Pad with virtual surface profiling

Abstract

The pad with virtual profiling may have a uniform or substantially uniform thickness or height, while different locations or regions of the pad may have different cushioning characteristics. The liner may include a patterned grid defined by interconnected walls. Different cushioning characteristics may result from features that harden or soften the hollow posts of the patterned mesh, such as enlarged junctions between the interconnected walls, voids in the interconnected walls, thicknesses of the interconnected walls, cross-sectional shapes and / or dimensions of the hollow posts defined by the interconnected walls, materials forming the interconnected walls, delamination of different patterned meshes, etc. Or any combination of the foregoing. Methods for designing, manufacturing, and using pads with virtual profiling are also disclosed.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 441,581, filed January 27, 2023, entitled “CUSHIONING ELEMENTS WITH VIRTUAL SURFACE CONTOURING” (“the '581 Provisional Application”). The entire disclosure of the '581 Provisional Application is hereby incorporated herein. Technical Field

[0003] The present disclosure generally relates to cushions having different zones that cushion differently, including cushions having a flat surface that has the feel of a contoured mattress (i.e., a virtually contoured mattress). This virtual surface contouring can be achieved by interconnecting multiple walls in the cushion to define a hollow column, with one or more stiffeners and / or one or more voids included in the walls of the hollow column defining a particular area or zone of the cushioning surface to impart the desired cushioning properties to that area or zone of the cushioning surface. Also disclosed are methods for designing cushions having interconnected walls defining the hollow column to impart virtual surface contouring to the cushion.

[0004] Public content

[0005] The gasket of the present disclosure includes a plurality of interconnected walls defining a plurality of cells, wherein the walls defining each cell constitute a hollow column. The walls of the plurality of interconnected walls can be formed of an elastomeric material, such as a material known as "gel". The walls can be arranged in a manner defining a grid (e.g., a square grid, a rectangular grid, a triangular grid, a hexagonal grid, etc.), wherein the hollow columns define the cells or spaces of the grid. This arrangement can be referred to as a "patterned gel layer". The hollow columns and the cells they define can be arranged in an array. For example, the walls can be arranged to form a square grid, wherein each hollow column is roughly square. In some embodiments, the walls can be arranged to form a hexagonal grid, wherein each hollow column is roughly hexagonal (i.e., a "honeycomb" arrangement). In some embodiments, the walls are arranged so that some areas of the gasket have a grid of one shape (e.g., a square, hexagon, triangle, rhombus, etc.), and some areas have a grid of another shape (e.g., a square, hexagon, triangle, rhombus, etc.).

[0006] The hollow posts and the cells they define may extend completely through the thickness of the liner, substantially through the thickness of the liner, or partially through the thickness of the liner. A thin layer or film of material (e.g., material forming interconnecting walls, etc.) may extend laterally across the ends or intermediate locations of the hollow posts and their cells, which extend substantially through the thickness of the liner. The thickness of such a thin layer or film may be about 5% or less of the thickness of the portion of the liner through which the hollow posts and their cells extend. A hollow post that extends partially through the liner may include one segment or multiple segments that, in combination, extend less than 95% of the thickness of the portion of the liner through which the hollow posts and their cells extend.

[0007] The cushion may have a configuration that gives it virtual contouring. In other words, the cushion may have a flat surface with different areas or zones that have different cushioning properties or support the cushioned object differently than other areas or zones of the cushioning surface.

[0008] The walls and / or hollow columns of each zone of such a cushion may include features that enable that zone of the cushion to have predetermined cushioning properties (e.g., stiffness (or firmness), deformability (e.g., the area of ​​the surface of the cushion that deforms under load, the extent to which the cushion deforms under load (e.g., depth, etc.), etc.), thereby cushioning an object (e.g., an individual, etc.) or a portion of an object in a predetermined manner. In this regard, the walls and / or hollow columns of a cushion according to the present disclosure may have a configuration (e.g., reinforcements, voids, etc. in the walls defining the hollow columns) that imparts a predetermined stiffness (i.e., softness and / or stiffness) and / or deformability to each zone of the cushion.

[0009] The elastomeric material forming a plurality of interconnected walls may comprise any suitable material that is easily deformed when placed under a load and elastically rebounds (i.e., returns to its original shape) when the load is removed. In various embodiments, the elastomeric material may comprise a gel or gel-like material. In a specific but non-limiting example, the gel or gel-like material may comprise a block copolymer that has been extended with a plasticizer. A non-limiting example of a block copolymer is a triblock copolymer, such as a material referred to as an ABA triblock copolymer. A non-limiting example of a plasticizer is mineral oil. Other materials referred to as "synthetic rubber" and other materials that can be used to form walls include, but are not limited to, rubber, foam (e.g., polyurethane foam, etc.) and other materials that are deformed when placed under a load and elastically rebound (e.g., return to its original shape, etc.) when the load is removed.

[0010] Alternatively, adjacent regions of the liner may be formed integrally, or formed during the same process step (eg, molded together, etc.).

[0011] In some embodiments, one or more regions of the liner may include a reinforcement or reinforcements. The reinforcement or reinforcements may be defined by a material (e.g., an elastomeric material, etc.) that defines a plurality of interconnected walls. Without limitation, the reinforcement or reinforcements may include an enlarged junction between interconnected walls at the corners of a hollow column or cell of the liner. The enlarged junction may include one or more filleted (i.e., rounded) inner corners (i.e., a "filleted junction") or any other suitable enlarged shape (e.g., a rounded cross-section, such as a circle, oval, ellipse, etc.; a polygonal cross-section, such as a diamond, square, etc.); etc.) within the interior of the hollow column. Each dimension across each end of such an enlarged junction (e.g., in line with the interconnected walls, a diagonal, etc.) may exceed the thickness of each of the multiple walls joined at the enlarged junction.

[0012] The arrangement of reinforcements across zones of the cushion can at least partially define the cushioning characteristics of each zone of the cushion and provide different cushioning characteristics for different zones of the cushion at different locations, regions, or zones on the cushioning surface of the cushion. As an example, locations of the cushioning surface intended to be relatively firm can include a firm arrangement of reinforcements (e.g., more reinforcements, larger reinforcements, etc.), while locations of the cushion intended to be relatively soft can include a soft arrangement of reinforcements (e.g., fewer reinforcements, smaller reinforcements, etc.).

[0013] The hollow column may include an enlarged joint (e.g., a rounded joint, etc.) at one corner. The hollow column may include an enlarged joint (e.g., a rounded joint, etc.) at multiple corners (e.g., opposing corners of the hollow column, etc.). Each corner of the hollow column may include an enlarged joint (e.g., a rounded joint, etc.) (i.e., all corners of the hollow column may include an enlarged joint).

[0014] All hollow columns of the cushion may include at least one reinforcement. Alternatively, only selected hollow columns of the cushion (e.g., hollow columns at the corners of the cushion, hollow columns at the outer edges of the cushion, hollow columns at locations of the cushion that are expected to receive the greatest load (e.g., midway between the head and foot of the mattress, etc.)) may include at least one reinforcement.

[0015] For example, each hollow column of the mattress pad that is arranged in the area (i.e., zone) corresponding to the position where the individual places his or her shoulders can include reinforcements only in selected (i.e., not all) hollow columns and / or include fewer reinforcements in at least some of the hollow columns to make the shoulder area of ​​the pad relatively soft. Similarly, the area (i.e., zone) of the pad that is located where the individual will rest his or her buttocks can include reinforcements only in selected (i.e., not all) hollow columns and / or include fewer reinforcements in at least some of the hollow columns to make the buttocks area of ​​the pad relatively soft. In contrast, the areas of the pad that receive the individual's head, back, and legs can include reinforcements in more hollow columns and / or include more reinforcements in at least some of the hollow columns to make these areas stiffer and, thereby, stronger than the shoulder and buttocks areas of the pad. The features of the walls of the flexion columns in the shoulder and buttocks areas can also be customized to provide different stiffness or firmness to these areas. The characteristics of the walls of the flexion columns in the head, back, and leg regions may also be tailored to provide different stiffness and / or firmness to these regions.

[0016] In some embodiments, the hollow posts comprising at least one reinforcement are arranged in a gradient throughout the cushion, thereby creating areas of the cushion having greater stiffness or firmness and areas of the cushion having less stiffness or firmness.

[0017] Each hollow column of a cushion that includes at least one reinforcement (e.g., one or more enlarged joints, etc.) can be reinforced in the same manner as every other hollow column that includes at least one reinforcement (e.g., they can have the same number of enlarged joints, etc.). Alternatively, the manner and extent to which each hollow column is reinforced (e.g., the type, number, and arrangement of reinforcements, such as enlarged joints, etc., of the hollow column) can correspond to the position of the hollow column on the cushion. In some embodiments, incorporating reinforcements into a cushion having interconnected walls defining hollow columns can help reduce the wall-to-wall distance or spacing (i.e., the distance across each cell), height, or thickness of the cushion.

[0018] In some embodiments, the cushion may include a softening feature. As a non-limiting example, such a softening feature may include a void in at least one wall defining at least one hollow column. Such a void may include a feature that removes material from a plurality of interconnected walls. In some embodiments, a void may include an opening in a wall of the plurality of interconnected walls. Such an opening may include a recess or notch in the edge of a wall. Such an opening may include a window in the wall. In other embodiments, a void may include a recess or thinned area (e.g., a pit, etc.) in one or both surfaces of the wall. Each void may have a size and shape that enables it to remove material from the wall, thereby reducing the weight of the wall and the weight and density of the cushion of which the wall is a part, without reducing the cushioning properties of the cushion. In some embodiments, incorporating voids into the walls of a cushion having interconnected walls defining hollow columns can help minimize or reduce the distance or spacing between the walls of the cushion (i.e., the distance across each cell) and / or the height or thickness of the cushion, relative to a conventional cushion comprising a plurality of interconnected walls formed of an elastomeric material and defining a grid.

[0019] The variation in voids from one hollow post to another or from one region of the cushion to another can be used to impart one or more gradients of stiffness and / or deformability to the cushioning surface of the cushion. Such gradients can be provided across the length and / or width of the cushion to provide transitions between regions having different stiffness and / or deformability, or for any other purpose.

[0020] In some embodiments, incorporating voids into the interconnected walls defining the hollow columns of a cushion can help increase the breathability of the cushion. Conventional cushions constructed from elastomeric materials typically do not allow air to flow through the elastomeric material and, therefore, do not allow air to flow laterally through the cushion. This blocked air flow can trap heat (e.g., body heat) within the hollow columns of the cushion. By including voids within the walls, air and heat can pass laterally through at least some portions of the cushion to the unblocked hollow columns and / or perimeter of the cushion. As a result, air and heat can more easily vent from the cushion, creating a cooler and more comfortable experience for the user.

[0021] The arrangement of voids or other softening features in the walls of a cushion can at least partially define one or more cushioning properties of the cushion at different locations or regions on its cushioning surface. As an example, the voids or other softening features can be evenly arranged on the cushion to impart the same cushioning properties to the cushion across the entire cushioning surface or substantially across the cushioning surface (e.g., perhaps with the exception of the edges of the cushion, etc.). As another example, locations on the cushioning surface that are intended to be relatively firm can include a firm arrangement of voids (e.g., fewer voids, smaller voids, voids of different shapes (i.e., void geometries), etc.) or other softening features, while locations on the cushion that are intended to be relatively soft can include a soft arrangement of voids (e.g., more voids, larger voids, voids of different shapes (i.e., void geometries), etc.) or other softening features. The locations on the cushion that are intended to be relatively soft can correspond to the head, shoulders, and / or hip regions of a user. The locations on the cushion that are intended to be relatively firm can correspond to the neck, back, legs, and / or arms of a user.

[0022] In some embodiments, a specific stiffness and / or deformability of a particular region of the cushion can be achieved by providing an elastomeric gel layer or patterned gel layer having a hollow pillar geometry (e.g., shape, size, wall thickness, etc.) that provides the desired stiffness and deformability in that region. For example, the stiffness and / or deformability of a patterned gel layer having interconnected walls defining cubic cells can be different from the stiffness / softness and / or deformability of a patterned gel layer in which the interconnected walls define hollow pillars having a similarly sized hexagonal or triangular cross-section taken transversely to the height of the hollow pillars or the height or thickness of the patterned gel layer. As another example, a patterned gel layer having interconnected walls defining cells of a particular shape (e.g., cubes, hexagonal prisms, triangular prisms, etc.) having relatively large dimensions can be less stiff (i.e., softer) and / or more deformable than a patterned gel layer having interconnected walls defining cells of the same shape having a smaller cross-section. Thus, patterned gel layers having different geometries may be included in different regions of the cushion to impart different stiffness and / or deformability to the different regions relative to one another.

[0023] Variations in stiffness and / or deformability from one region of the cushion to another region of the cushion may also be achieved by using elastomeric gel materials having different stiffnesses (or softnesses) to define different regions of the cushion.

[0024] The difference in stiffness and / or deformability from one zone of the cushion to another zone can also be achieved by layering. For example, one or more zones of the cushion can include a single patterned gel layer. One or more other zones of the cushion can include two or more superimposed layers whose interconnected walls and cells are at least partially offset from each other. The superimposed layers can have the same or different geometric shapes as each other. Compared to other embodiments of the cushion, this offset arrangement can provide greater support to the user. In embodiments in which the superimposed layers are made of the same material, the stiffness and / or deformability of the zone with the superimposed layers can be different from the stiffness and / or deformability of the zone with a single layer (e.g., less stiff, less easily deformed, etc., than the zone with a single layer). Similarly, the stiffness and / or deformability of the zone with three superimposed layers can be different from the stiffness and / or deformability of the zone with two superimposed layers.

[0025] Any combination of reinforcements, wall voids, hollow column geometries, materials, layering, etc. can be used to provide regions of the cushion having desired stiffness and / or deformability, and to provide variations in the stiffness and / or deformability of the cushion from one region to another, thereby providing virtual contouring of the cushion and its cushioning surface.

[0026] A method for designing a cushion having a plurality of interconnected walls defining a hollow column may include determining one or more cushioning properties (e.g., stiffness and / or deformability) for different regions of the cushion, and optimizing (e.g., minimizing, etc.) each region of the cushion to achieve the one or more cushioning properties. This method may include one or more of the following: incorporating features that optimize the cushioning properties of the cushion into each region of the cushion, using patterned gel layers having different geometries in different regions of the cushion, using patterned gel layers with different layers in different regions of the cushion, using materials with different mechanical properties (e.g., hardness, elasticity, etc.) in different regions of the cushion, etc.

[0027] Other aspects of the disclosure, as well as features and advantages of various aspects of the disclosed subject matter, will be apparent to one of ordinary skill in the art from consideration of the ensuing description, drawings, and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In the attached figure:

[0030] Figure 1 is a perspective view of a section of an existing liner;

[0031] Figure 2 is a perspective view of a section of an embodiment of a liner designed with an embodiment of a reinforcement to provide Figure 1 The segments of the prior art pad shown in FIG have the same or substantially the same cushioning characteristics as the segments of the prior art pad shown in FIG, but have a Figure 1The sections of the prior art gasket shown in have smaller wall-to-wall distance or spacing (i.e., the distance across each cell), height or thickness, weight, and / or density;

[0032] Figure 2 Also shown are embodiments of voids in the walls defining a hollow column that can be used to provide a structure having a Figure 1 The cushioning characteristics of the segments shown in FIG are the same or substantially the same as those of the segments shown in FIG, but with a cushioning characteristic greater than Figure 1 The sections of the prior art pad shown in have smaller weights and / or wall-to-wall distances or spacings (i.e., the distance across each cell), heights or thicknesses, and / or densities;

[0033] Figure 2A It is limited Figure 2 an enlarged view of an embodiment of a void in a wall of a portion of a hollow column of a liner;

[0034] Figure 3 is a perspective view of a section of another embodiment of a liner designed with voids in the wall of the liner and other embodiments of optional reinforcements to provide Figure 1 The segment liner shown in FIG has the same or substantially the same cushioning characteristics, but has a Figure 1 The sections of the prior art pad shown in have a smaller weight, wall-to-wall distance or spacing (i.e., the distance across each cell), height or thickness, and / or density;

[0035] Figure 4-Figure 7 front, left, top, and perspective views, respectively, showing the results of a topological study of a 2-inch (5.1 cm) thick liner segment comprising a 3-by-3-column square patterned gel layer of conventional configuration, illustrating areas of the liner's interconnecting walls that should be retained and areas that can be removed without significantly affecting the cushioning properties of the segment of the liner;

[0036] Figure 8 is a graph that provides a comparison of the displacements achieved with multiple pad sections, including the displacements achieved with multiple pad sections under multiple loads. Figure 1 Experimental displacement data achieved by the depicted segments of the pre-existing cushion, simulated with segments of the cushion of the present disclosure, and achieved with segments of a pre-existing mattress cushion from Purple Innovation having standard wall dimensions and spacing and a height or thickness of three inches;

[0037] Figure 9 is a graph comparing the cushioning characteristics of a pad according to the present disclosure with the cushioning characteristics of a thicker, heavier pad of conventional construction;

[0038] Figure 10 and Figure 11 The stresses at various locations of a 3 by 3 square, 2 inch (5.1 cm) thick section of a conventionally constructed liner having no reinforcements or voids in its walls and a thinner 3 by 3 square section of an embodiment of a liner according to the present disclosure (i.e., an optimized liner) are shown, respectively;

[0039] Figure 12 and Figure 13 Deflection at various locations of a 3 by 3 square, 2 inch (5.1 cm) thick section of a conventionally constructed cushion having no reinforcements or voids in its walls, and a thinner 3 by 3 square section of an embodiment of a cushion according to the present disclosure (i.e., an optimized cushion) are shown, respectively;

[0040] Figure 14 is a perspective view showing the results of a topological study of an 8 column by 8 column square, 2 inch (5.1 cm) thick section of a conventionally constructed liner, illustrating areas of the interconnecting walls of the liner that should be retained and areas of the interconnecting walls that can be removed without significantly affecting the cushioning properties of the section of the liner.

[0041] Figure 15A and Figure 15B An embodiment of a grid formed by a plurality of interconnected walls defining a plurality of hollow posts in a gasket according to the present disclosure is shown.

[0042] Detailed description

[0043] Figure 2 An embodiment of a gasket 10 comprising a patterned layer is shown. The patterned layer of the gasket 10 comprises and is defined by a plurality of walls 20. The walls 20 are connected to one another at joints 22 and, therefore, may be referred to as "interconnected walls." The walls 20 are arranged in an array defining cells 32. The walls 20 defining each cell 32 together form a hollow column 30. As shown, the walls 20 are arranged in a grid pattern and define the hollow column 30 having or exhibiting a cross-section taken transverse to the height of the hollow column 30 that is generally square in shape (e.g., having rounded corners, etc.). Figure 15A and Figure 15B As shown, the walls 20 can be arranged in a grid pattern and define hollow pillars 30 having or exhibiting a cross-section taken transverse to the height of the hollow pillars 30 that is generally hexagonal in shape (e.g., with rounded corners, etc.), thereby creating a "honeycomb" grid. Liners 10 with hollow pillars 30 having other cross-sectional shapes (e.g., diamond-shaped, triangular, etc.) are also within the scope of the present disclosure.

[0044] The wall 20 of the liner 10 can be formed from any suitable material, including but not limited to an elastomeric material. The elastomeric material can include a gel, which can be referred to as an "elastomeric gel" or "gel elastomer." Examples of elastomeric materials including gels include, but are not limited to, plasticizer-extended block copolymers (e.g., plasticizer-extended diblock copolymers, plasticizer-extended triblock copolymers, etc.). U.S. Patents 5,994,450, 6,797,765, and 7,964,664 (the entire disclosures of which are hereby incorporated herein) disclose multiple embodiments of ABA triblock copolymers that can be used to form the wall 20 of the liner 10. Purple Innovation, LLC's Hyper-Elastic Polymer 4.0 mix, which includes a mineral oil-extended ABA triblock copolymer, is a specific example of a gel that can be used to define the wall 20 of the liner 10. In embodiments where the wall 20 is formed from a gel, the liner 10 can include a patterned gel layer.

[0045] When the liner 10 is placed under a load, the hollow column 30 can bend, as described in U.S. Patents 7,730,566 and 8,919,750, the entire disclosures of which are hereby incorporated herein, or the hollow column 30 can bulge, as described in U.S. Patent Application Publication No. US2019 / 0075884 A1, the entire disclosure of which is hereby incorporated herein.

[0046] like Figure 2 As shown, each joint 22 between interconnecting walls 20 can be enlarged relative to the thickness of the walls 20 defining the joint 22. More specifically, such joints 22 can define filleted (i.e., rounded) interior corners within the interior of the hollow column 30 and, thus, comprise "radii joints" or reinforcements. Each dimension across each end 23, 24 of such joints 22 (e.g., dimensions colinear with or diagonal to the interconnecting walls 20, etc.) can exceed the thickness of each wall 22 extending into the joint 22. Alternatively, the joints 22e can define exterior fillets (i.e., rounded protrusions) at the outer edges 10e and / or corners 10c of the liner 10.

[0047] also, Figure 2 An embodiment of a gasket 10 is shown that includes a void 28 in a portion of a wall 20 defining a hollow column 30. More specifically, the void 28 comprises a recess or notch (e.g., a trapezoidal notch, etc.) extending upward from a base 26 of the wall 22 toward a top edge 27 of the wall 20. The void 28 may extend upward from the base 26 to any length on the wall 20 and may be positioned on every wall 20 or on selected walls 20. Figure 2AThe shape and size of a specific embodiment of void 28 are shown.

[0048] Now refer to Figure 3 , another embodiment of a cushion 10′ is shown. The cushion 10′ includes walls 20′ formed from an elastomeric material such as gel. The walls 20′ are connected at joints 22′. The walls 20′ define a hollow column 30′. A void 28′ can be defined in the walls 20′ (e.g., in the plane of the walls 20′, etc.). The void 28′ can include a recess in the base 26′ of the wall 20′ and / or a recess in the top edge 27′ of the wall 20′. Optionally, the void 28′ can have a shape referred to as a “keyhole” that extends to the base 26′ or top edge 27′ of the wall 20′. In addition, selected joints 22′ can be enlarged relative to the thickness of the wall 20′ defining these joints 22′.

[0049] Figure 4-Figure 7 and Figure 14 Depicted are the results of a topological study conducted by fixing the position of the base 112 of the segments of the pads 110, 210 (i.e., the bottom edges 126, 226 of the walls 120, 220) and applying a compressive force to the top 114 of the segments of the pads 110, 210 (i.e., the top edges 127, 227 of the walls 120, 220). This study was computer simulated. Figure 4-Figure 7 In , topological studies were conducted on 3-by-3-column square sections of a 2-inch (5.1 cm) thick pad 110. Figure 14 In Figure 1, topological studies were conducted on 8-by-8-row square, 2-inch (5.1 cm) thick sections of the liner 210. The walls 120, 220 of each section of the liner 110, 210 were 0.12 inches (30 mm) thick and defined a hollow column 130, 230 having a generally square cross-section taken transversely to the length of the hollow column 130, 230. The joints 122, 222 between the interconnecting walls 120, 220 were cylindrical in shape with a diameter of 0.26 inches (67 mm). The center of each joint 122, 222 was spaced 1.2 inches (2.9 cm) from its adjacent joint 122, 222 along the walls 120, 220 defining the joint 122, 222. Each segment of the gasket 110, 210 is made from Purple's Hyper-Elastic Polymer 4.0 mix, which comprises a mineral oil-extended ABA triblock copolymer.

[0050] Figure 8 is a calibration graph for the mathematical model used to calculate elastomeric materials. Figure 4-Figure 7The results of the depicted topological study reveal areas of the walls 120, 220 of the liner that provide structural integrity to the liner 110, 210 (yellow areas), areas of the walls 120, 220 that appear to be unnecessary for the liner 110, 210 to function as intended (transparent areas, appearing as holes in the walls 120, 220), and areas of the walls 110, 210 that may provide some structural integrity but are unnecessary for the liner 110, 210 to function as intended (different shades of blue areas).

[0051] exist Figure 2 and Figure 2A The topological studies were simulated on an embodiment of a pad 10 shown in FIG. 1 , which has a wall-to-wall distance or spacing (ie, the distance across each cell), 1 3 / 4 inches (4.4 cm) in height or thickness, with 0.10 inches (2.5 mm) rounded inner corners, and a hollow post 30 having Figure 2A The gap 28 is of the size shown in FIG. Figure 9 Provides a simulation topology study that is similar to the above topology study (reference Figure 4-Figure 7 ). Figure 9 As shown, thinner, lighter weight pads according to the present disclosure can provide the same cushioning characteristics as conventionally constructed pads.

[0052] Figure 10 The stresses at various locations on a segment of a conventionally configured liner 110 during a topology study are shown. Figure 11 Stresses under the same conditions induced at different locations of a section of an embodiment of a liner 110' including voids 128' in selected walls 120' (ie, depicted windows (eg, rectangular, etc.) in various walls 120') are shown.

[0053] Figure 12 The deflections of various locations of a segment of a conventionally configured pad 110 during a topology study are shown. Figure 13 Simulated deflections resulting from the same conditions at different locations of a section of an embodiment of the liner 110' including voids 128' in selected walls 120' are shown.

[0054] Figures 8-13The various results shown indicate that including voids 28 in the walls 120′, 220′ of the cushions 110′, 210′ ​​does not alter the overall buckling or concavity profile of the cushions 110′, 210′. That is, cushions 110′, 210′ ​​including walls 120′, 220′ having one or more voids 28 can provide the same cushioning characteristics as conventionally constructed cushions 110, 210. Furthermore, including voids 28 in the walls 120′, 220′ can result in cushions 110′, 210′ ​​that are lighter overall, even when maintaining a uniform wall-to-wall distance or spacing (i.e., the distance across each cell), height, or thickness throughout the cushions 110′, 210′.

[0055] For example, returning a reference Figure 2 The liner 10, constructed of an elastomeric material, includes a plurality of interconnected walls 20 defining a plurality of hollow pillars 30, wherein the walls 20 are arranged to define a grid (e.g., a square grid or a honeycomb grid). The liner 10 can have an overall wall 20-to-wall 20 distance or spacing (i.e., the distance across each hollow pillar 30) of about 1 inch (2.54 cm) and a height or thickness of about 2 inches (5.1 cm) to about 4 inches (10.2 cm) (e.g., 2 inches (5.1 cm), 2.5 inches (6.4 cm), about 3 inches (7.6 cm), 3.5 inches (8.9 cm), etc.). The wall 20-to-wall distance or spacing (i.e., the distance across each hollow pillar 30) can be uniform or substantially uniform from one edge of the liner 10 to the opposite edge of the liner 10. The height or thickness of the liner 10 can be uniform or substantially uniform (e.g., to account for design tolerances, rounding or tapering at the edges of the liner 10, etc.), and thus, the height of the hollow posts 30 of the liner 10 or portions thereof can be the same or substantially the same across the surface area occupied by the liner 10 or portions thereof. At least some of the plurality of interconnected walls 20 include one or more reinforcing joints 22 (and / or voids 28 ( Figure 3) and / or other features (shape of the hollow post 30, size of the hollow post 30, thickness of the wall 20, material, etc.). For example, the joints 22 between the interconnected walls 20 at the corners of the hollow post 30 can be enlarged to impart greater stiffness to specific locations or areas of the cushion 10. Including more enlarged joints 22 results in overall stiffer locations or areas of the cushion 10. Including fewer or no enlarged joints 22 at specific locations or areas of the cushion 10 results in overall softer or more flexible locations or areas of the cushion 10. Therefore, the enlarged joints 22 can impart a virtual contouring effect or virtual contouring cushioning properties to the cushion 10. In addition, the enlarged joints 22 can be graded in (i) size, (ii) location, and / or (iii) concentration to provide a smooth virtual transition between different areas of the virtual contouring cushion 10 having different cushioning properties to impart a smooth virtual transition to the cushion 10 between the different areas.

[0056] Additionally and / or alternatively, return reference Figure 3 At least some of the plurality of interconnected walls 20' (e.g., some walls 20', each wall 20', etc.) may include one or more voids 28 (e.g., windows, cutouts, recesses, etc.) (see Figure 2A-Figure 7 ). Voids 28 may be included in the walls 20′ of the cushion 10′ to soften the cushion 10′. The voids 28 may reduce the weight of the cushion 10′ and / or soften the cushion 10′ or a portion thereof. Including the voids 28 may not change or affect the height of each wall 20′, or therefore, may not affect the height or thickness of the cushion 10′. Including the voids 28 in the walls 20′ may not change or affect the overall wall 20′ to wall 20′ distance or spacing (i.e., the distance across each hollow column 30′). Rather, the presence of the voids 28 in multiple walls 22′, as well as the size, shape and / or number of the voids 28 (each of which contributes to the concentration of the voids 28), the location of the voids 28 in the walls 20′, etc., may impart desired cushioning properties to a location or area of ​​the cushion 10′. By varying the manner in which voids 28 are included in wall 20′ in different locations or regions of pad 10′, voids 28′ can impart a virtual contouring effect or virtual contoured cushioning properties to pad 10′. Furthermore, the location of voids 28 in wall 20′ of pad 10′ can be graded in (i) size, (ii) location, and / or (iii) concentration to provide smooth virtual transitions between different regions of a virtual contoured pad 10′ having different cushioning properties, thereby imparting a smooth virtual transition between the different regions of pad 10′.

[0057] In some embodiments, the virtual contouring of the liner 10, 10' is achieved by using an enlarged joint 22 ( Figure 2In other embodiments, the virtual contour of the pad 10, 10' is created by using a gap 28 ( Figure 3 ) in a manner. In still other embodiments, other features (e.g., the cross-sectional shape of the hollow posts 30, 30′, the cross-sectional dimensions of the hollow posts 30, 30′, the thickness of the walls 20, 20′, the material forming the walls 20, 20′, layering, etc.) can contribute to the virtual contouring of the pads 10, 10′. In addition, the combination of the aforementioned (e.g., enlarged joints 22, gaps 28, etc.) can be varied to impart a virtual contouring to the pads 10, 10′ having a uniform or substantially uniform height or thickness. For example, a pad of the present disclosure having contouring cushioning properties can have an area with stiffer cushioning properties, an area with softer cushioning properties, and a combination thereof. The gradient of cushioning properties formed between the two areas can correspond to areas of the human body that would benefit from firmer and / or softer cushioning properties. Specifically, the area with stiffer cushioning properties can correspond to the neck, shoulder, and / or hip areas of the human body. Additionally, the area with softer cushioning properties can correspond to the back and / or leg areas of the human body.

[0058] Figure 15B An embodiment of a cushion 300 is depicted having a plurality of distinct zones 310A, 310B, etc. (each zone may also be referred to as a zone 300, and any combination of zones may be referred to as a zone 300) that impart virtual contouring to the cushion 300. Each zone 310 has cushioning properties (e.g., stiffness and / or deformability) that differ from the cushioning properties of each adjacent zone 310. Alternatively, adjacent zones 310 may be integrally formed. A gradient may be formed from one zone 310 to an adjacent zone 310. Such a cushion 300 may comprise at least a portion of a mattress, a mattress topper, a seat cushion, a pillow, or any other type of cushioning device.

[0059] Return to reference again Figure 2 and Figure 3The contoured cushioning properties imparted to the cushion 10, 10' by the enlarged joint 22, the void 28, and / or other features do not cause the cushion 10, 10' to feel thinner to the user. Instead, in some embodiments, the contoured cushioning properties can cause the cushion 10, 10' to feel thicker or more buoyant to the user. For example, in a cushion 10, 10' having a height or thickness of approximately 3 inches (approximately 7.5 cm), the user may perceive the cushion 10, 10' as having a height or thickness of approximately 4 inches (approximately 10 cm) due to the cushioning properties of the cushion 10, 10' or one or more locations or regions of the cushion 10, 10'. That is, the user may perceive the cushion 10, 10' as being thicker or more comfortable if the cushion 10, 10' provides more support to key areas of the user's body (e.g., the neck, shoulder, and / or hip areas, etc.). In this manner, the cushion 10, 10' can have a thinner and more uniform overall profile or construction while giving the user a feeling that the cushion is substantial and comfortable.

[0060] In addition to giving the liner 10' ( Figure 3 ) In addition to the "contouring" effect or contoured cushioning properties, including voids 28 in wall 20' of liner 10' results in an overall lighter liner 10', as well as a liner 10' that is easier to handle during manufacturing, shipping, setup, and moving. Furthermore, less energy is required to transport a lighter liner 10'. Additionally, a liner 10' having voids 28 can be more easily removed from the mold used to form the liner 10'. That is, by being lighter and slightly more flexible, the liner 10' can be more easily pulled from the mold. Reducing the weight of the liner 10' can also reduce the time required to manufacture and transport the liner 10'.

[0061] Although this disclosure provides many details, these should not be construed as limiting the scope of any of the appended claims, but rather as providing illustrations of some embodiments of the elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter and its elements and features may be devised without departing from the spirit or scope of any claim. Features from different embodiments may be used in combination. Therefore, the scope of each claim is limited only by its concise language and its legal equivalents.

Claims

1. A pad comprising: a first region comprising a first patterned gel layer including first interconnected walls formed of a first elastomeric material and defining a first plurality of hollow posts, the first region having a first stiffness and / or deformability; and a second region comprising a second patterned gel layer including second interconnected walls formed of a second elastomeric material and defining a second plurality of hollow posts, the second region having a second stiffness and / or deformability, The first region includes first reinforcements and / or first gaps in at least some of the first plurality of interconnected walls to impart the first stiffness and / or deformability to the first region, and / or the second region includes second reinforcements and / or second gaps in at least some of the second walls in the second plurality of interconnected walls to impart the second stiffness and / or deformability to the second region.

2. The pad according to claim 1, wherein The first region includes a first reinforcement, and the second region includes a second reinforcement.

3. The pad according to claim 2, wherein A first number of first reinforcement portions per unit area of ​​the first region exceeds a second number of second reinforcement portions per unit area of ​​the second region.

4. The pad according to claim 2 or claim 3, wherein: The first reinforcement portion is larger than the second reinforcement portion.

5. The pad according to any one of claims 1 to 4, wherein The first region includes first voids in at least some of the first walls, and the second region includes second voids in at least some of the second walls.

6. The pad according to claim 5, wherein A first number of the first voids per unit area of ​​the first region exceeds a second number of the second voids per unit area of ​​the second region.

7. A pad according to claim 5 or claim 6, wherein: The first gap is smaller than the second gap.

8. The pad according to any one of claims 1 to 7, wherein The second region is free of reinforcements and / or recesses in the second wall.

9. The pad according to any one of claims 1 to 8, wherein The first elastomeric material and the second elastomeric material are the same elastomeric material.

10. The pad according to claim 1, wherein At least one of a first number of layers in the first patterned gel layer, the first elastomeric material, and a first geometry of the first patterned gel layer is different from a second number of layers in the second patterned gel layer, the second elastomeric material, and a second geometry of the second patterned gel layer.

11. The pad according to any one of claims 1 to 10, further comprising: A gradual transition between the first region and the second region is defined by at least one of a reinforcement and / or a void in the walls of adjacent portions of the first region and the second region.

12. The pad according to any one of claims 1 to 11, wherein The first region and the second region are integrally formed.

13. A method for manufacturing a gasket, comprising: forming a first region to include a first patterned gel layer having first interconnected walls defining a first buckling post, the first region having first cushioning properties; and A second region is formed to include a second patterned gel layer having second interconnected walls defining second buckling posts, the second region having a second cushioning characteristic different from the first cushioning characteristic, the second region being formed continuously and integrally with the first region.

14. The method according to claim 13, wherein Forming the first region includes forming a first reinforcement at an intersection between interconnected first walls of the first interconnected walls.

15. The method according to claim 14, wherein Forming the second zone includes forming a second reinforcement at an intersection between interconnected second walls in the second interconnected walls, at least one of a first size of the first reinforcement and a first number of the first reinforcement per unit area of ​​the first zone being different from a second size of the second reinforcement and a second number of the second reinforcement per unit area of ​​the second zone.

16. The method according to any one of claims 13 to 15, wherein: Forming the first region includes forming a first void in a first wall of the first interconnecting walls.

17. The method according to claim 16, wherein Forming the second region includes forming second voids in a second wall in the second interconnected wall, at least one of a first size of the first voids and a first number of the first voids per unit area of ​​the first region being different from a second size of the second voids and a second number of the second voids per unit area of ​​the second region.

18. The method according to any one of claims 13 to 17, wherein Forming the first region includes forming the first patterned gel layer to have a first geometric shape, and forming the second region includes forming the second patterned gel layer to have a second geometric shape, the first geometric shape being different from the second geometric shape.

19. The method according to any one of claims 13 to 18, wherein Forming the first region includes forming the first region to include a first number of the first patterned gel layers, and forming the second region includes forming the second region to include a second number of the second patterned gel layers, the first number of layers being different from the second number of layers.

20. The method according to claim 19, wherein Forming the first region and / or forming the second region includes forming the first region and / or the second region to include a plurality of superimposed layers having laterally offset interconnected walls.

21. The method according to any one of claims 13 to 20, wherein: Forming the first region includes forming the first region from a first elastomeric material, and forming the second region includes forming the second region from a second elastomeric material, the first elastomeric material being different from the second elastomeric material.

22. The method according to any one of claims 13 to 21, further comprising: A gradient is defined from the first cushioning characteristic of the first region to the second cushioning characteristic of the second region.

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