, 33 on the supporting surface underneath the cushion 11 are not shown in FIG. 9.

[0045] FIG. 10 illustrates a side perspective view of a cushion 34 composed of multiple pieces of long and specially shaped close cell foam profiles 35 between two non-woven sheets 13. Each of the foam profiles 35 has geometry of reduced cross-section area from top to bottom in terms of its vertical projection, as shown in FIG. 11. In this embodiment, the foam profile 35 contains an opening 41. The non-woven sheets 13 are affixed to the foam profile 35 to cover the top and bottom of the foam profiles 35. All of the pieces of the foam profiles 35 are in parallel and distanced from each other with a small space. Because of the strong bonding of the foam profiles 35 with the non-woven sheets 13, the cushion 34 has good integrity. Since the non-woven sheets 13 are soft and flexible, the cushion 34 can be bent. When a compression force is imposed on the cushion 34, the foam profile 35 changes its shape to adapt to a large deformation. The non-woven sheets 13 play a role of keeping each individual foam profile 35 locked in a proper position in the cushion 34. Once a compression force is removed, the foam profiles 35 return to their original shapes.

[0046] FIGS. 12A and 12B illustrate perspective and side views, respectively, of a foam profile 35 employed in the cushion 34 of FIG. 10 with optional cuts 42 disposed therein. Providing the optional cuts 42 may serve to provide a desired cushioning effect and may also reduce the weight of the cushion 34. With the optional multiple cuts 42 cut from the bottom to trim out a portion of the foam profile 35, the foam profile 35 becomes foam profile 36, as shown in FIGS. 12A and 12B.

[0047] Many modifications and other embodiments of the embodiments set forth herein will come to mind to one skilled in the art to which the embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the description and claims are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. It is intended that the embodiments cover the modifications and variations of the embodiments provided they come within the scope of the appended claims and their equivalents. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.