Foam pad with orthogonal alternating structure

Abstract

A foam pad having an orthogonal alternating structure and cushioning articles formed from or incorporating such foam pads are provided. Orthogonal alternating structures may be formed by assembling foam layers and bonding all or part of the interfaces, wherein the layers are formed from foams of at least two types or hardness. If necessary, the layered arrangement of foam may be cut to form a foam pad, with each layer extending along the length or width of the foam pad, or orthogonal to the direction of the force to be supported by the foam pad. A foam pad component having a base and a layer emanating from the base may be used to form a foam pad.

Description

Background Art

[0001] Foam is commonly used as a cushioning material in a variety of applications. For example, mattresses are often formed from memory foam due to its ability to mold to the body to provide even support. However, memory foam also has various undesirable characteristics. Many people complain that memory foam feels dead, meaning it tends to absorb forces rather than bounce back like a traditional spring mattress or traditional polyurethane non-memory foam. It can also be difficult to roll over on a memory foam mattress due to the indentations that form around the body. Additionally, memory foam has poor breathability, making it too hot for many people.

[0002] To overcome these shortcomings of foams, particularly memory foams, other materials have been used in mattresses and other cushioning products. For example, mattresses such as those sold under the Purple trademark are made of a gel material in the shape of adjacent hollow columns. Mattresses made from such gel-like materials provide local instability and overall stability because the columns are able to flex where needed, such as under an individual's hips. However, such mattresses are very heavy and require specialized manufacturing. Summary of the invention

[0003] The present invention extends to foam pads having an orthogonal alternating structure and cushioning articles formed from or containing such foam pads. The orthogonal alternating structure can be formed by bonding together foam layers, wherein the layers are formed from at least two types or hardnesses of foam. If necessary, the layered arrangement of foam can be cut to form a foam pad, wherein the layers extend along the length or width of the foam pad, or orthogonal to the direction of the force to be supported by the foam pad. A foam pad component having a base and layers emanating from the base can be used to form the foam pad.

[0004] In some embodiments, the present invention may be implemented as a foam pad that includes a foam layer arranged along the length of the foam pad.

[0005] In some embodiments, the present invention may be implemented as a cushioning article including a first foam pad.The first foam pad may include a foam layer disposed along a length of the foam pad.

[0006] In some embodiments, the present invention can be implemented as a method for making a mattress. Foam sheets can be stacked along an axis to form a layered foam block. The layered foam block can be cut along the axis to form a foam pad including a foam layer. The foam pad can be oriented within the mattress so that the foam layer is aligned along the length of the mattress.

[0007] In some embodiments, the present invention can be implemented as a method for making a foam cushion. A first sheet of foam and a second sheet of foam can be formed into a desired shape. The first sheet of foam and the second sheet of foam can be cut into corresponding layers. Alternating layers of the first sheet of foam and the second sheet of foam can be bonded together to form the desired shape.

[0008] In some embodiments, the present invention may be implemented as a method for assembling a foam pad. A first foam pad component may be obtained that includes a base and layers emanating from the base. A second foam pad component may be obtained that includes a base and layers emanating from the base. The layers of the first foam pad component may be interposed between the layers of the second foam pad component to form a foam pad.

[0009] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

[0011] Figure 1A and Figure 1B are a side perspective view and a side view, respectively, of a foam pad having an orthogonal alternating structure according to one or more embodiments of the present invention;

[0012] Figure 2A and Figure 2B are a side perspective view and a side view, respectively, of another foam pad having an orthogonal alternating structure according to one or more embodiments of the present invention;

[0013] Figure 3A and Figure 3B are a side perspective view and a side view, respectively, of another foam pad having an orthogonal alternating structure according to one or more embodiments of the present invention;

[0014] Figure 4 provides an example of how a foam pad having an orthogonal alternating structure can be formed according to one or more embodiments of the present invention;

[0015] FIG. 5A to FIG. 5D are each cross-sectional side views of a mattress including a foam pad having an orthogonal alternating configuration according to one or more embodiments of the present invention;

[0016] Figure 6 is a cross-sectional perspective top view of a mattress according to one or more embodiments of the present invention, the mattress including a foam pad having an orthogonal alternating structure;

[0017] Figure 7 and 7A to 7C provides an example of how a non-rectangular foam pad having an orthogonal alternating structure can be formed according to one or more embodiments of the present invention;

[0018] Figure 8 An example of a mattress according to one or more embodiments of the present invention is provided, the mattress including a foam pad formed of opposing foam pad components;

[0019] Fig. 9 Another example of a mattress according to one or more embodiments of the present invention is provided, the mattress including a foam pad formed of opposing foam pad components;

[0020] FIG. 10A to FIG. 10C An example of a foam pad formed from opposing foam pad components and further comprising a gap is provided;

[0021] Fig.11 An example of a foam pad formed from opposing foam pad components in accordance with one or more embodiments of the present invention is provided in which each layer has rounded ends;

[0022] FIG. 12A to FIG. 12C An example of a mattress according to one or more embodiments of the present invention is provided, the mattress including a single foam pad formed of opposing foam pad components;

[0023] FIG. 13A to FIG. 13E An example of a mattress according to one or more embodiments of the present invention is provided, the mattress including two foam pads, each foam pad being formed of opposing foam pad components;

[0024] Fig.14 An example of a pillow formed from opposing foam cushion components according to one or more embodiments of the present invention is provided;

[0025] Fig.15A and Fig. 15B provides examples of how a foam pad can be formed from opposing foam pad components; and

[0026] Figures 16 to 18 is a table summarizing the results of experiments conducted to test embodiments of the present invention. DETAILED DESCRIPTION

[0027] In this specification and claims, the term "cushioning article" is intended to include mattresses, pillows, sofas, car seats, airplane seats, aftermarket seat cushions, and other furniture or articles that provide cushioning for an individual. The cushioning article may include one or more foam pads configured according to one or more embodiments of the present invention. Foam pads configured according to embodiments of the present invention may also be separate and / or independent from the cushioning article and may be covered with fabric or plastic film or other flexible covering. The term "about" means within 10% of the stated value.

[0028] According to embodiments of the present invention, the foam pad may be formed of foam layers having an orthogonal alternating structure. In this case, the term "orthogonal" is intended to mean that the layers are arranged along an axis orthogonal to the forces to be supported by the foam pad. The term "alternating" is intended to mean that the layers are formed of alternating types or hardnesses of foam.

[0029] Figure 1A and Figure 1B An example of a foam pad 100 having an orthogonal alternating structure is provided. The foam pad 100 has a rectangular shape that is labeled as having a length, a width, and a height. When the foam pad 100 is laid flat, the height can be considered the vertical dimension, while the length and the width can be considered the horizontal dimensions. The foam pad 100 is formed of two types of foams that are arranged in alternating layers 101 and 102 along the length of the foam pad (the length need not be longer than the width). Therefore, the combined thickness of all layers 101 and 102 defines the overall length of the foam pad 100. In this embodiment, the width of each layer 101 and 102 defines a consistent width of the foam pad 100, but in some embodiments (e.g., to form a foam pad of a non-rectangular shape), the layers may have different widths. In this embodiment, the height (L H ) define a consistent height for the foam pad 100, but the layers may have different heights or may be arranged in different vertical positions relative to each other as described below.

[0030] The thickness (L T ) (i.e., the dimension of the layer along the length of the foam pad 100) can be smaller than the height of each layer, thereby creating local instability. In other words, when lying on the foam pad 100, this smaller thickness causes each layer 101, 102 to collapse more easily under downward forces (such as forces from the individual's hips or shoulders). However, the combination of layers 101 and 102 can still provide overall stability on the foam pad 100. For example, if the foam pad 100 is a mattress, the individual layers 101 and 102 can collapse under local pressure from the individual's hips and shoulders, while the combination of layers 101 and 102 extending across a wider part of the body (such as the torso) can exhibit overall stability to provide back support.

[0031] Because layer 101 can be formed of a different type of foam than layer 102, foam pad 100 can exhibit synergistic benefits compared to using a single type of foam or a foam arrangement of different structures. In other words, the foam type of layer 101 can have a first set of properties, the foam type of layer 102 can have a second set of properties, and the orthogonal alternating structure of these layers can produce a synergistic benefit between the first set of properties and the second set of properties. For example, layer 101 can be formed of a relatively hard foam, and layer 102 can be formed of a relatively soft foam, so that each layer collapses / compresses differently from the adjacent layers. As other examples, layers 101 and 102 can have different air permeabilities, resilience, and / or softness.

[0032] You can choose the height of each layer (L H ) and the thickness of each layer (L T ) to achieve the desired layer instability under significant pressure (e.g., due to the hips or shoulders when an individual lies on the mattress). In some embodiments, the ratio can be at least 2.5, at least 3.0, at least 3.5, at least 4.0, at least 4.5, or more. Higher ratios may cause the layers to exhibit greater instability, or in other words, collapse under pressure to better form to the individual's body.

[0033] The IFD of the foam used for each layer can also be selected to achieve a desired instability. For example, alternating higher IFD foam layers with lower IFD foam layers may cause the higher IFD foam layers to bend more easily because the lower IFD foam layers do not provide significant resistance to such bending (i.e., the lower IFD foam layers may compress to accommodate the bending of the higher IFD foam layers).

[0034] The layered structure of a foam pad configured according to embodiments of the present invention allows this instability to occur only in response to sufficient load / pressure. Thus, a mattress configured according to embodiments of the present invention may provide only under the hips or shoulders, while remaining firm under other parts of the body.

[0035] As a specific example, foam pad 100 may represent a mattress or a portion of a mattress, layer 101 may be formed of latex foam (or latex foam rubber), and layer 102 may be formed of memory foam. In this case, latex foam may provide a mattress with some of the properties that are desired in a mattress, such as breathability, rebound when shifting positions on the mattress, and softness. Memory foam lacks these properties. It is known for feeling "dead" when lying on the mattress or doing other activities. It is also known for being difficult to roll on the mattress because it creates a body-shaped depression that takes some time to return to its original shape. It is also known for not being very breathable, so the person lying on the mattress will heat up due to body heat or steam that cannot escape. It does not have the amazing softness of latex foams (such as Talalay latex foam rubber). Memory foam may also lack back support because as the body heats up the memory foam, it becomes softer and the heavy torso of the body will sag into this soft state. Memory foam does have positive properties that latex foam lacks, however the most important of which is that memory foam is known to mold itself to the shape of the body over time, providing more even support to the body (relieving pressure points). Therefore, alternating layers of memory foam and latex foam can create a synergistic effect. Latex foam will deform elastically immediately, which will speed up the memory foam's ability to regain shape after deformation and will feel more lively (as opposed to the dullness of memory foam). Latex foam is more breathable, and body heat and steam can escape through the intermittent layers of latex foam. The softness of latex foam gives a softer "feel" from mattress to mattress and overcomes the initial hard feel that exists when memory foam heats to body temperature and slowly molds to the body. The elastic properties of latex foam will help offset the loss of support when memory foam heats and softens. Alternating layers of memory foam increase synergy by enhancing shape-matching properties, thereby reducing pressure points. These synergistic benefits, combined with the benefits of local instability and overall stability, can produce a very desirable mattress or other foam pad.

[0036] In some embodiments, the foam pad can have more than two types of foam arranged in layers. Using the above example, a reticulated foam layer can be used with a memory foam layer and a latex foam layer to provide greater breathability. As another example, if greater hardness is desired, or if a faster rebound to the shape of an adjacent memory foam is desired, the soft Talalay latex in the above example can be replaced with a harder latex, typically prepared by a Dunlop process rather than a Talalay process. Although each layer 101 and 102 is shown as being formed from a single piece of foam, in some embodiments, layer 101 or layer 102 can be formed from multiple pieces of the same foam.

[0037] A wide variety of foams can be used in embodiments of the present invention. Foams include, but are not limited to: fast-rebound polyurethane foam (selected from the group including conventional polyurethane foam, high-elastic polyurethane foam, and reticulated polyurethane foam), slow-rebound polyurethane foam (selected from the group including slow-rebound memory foam, fast-rebound memory foam, and gel memory foam), latex foam (selected from the group including natural latex foam, organic natural latex foam, synthetic latex foam, and part natural part synthetic latex foam), expanded polyolefin foam, EVA foam, silicone foam, melamine foam, PVDF foam, polyethylene foam, shredded and then rebound foam (including any shredded flexible foam type), Energex® foam (a unique foam manufactured by Elite Comfort Solutions, which is a highly breathable, somewhat viscoelastic foam that changes from its original viscoelastic [memory] foam to an elastic foam with elasticity similar to latex when heated to body temperature), etc. Foams with different hardnesses are intended to include, but are not limited to, conventional polyurethane open-cell cushioning foams or their equivalents using hardnesses of IFD (Indentation Force Deflection) 8, IFD 13, IFD 18, IFD 24, IFD 32, IFD 36, IFD 44, IFD 55, and IFD 60. In embodiments of the present invention, the type of foam may be different in one layer adjacent to the next layer, or the stiffness of the foam may be different in another layer adjacent to the next layer, or both. Two or more types of foam may be selected to synergize with the properties of adjacent layers, and two or more hardnesses of foam may be selected to create stability under wide areas of the body or other cushioning object and instability under sharp areas of the body or other cushioning object. The results will be more pronounced if the types and stiffnesses of adjacent foams are different.

[0038] Figure 2A and Figure 2B Another example of a foam pad 200 having an orthogonal alternating structure is provided. In the foam pad 200, the layers 101 are vertically offset relative to the layers 102, thereby forming gaps 103 at the top and bottom of the foam pad 200. In the depicted embodiment, the gaps 103 are formed at the top of the foam pad 200 between adjacent pairs of layers 102, and the gaps 103 are formed at the bottom of the foam pad 200 between adjacent pairs of layers 101.

[0039] Figure 3A and Figure 3B Another example of a foam pad 300 having an orthogonal alternating structure is provided. In the foam pad 300, the layers 102 have a different height than the layers 101 (i.e., are taller than the layers 101), thereby forming gaps 103 between adjacent pairs of the layers 102 at the top of the foam pad 300 (or at the bottom if the foam pad 300 is flipped over).

[0040] In foam pads 200 and 300, gaps 103 form air pockets that may provide higher air permeability, lower overall stiffness, lower initial stiffness when a body or other cushioning object initially descends into the foam pad, and lower foam costs.

[0041] Figure 4 Examples of how foam pads 100, 200, and 300 may be cut from a layered foam block 400 are provided. For example, sheets of foam of different types and / or hardness may be alternately stacked and bonded together to form a layered foam block 400. The layered foam block 400 may then be cut into a desired pattern (e.g., using a CNC band saw) to produce foam pads 100, 200, and / or 300. By cutting foam pads 100, 200, and / or 300 from a layered foam block 400, foam waste, labor, and time may be minimized. In some embodiments, the foams may be bonded together using a flexible or stretchable adhesive with a precisely controlled thickness to prevent the bond from creating excessive localized stiffness. It should be noted that in one embodiment, when the foam pad 300 is formed with Figure 4 When the pattern shown is cut, half of the resulting pad 300 has an upper portion of foam of a first type or hardness and the other half of the resulting pad 300 has an upper portion of foam of a second type or hardness. The cut can also be shifted half a layer so that the upper portion and the lower portion have 50% foam of the first type or hardness and 50% foam of the second type or hardness, respectively. This offset cut will make all of the foam pads 300 essentially the same, while a non-offset cut will result in two different foam pads 300, which can then form a separate pad design. For example, in a non-shifted cut where the upper portion is latex foam and the lower portion is memory foam, the properties of the latex foam may be more expressed than the properties of the memory foam. As another example, for a non-shifted cut where the upper portion is memory foam and the lower portion is latex foam, the properties of the memory foam may be more expressed than the properties of the latex foam.

[0042] FIG. 5A to FIG. 5D 5 is a cross-sectional view that provides examples of how foam pads 100, 200, and 300 can be integrated into a mattress 500. In each example, a foam pad 100, 200, or 300 is supported on top of a base layer 501 and surrounded by side layers 502. A top layer 503 can be positioned on top of the side layers 502 and the foam pads 100, 200, or 300. Figure 5A In FIG. 5 , the mattress 500 includes a foam pad 100 that is the same height as the side layer 502 so that no air pockets are formed. Figure 5B In FIG. 5 , the mattress 500 includes a foam pad 200 having the same height as the side layer 502, thereby forming a gap 103 toward the base layer 501 and toward the top layer 503. Figure 5CIn FIG. 5 , the mattress 500 includes a foam pad 300 that is the same height as the side layers 502, with the gap 103 being oriented toward the top layer 503. Figure 5D In the embodiment, the mattress 500 includes the foam pad 300, but the gap 103 is oriented toward the base layer 501. It is worth noting that the mattress can also be formed by the foam pad 100, 200 or 300, but without any or all of the base layer 501, the side layer 502 and the top layer 503. Figure 6 yes Figure 5A or Figure 5D A cross-sectional perspective view of a mattress 500 configured in FIG.

[0043] Figure 7 and 7A to 7C Another technique that can be used to produce a foam cushion configured according to an embodiment of the present invention is shown. This technique is particularly suitable for producing foam cushions that do not have a rectangular cross-sectional shape, such as pillows or car seats. Figure 7 A piece of foam 700 shaped like a pillow is shown. It is noteworthy that at least two pieces of foam 700 having different properties (ie, two different types and / or stiffnesses of foam as described above) should be used and can be molded into the desired shape of the foam cushion.

[0044] Fig. 7A is a side view of two pieces of foam 700 and illustrates how these pieces of foam 700 can be cut to produce Figure 7B Each piece of foam 700 can be cut in a similar manner so that the set of layers 701 has the same shape and size as the layer 702. Then, as shown in FIG. Figure 7C As shown, layers 701 and 702 may be bonded together to form the above-described orthogonal alternating structure, thereby producing two foam pads 750. Foam pads 750 have the same general shape as block of foam 700, however, this is not necessarily the case when less than all layers 701 or 702 are used.

[0045] You can also use Figure 4 The technique shown in creates a non-rectangular foam cushion by performing one or more cuts to create a desired shape (e.g., rounded edges, tapered edges, barrel or other indentations, etc.). This can be accomplished, for example, by sawing the block / stack 400 from both sides with a band saw. In one embodiment, a bed pillow that tapers in all four directions from its center (a standard pillow shape) can be created by sawing one side of the block / stack 400 with a band saw into a tapered shape to achieve the taper on both sides of the pillow, and then sawing a second side of the block or stack 400 with a band saw into a tapered shape to achieve the taper on the other two sides of the pillow. Non-rectangular foam cushions can also be created using Figure 4 , by first cutting Figure 4The rectangular block shown is then milled to its final shape using a CNC milling machine.

[0046] Figure 8 An example of a mattress 800 configured in accordance with one or more embodiments of the present invention is provided. Mattress 800 includes a base layer 801 and a foam pad 802, which, like foam pads 100, 200, and 300, includes alternating layers 101 and 102. However, unlike foam pads 100, 200, and 300, layers 101 and 102 in foam pad 802 emanate from bases 101a and 102a, respectively. In some embodiments, base 101a and each layer 101 may be a unitary piece of foam (or "foam pad component"), and base 102a and each layer 102 may be separate foam pad components. In foam pad 802, base 101a and base 102a have the same height (or vertical thickness) (B H ,like Fig. 12C ), all layers 101 and 102 have the same length (L H ,like Fig. 12C However, in other embodiments, base 101a and base 102a may have different heights and / or layer 101 and layer 102 may have different heights.

[0047] Fig. 9 An example of a mattress 900 configured according to one or more embodiments of the present invention is provided. Mattress 900 includes only foam pad 901. Foam pad 901 is identical to foam pad 802, except that in foam pad 901, the height of base 101a is significantly greater than base 102a. For example, the height of base 101a can be increased so that base 101a can be used as a base layer of mattress 900.

[0048] FIG. 10A to FIG. 10C Other examples of foam pads 1001-1003 are provided respectively, which are similar to foam pad 802, but include gaps 103. In foam pad 1001, gaps 103 are formed between layer 101 and base 102a, and between layer 102 and base 101a. This can be achieved by bonding or otherwise adhering layer 101 to layer 102 without completely interposing the layers between each other.

[0049] In foam pad 1002, gap 103 is formed only between layer 101 and base 102a. This can be achieved by configuring layer 102 to have a greater height than layer 101, so that even if layer 101 is completely interposed between layers 102, gap 103 is still formed.

[0050] Foam pad 1003 is similar to foam pad 1002, except that gap 103 is formed between layer 102 and base 101a. This can be achieved by configuring layer 101 to have a greater height than layer 102, so that even if layer 102 is completely inserted between layers 101, gap 103 is still formed.

[0051] Fig.11 An example of a foam pad 1100 is provided, which includes layers 101 and 102 emanating from bases 101a and 102a, respectively, as described above (i.e., the foam pad 1100 is formed of opposing foam pad components). Unlike the previous example, the ends of the layers 101 and 102 are rounded, and the portions of the bases 101a and 102a between the layers 101 and 102 are respectively rounded. In some embodiments, the layers 101 and 102 can be coupled together by bonding only the rounded ends, while in other embodiments, glue can be applied along the entire interface between the layers.

[0052] FIG. 12A to FIG. 12C An example of a mattress 1200 is provided that is formed from a single foam pad 1201. Foam pad 1201 is identical to foam pad 1100, except that base 102a is greater in height than base 101a. Fig. 12C Examples of suitable dimensions that foam pad 1201 may have are provided. However, any other reasonable dimensions may be used. In this example, the thickness (L T ) is approximately 1.4815 inches, and the radius (R) of the rounded end is approximately 0.7407 inches. The height (L H ) is approximately 7.000 inches, while the heights of bases 101a and 102a may be approximately 0.500 inches and 2.500 inches, respectively. Thus, the height of foam pad 1201 / mattress 1200 is approximately 10.000 inches.

[0053] FIG. 13A to FIG. 13E An example of a mattress 1300 is provided, formed of a foam pad 1301 positioned on top of a foam pad 1302. Foam pads 1301 and 1302 each include opposing foam pad components.

[0054] Fig. 13B and Fig. 13C A separate foam pad 1301 is shown and suitable dimensions are provided. However, any other reasonable dimensions may be used. In this example, the width of layers 101 and 102 is approximately 1.000 inches, and the radius of the rounded ends is approximately 0.500 inches. The height of layers 101 and 102 is approximately 3.000 or 4.000 inches, and the height (B) of bases 101a and 102a is approximately 0.500 inches. H) is approximately 0.500 inches. Therefore, the height of foam pad 1301 can be approximately 4.000 inches or 5.000 inches.

[0055] Fig.13D and Fig.13E A separate foam pad 1302 is shown and suitable dimensions are provided. However, any other reasonable dimensions may be used. In this example, the width of layers 101 and 102 is approximately 1.4815 inches, and the radius of the rounded ends is approximately 0.7407 inches. The height of layers 101 and 102 is approximately 7.000 inches, while the height of bases 101a and 102a is approximately 0.500 inches. Therefore, the height of foam pad 1302 can be approximately 8.000 inches, and the height of mattress 1300 can be approximately 12.000 inches or 13.000 inches.

[0056] For each foam pad formed by the relative foam pad components, the foam type of the top foam pad component and the bottom foam pad component can be selected to provide one or more desired benefits. For example, the top foam pad component can be formed by a more breathable foam than the bottom foam pad component to enhance breathability. In contrast, the top foam pad component can be formed by a less breathable memory foam, while the bottom foam pad component can be formed by a more breathable foam. In this case, the more breathable foam of the bottom foam pad component can enhance the breathability of the less breathable foam of the top foam pad component. This may be because the layer of the bottom foam pad component extends upward and is positioned close to the base of the top foam pad component, so heat does not need to be conducted far through the less breathable foam to reach the more breathable foam.

[0057] Fig.14 An example of a foam pad 1400 in the form of a pillow is provided. The foam pad 1400 is formed by opposing foam pad components configured in a similar manner as described above. In addition, the bases 101a and 102a include tapered extensions 101b and 102b, respectively, which extend parallel to the layers 101 and 102 to form a pillow shape.

[0058] Fig.15A and Fig. 15B An example is provided of how a foam pad can be produced according to one or more embodiments of the present invention. Fig.15A A first sheet of foam 1510 and a second sheet of foam 1520 are shown. Foam 1510 and foam 1520 may be different types of foam and may be sized and shaped to allow for multiple foam pad components 1511 and 1521, respectively, to be cut therefrom. For example, foams 1510 and 1520 may have rectangular dimensions that are multiples of the desired dimensions of the mattress to be produced. Fig.15AIn the embodiment, the length of foam 1510 and 1520 is twice the desired length of the mattress, the width may be the same as the desired width of the mattress, and the height is six times the desired height of the mattress (which is the case in this example because foam pad components 1511 and 1521 have the same height). Fig.15A Also shown is how foam pad components 1511 and 1521 can be cut from foams 1510 and 1520, respectively. In some embodiments, foam pad component 1511 can be cut from foam 1510 and foam pad component 1521 can be cut from foam 1520 using a single CNC sawing process.

[0059] Fig. 15B It is shown how to take out a pair of opposing foam pad components 1511 and a pair of opposing foam pad components 1521 from foams 1510 and 1520, respectively, and then separate them from each other. One of the foam pad components 1511 and one of the foam pad components 1521 can be turned over, and then the foam pad components 511 and the foam pad components 1521 can be coupled together. In some embodiments, this coupling can be performed in a zipper manner. In particular, the layers 101 and 102 at one end of the foam pad components 1521 and 1511 can initially be inserted together, respectively, and then the next layer 101 and 102 is inserted until all layers 101 and 102 are combined together. In some embodiments, glue or another adhesive can be placed at least on the ends of the layers 101 and 102 before the layers are zipped together in this manner.

[0060] although Fig.15A and Fig. 15B The production of a foam pad having a rectangular shape (eg, for a mattress) is shown, but the same production techniques can be used to produce foam pads having other shapes (eg, foam pad 1400).

[0061] In some embodiments, a lubricant may be used during the assembly of the foam pad components. For example, the ends of layers 101 and 102 (whether rounded or not) may be coated with a lubricant to facilitate the insertion of the layers into each other. In an embodiment using an adhesive, a lubricant may be added to the adhesive, and then the mixture of the adhesive and the lubricant may be applied to the ends of layers 101 and 102. In some embodiments, the adhesive may be water-based (e.g., Simalfa 350), and the lubricant may also be water-based (e.g., KY jelly). In some embodiments, the mixture of the adhesive and the lubricant may include 10% lubricant by volume, 20% lubricant by volume, or 50% lubricant by volume. In some embodiments, the lubricant may reduce the evaporation rate of the adhesive, thereby extending the working time of the adhesive (i.e., the lubricant may slow down the drying of the adhesive). This may be particularly beneficial for assembling foam pad components, such as foam pad components 1511 and 1521, which may require a lot of time to perform zipper-style pairing.

[0062] In embodiments where glue (or other adhesives) are used to couple the layers together, the instability of the layers can be controlled by applying glue only at or near the top and / or bottom of the layers (rather than along the entire interface between the layers). In this way, an otherwise unstable layer (e.g., a layer with a higher IFD) is more likely to collapse due to the shortened length along which it is coupled to an adjacent layer. As described above, the instability of this design can cause the mattress (or other cushioning product) to yield in response to considerable pressure (e.g., at the hips or shoulders) while the rest of the mattress provides firm support.

[0063] Experiments and Results

[0064] Various experiments were conducted on the different types of foam pads and different configurations of such foam pads described herein. The results of these experiments are summarized below.

[0065] Tested with Figure 1A and Figure 1B Various foam pads matching the configuration shown (e.g., layers 101 and 102 made of foam A and B, respectively) were used as the foam pads for the mattresses. In each test, the foam pads were placed on a base consisting of a 1-inch 32 ILD conventional polyurethane foam, which was placed on top of an 8-inch pocket coil spring. Fig.16 is a table summarizing the results of these tests. The results show that different synergistic results can be obtained using different layering arrangements of foams.

[0066] Tested with Fig.11 Various foam pads of substantially corresponding configurations were used as foam pads for the mattress. In tests 14 and 15, no foundation was used. In test 16, the foam pad was tested as the foundation for the mattress. Fig.17 is a table summarizing the results of these tests. The results show that different synergistic results can be obtained using different layering arrangements of foams.

[0067] Also tested with FIG. 12A to FIG. 13E Various mattresses with substantially corresponding configurations shown. In each test, the foam pad of Test 16 or a variation thereof was used as the base foam pad. Fig.18 is a table summarizing the results of these tests. The results show that different synergistic effects can be obtained by using layered arrangements of different foams in the top foam pad and the bottom foam pad.

[0068] Also tested with Fig.14 The configurations shown generally correspond to various pillows. Fig.19 is a table summarizing the results of these tests. The results show that different synergistic results can be obtained using different layering arrangements of foams.

[0069] The present invention may be embodied in other specific forms without departing from its spirit or essential features. The described embodiments are to be considered in all respects as illustrative only and not restrictive. Therefore, the scope of the present invention is indicated by the appended claims rather than by the above description.

Claims

1. A foam pad, comprising: A foam layer is disposed along the length of the foam pad.

2. The foam pad of claim 1, wherein the foam layer is formed of at least two types of foam.

3. The foam pad of claim 2, wherein the at least two types of foam are arranged in alternating layers.

4. The foam pad of claim 3, wherein the at least two types of foam have indentation force deflection (IFD) that differ by at least 15%.

5. The foam pad of claim 3, wherein the at least two types of foam have indentation force deflection (IFD) that differ by at least 20%.

6. The foam pad of claim 3, wherein the at least two types of foam have indentation force deflection (IFD) that differ by at least 25%.

7. The foam pad of claim 3, wherein the at least two types of foam are selected from: Quick-rebound polyurethane foam; Slow rebound polyurethane foam; latex foam; Expanded polyolefin foam; EVA foam; Silicone foam; Melamine foam; PVDF foam; Polyethylene foam; Foam that has been shredded and then re-glued; and Energex Foam.

8. The foam pad of claim 1, wherein each layer has a thickness and a height, the thickness being less than the height.

9. The foam pad of claim 8, wherein a ratio of the height to the thickness is at least 2.

5.

10. The foam pad of claim 8, wherein a ratio of the height to the thickness is at least 3.

11. The foam pad of claim 8, wherein a ratio of the height to the thickness is at least 3.

5.

12. The foam pad of claim 8, wherein a ratio of the height to the thickness is at least 4.

13. The foam pad of claim 1, wherein the layer is formed from opposing first and second foam pad components.

14. The foam pad of claim 13, wherein each of the first and second foam pad components comprises layers emanating from a base, and the layers of the first foam pad component alternate with the layers of the second foam pad component.

15. The foam pad of claim 14, wherein the base of the first foam pad component has a greater height than the base of the second foam pad component.

16. The foam pad of claim 14, wherein a height of the layer of the first foam pad component is greater than a height of the layer of the second foam pad component.

17. The foam pad of claim 16, wherein a gap is formed between the layer of the second foam pad component and the base of the first foam pad component.

18. The foam pad of claim 14, wherein a gap is formed between the layer of the second foam pad component and the base of the first foam pad component.

19. The foam pad of claim 18, wherein a gap is also formed between the layer of the first foam pad component and the base of the second foam pad component.

20. The foam pad of claim 14, wherein ends of the layers of the first and second foam pad components are rounded.

21. The foam pad of claim 20, wherein the layers of the first and second foam pad components are secured together by applying glue only to the rounded ends.

22. The foam pad of claim 14, wherein each layer has a thickness and a height, the thickness being less than the height.

23. The foam pad of claim 22, wherein a ratio of the height to the thickness is at least 2.

5.

24. The foam pad of claim 22, wherein a ratio of the height to the thickness is at least 3.

25. The foam pad of claim 22, wherein a ratio of the height to the thickness is at least 3.

5.

26. The foam pad of claim 22, wherein a ratio of the height to the thickness is at least 4.

27. The foam pad of claim 14, wherein the layer of the first foam pad component is formed from a first type of foam and the layer of the second foam pad component is formed from a second type of foam.

28. The foam pad of claim 27, wherein the first type of foam and the second type of foam have indentation force deflections that differ by at least 15%.

29. The foam pad of claim 27, wherein the first type of foam and the second type of foam have indentation force deflections that differ by at least 20%.

30. The foam pad of claim 27, wherein the first type of foam and the second type of foam have indentation force deflections that differ by at least 25%.

31. The foam pad of claim 1 wherein the foam layers are vertically offset to create gaps between layers.

32. The foam pad of claim 1, wherein the foam layers have different heights, thereby creating gaps between layers.

33. The foam pad of claim 1, wherein the foam pad has a rectangular cross-sectional shape.

34. The foam pad of claim 1, wherein the foam pad has a non-rectangular cross-sectional shape.

35. A cushioning product comprising: A first foam pad includes a foam layer disposed along a length of the foam pad.

36. The cushioning article of claim 35, further comprising: A second foam pad includes a foam layer disposed along a length of the foam pad, the first foam pad being positioned on top of the second foam pad.

37. The cushioning article of claim 36, wherein the layer of the first foam pad is formed from opposed first and second foam pad components, and the layer of the second foam pad is formed from opposed third and fourth foam pad components.

38. A cushioning product according to claim 37, wherein each of the first foam pad component and the second foam pad component includes layers emanating from a base and the layers of the first foam pad component alternate with the layers of the second foam pad component, and each of the third foam pad component and the fourth foam pad component includes layers emanating from a base and the layers of the third foam pad component alternate with the layers of the fourth foam pad component.

39. The cushioning article of claim 38, wherein the layers of the first and second foam cushion components have a shorter height than the layers of the third and fourth foam cushion components.

40. The cushioning article of claim 38, wherein the layers of the first, second, third, and fourth foam cushion components are each made from a different type of foam.

41. The cushioning article of claim 38, wherein each layer of the first, second, third, and fourth foam cushion components has a height and a thickness, and wherein a ratio of the height to the thickness is at least 2.

5.

42. The cushioning article of claim 35, further comprising: A second foam pad, the first foam pad being positioned on top of the second foam pad.

43. The cushioning article of claim 35, wherein the layers comprise alternating types of foam.

44. The cushioning article of claim 43, wherein the alternating types of foams have different indentation force deflections.

45. The cushioning article of claim 35, wherein each of the layers has a height and a thickness, and wherein a ratio of the height to the thickness is at least 2.

5.

46. ​​A method for making a mattress, comprising: stacking foam sheets along an axis to form a layered foam block; cutting the layered foam block along the axis to form a foam cushion including a foam layer; and The foam pad is oriented within the mattress so that the foam layer is aligned along the length of the mattress.

47. The method of claim 46, wherein the thickness of each of the one or more layers of the foam layer is less than the height of each of the one or more layers of the foam layer.

48. The method of claim 46, wherein the foam pad is oriented on top of a base layer of the mattress.

49. The method of claim 46, wherein the foam pad is surrounded by side layers of the mattress.

50. The method of claim 46, wherein cutting the layered foam block along the axis comprises performing a linear cut.

51. The method of claim 46, wherein cutting the layered foam block along the axis comprises performing a non-linear cut to create gaps between the foam layers.

52. The method of claim 46, further comprising: Prior to cutting the layered foam blocks, the stacked foam sheets are glued together.

53. The method of claim 46, further comprising: The foam layers are bonded together after cutting the layered foam blocks.

54. The method of claim 46, further comprising: The foam pad is bonded to another cushioning layer that includes one or more of springs, foam, quilted panels, gel elastomer, or air pockets.

55. The method of claim 54, further comprising: A fabric cover was applied over the foam pad.

56. The method of claim 46, wherein the foam layer comprises alternating types of foam having different indentation force deflections.

57. The method of claim 46, wherein each of the layers has a height and a thickness, and wherein a ratio of the height to the thickness is at least 2.

5.

58. A method for making a foam pad, comprising: producing a first sheet of foam and a second sheet of foam in a desired shape; cutting the first sheet of foam and the second sheet of foam into respective layers; Alternating layers of the first sheet of foam and the second sheet of foam are bonded together to form the desired shape.

59. The method of claim 58, wherein the desired shape is a pillow, an aftermarket seat cushion, a furniture cushion insert, or a bucket seat insert.

60. The method of claim 58, wherein the first sheet of foam and the second sheet of foam are molded or cut into desired shapes.

61. The method of claim 58, wherein at least some of the layers have a thickness less than their height.

62. A method for assembling a foam pad, comprising: obtaining a first foam pad component, the first foam pad component comprising a base and a layer emanating from the base; obtaining a second foam pad component, the second foam pad component comprising a base and a layer emanating from the base; and The layers of the first foam pad component are interposed between the layers of the second foam pad component to form a foam pad.

63. The method of claim 62, wherein the layers of the first foam pad component are zippered between the layers of the second foam pad component.

64. The method of claim 62, further comprising: Glue is applied to ends of the layers of the first and second foam pad components prior to interposing the layers of the first foam pad component between the layers of the second foam pad component.

65. The method of claim 64, wherein the end portions are rounded.

66. The method of claim 62, further comprising: A lubricant is applied to ends of the layers of the first and second foam cushion components prior to interposing the layers of the first foam cushion component between the layers of the second foam cushion component.

67. The method of claim 66, wherein the lubricant is mixed with a binder.

68. The method of claim 62, wherein the layer of the first foam cushion component is formed from a first type of foam and the layer of the second foam cushion component is formed from a second type of foam.

69. The method of claim 68, wherein the first type of foam and the second type of foam have different indentation force deflections.

70. The method of claim 62, wherein each of the layers has a height and a thickness, and wherein a ratio of the height to the thickness is at least 2.5.

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