Cushions including a coated elastomeric cushioning element and related methods

Abstract

A cushion includes a cushioning element and a coating provided on a surface of the cushioning element. The cushioning element comprises an elastomeric material forming a plurality of intersecting buckling walls defining a plurality of hollow columns in an expanded form. The elastomeric material comprises an elastomeric polymer and a plasticizer. The coating comprising an olefin powder formulated to hinder adhesion of the elastomeric material when the cushioning element is in a compressed form such that the plurality of intersecting buckling walls is pressed together. The cushioning element is configured to be compressed by a roll-packing machine into the compressed form and subsequently released from the compressed form to transform to the expanded form. Methods of forming the cushion include forming the cushioning element comprising an elastomeric material, coating a surface of the cushioning element with olefin powder, and compressing the cushioning element into a compressed form.

Description

TECHNICAL FIELD[0001]Embodiments of the disclosure relate generally to elastomeric cushioning elements for compressible cushions, including mattresses, mattress toppers, seat cushions, etc., to coatings for the cushioning elements, and to methods of forming cushions including coated cushioning elements.BACKGROUND[0002]Cushioning materials have a variety of uses, such as for mattresses, seating surfaces, shoe inserts, packaging, medical devices, etc. Cushioning materials may be formulated and / or configured to reduce peak pressure on a cushioned body, which may increase comfort for humans or animals, and may protect objects from damage. Cushioning materials may be formed of materials that deflect or deform under load, such as polyethylene or polyurethane foams (e.g., convoluted foam), vinyl, rubber, springs, natural or synthetic fibers, fluid-filled flexible containers, etc. Different cushioning materials may have different responses to a given pressure, and some materials may be well...

AI Technical Summary

Benefits of technology

This patent describes a cushion that has a unique structure made up of intersecting buckling walls that form hollow columns when expanded. The cushion is coated with an olefin powder that prevents the buckling walls from sticking when the cushion is compressed. This results in a more durable and high-quality cushion that can be easily compressed and released. The technical effect of this invention is a more robust and reliable cushion that can be easily compressed and released for use in various applications.

Problems solved by technology

Buckling of the first wall may cause buckling of a second wall, which may decrease the chance that the first wall will “bottom out.” Bottoming out would increase pressure on the portion of the cushioned object over the buckled portion of the cushion.

Cushioning materials, such as mattresses, are generally bulky objects that are difficult and costly to transport from a manufacturer to a retailer or a customer.

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