Cushion cover for cushion

Abstract

A cover for a mat includes a first panel, a second panel, and a main container defined between the first panel and the second panel. The primary container may contain a primary cushioning element, such as a pillow, pillow insert, or filler material. At least one of the first panel and the second panel includes a secondary buffer element. The secondary cushioning element may be defined by a compressible, resilient elastomeric material that defines a plurality of thin interconnected walls that in turn define an array of open cells or columns. Each cell or column may have a hexagonal shape to impart an array of open cells or columns with a cellular appearance. A method of assembling a primary cushioning element with such a cover is also disclosed.

Description

[0001] This application is a divisional application of the application with the application number 202080019730.X, the application date of June 15, 2020, and the invention title of "Cushion Cover for a Mat". Technical Field

[0002] The present disclosure generally relates to covers for pillows or other primary cushioning elements, and more particularly, to covers having panels that include secondary cushioning elements. Even more particularly, the present disclosure relates to a cover having a central pocket that receives a cushioning element (such as a pillow or a pillow insert) between a pair of secondary cushioning elements of the cover. The present disclosure also relates to a cushion (such as a pillow) that includes such a cover, as well as methods of manufacturing and using a cover for a pillow or other primary cushioning element. Summary of the Invention

[0003] A cover according to the present disclosure can have a configuration that enables it to receive a primary cushioning element (e.g., a pillow insert or a pillow). The cover can include a first panel (which carries a secondary cushioning element), a second panel, and a primary container or pocket (which is defined between the first panel and the second panel). The pocket can receive the primary cushioning element. In some embodiments, the second panel can also carry a secondary cushioning element.

[0004] The secondary cushioning element of the first panel can include any suitable type of cushioning element. In a particular embodiment, the secondary cushioning element can include a compressible, resilient elastomeric material that defines a plurality of thin interconnected walls that define an array of cells or columns. Even more particularly, the compressible, resilient elastomeric material can define a plurality of thin walls that in turn define a hexagonal cell array in a so-called "honeycomb" arrangement. Such a secondary cushioning element can be fixed to (e.g., formed on, adhered to, attached to, etc.) a portion of the first panel.

[0005] The first panel can include an outer layer and an inner layer, with a secondary container defined therebetween. In some embodiments, the outer peripheral edge of the inner layer can be fixed to the inner surface of the outer layer and / or the outer peripheral edge of the outer layer. The inner layer can be fixed directly to the outer layer. Alternatively, the inner layer can be fixed to the inner edge of a lining, the outer edge of the lining is in turn fixed to the outer layer, and the lining spaces the inner layer and the outer layer apart from each other. The secondary container between the inner layer and the outer layer can receive or carry the secondary cushioning element. In some embodiments, the secondary cushioning element can be fixed to one or both of the outer layer and the inner layer of the first panel. The secondary cushioning element can be permanently fixed within the secondary container in a manner that prevents access to the secondary cushioning element.

[0006] In embodiments where the second panel includes a secondary buffer element, the secondary buffer element of the second panel can also include any suitable type of buffer element, including but not limited to a buffer element having a compressible, resilient elastomeric material with a plurality of thin interconnecting walls defined therein, and the interconnecting walls in turn defining an array of cells or columns. In such embodiments, the second panel can also include an outer layer and an inner layer, as well as a secondary container defined between the outer layer and the inner layer. In such embodiments, the outer peripheral edge of the inner layer can be fixed to the inner surface of the outer layer and / or fixed to the outer peripheral edge of the outer layer. The inner layer can be directly fixed to the outer layer. Alternatively, the inner layer can be fixed to the inner edge of a liner, and the outer edge of the liner is in turn fixed to the outer layer, with the liner spacing the inner layer and the outer layer apart from each other. The secondary container between the inner layer and the outer layer can accommodate or carry the secondary buffer element of the second panel. The secondary buffer element of the second panel can be fixed to one or both of the outer layer and the inner layer of the second panel. The secondary buffer element can be permanently fixed within the secondary container in a manner that prevents access to the secondary buffer element.

[0007] The outer peripheral edges of the first panel and the second panel of the cover can be fixed to each other in a manner that defines a main container between the first panel and the second panel. In some embodiments, portions of the outer peripheral edges of the first panel and the second panel that are inseparably fixed to each other can be directly fixed to each other. In other embodiments, portions of the outer peripheral edges of the first panel and the second panel that are inseparably fixed to each other can be indirectly fixed to each other. For example, the outer peripheral edge of the first panel of the cover (e.g., the top panel, etc.) can be fixed to the first edge of a liner (e.g., the top edge, etc.), and the outer peripheral edge of the second panel of the cover (e.g., the bottom panel, etc.) can be fixed to the second edge of the liner (e.g., the bottom edge, etc.), where the liner defines the outer periphery of the cover and is thus referred to herein as the "outer peripheral liner". In embodiments where the first panel includes an outer layer and an inner layer and the second panel includes an outer layer and an inner layer, the inner layers of the first panel and the second panel can at least partially define the main container. In embodiments where the cover further includes an outer peripheral liner, the outer peripheral liner can also define part of the main container.

[0008] The cover can also include a main opening that provides access to the main container. The main opening can be defined by separable edges of the cover. For example, portions of the edges that define the main opening can be separated from each other to open the main opening and provide access to the main container of the cover. As another example, a zipper between portions of the edges that define the main opening can be selectively unzipped to open the main opening leading to the main container. In yet another example, a button or other fastener that fixes portions of the edges that define the main opening to each other can be unbuttoned or undone to open the main opening and provide access to the main container.

[0009] Since the main opening of the cover is open, the main container can accommodate the main cushioning element. More specifically, the main opening of the cover can facilitate the introduction (or removal) of the main cushioning element (such as pillow filling, pillow insert, pillow, etc.) into (or from) the main container. The main container can accommodate the main cushioning element in such a way that each secondary cushioning element at least partially or even completely covers the corresponding surface of the main cushioning element.

[0010] In another aspect, a mat (e.g., a pillow) is disclosed that includes a cover according to the present disclosure and a cushioning element located inside the cover.

[0011] Also disclosed is a method for enhancing the cushioning of a cushioning element. A main cushioning element (such as filling for a pillow, pillow insert, existing pillow, etc.) can be introduced into the main container of a cover that includes secondary cushioning elements in one or both of its panels (i.e., main surfaces). When the main cushioning element is introduced into the main container, each secondary cushioning element of the cover can at least partially overlap the pillow or filling. The resulting mat can then be used to support a body part (such as an individual's head, back, legs, etc.). The overlap of the secondary cushioning elements on at least a portion of the main cushioning element can change or enhance the way the main cushioning element cushions the body part.

[0012] Other aspects of the disclosed subject matter, as well as the features and advantages of the various aspects of the disclosed subject matter, will become apparent to those of ordinary skill in the art by considering the subsequent disclosure, the drawings, and the appended claims. Description of the Drawings

[0013] In the drawings:

[0014] Figure 1 is an exploded perspective view of an embodiment of a mat and a cover of the mat according to the present disclosure, wherein the cover includes a first panel carrying secondary cushioning elements, a second panel carrying secondary cushioning elements, and a main cushioning element that can be placed between the first panel and the second panel;

[0015] Figure 1A provides Figure 1 a top view of the mat and the cover shown;

[0016] Figure 1B is depicted from one side Figure 1 the mat and the cover shown;

[0017] Figure 2 is Figure 1 a cross-sectional view of a variant of the cover, wherein the secondary cushioning elements of the first panel and the second panel of the cover are offset relative to each other;

[0018] Figure 3 is Figure 2Cross-sectional view of an embodiment of a secondary buffer element of a panel of a variant of the shown cover, showing that the secondary buffer element is thicker at its center than at its outer periphery;

[0019] Figure 3A shows Figure 3 an embodiment of the surface of the secondary buffer element of the shown embodiment; and

[0020] Figure 4 is Figure 1 a cross-sectional view of another variant of the cover, wherein the secondary buffer elements of the first panel and the second panel of the cover are substantially aligned with each other;

[0021] Figure 5 is Figure 1 a cross-sectional view of yet another variant of the cover, wherein the secondary buffer element of each of the first panel and the second panel of the cover includes a half portion that defines opposite surfaces of the secondary buffer element and has a pattern offset relative to each other;

[0022] Figure 6 is Figure 5 a cross-sectional view of a first selection of a secondary buffer element of a variant of the shown cover, wherein one half portion of the secondary buffer element is thicker at its center than at its outer periphery, while the other half portion of the secondary buffer element has a substantially uniform thickness;

[0023] Figure 7 is Figure 5 a cross-sectional view of a second selection of a secondary buffer element of a variant of the shown cover, wherein both half portions of the secondary buffer element are thicker at its center than at its outer periphery;

[0024] Figure 8 is Figure 1 a cross-sectional view of yet another variant of the cover, wherein the secondary buffer elements of the first panel and the second panel of the cover have a substantially uniform thickness;

[0025] Figure 9 is Figure 8 a cross-sectional view of a secondary buffer element of a panel of a variant of the shown cover;

[0026] Figure 10 a cross-sectional view of another embodiment of a cover for a cushion according to the present disclosure, wherein the first panel and the second panel are fixed to each other by a peripheral lining but spaced apart from each other;

[0027] Figure 11 is a perspective view of an embodiment of a cushion having a cover according to the present disclosure; and

[0028] Figure 12 is an alternative embodiment of a pillow or pillowcase having a top panel, a bottom panel, a cushion insert, and a first buffer element. Detailed Description

[0029] Reference Figure 1 、 1A and 1B illustrate embodiments of a mat 10 according to the present disclosure. The mat 10 may include a pillow or other type of mat. The mat 10 includes a cover 20 having a first panel 40, a second panel 60, and a main container 80 between the first panel 40 and the second panel 60. The first panel 40 and the second panel 60 may include opposite sides of the cover 20 (e.g., top and bottom, etc.). The main container 80 (which may also be referred to herein as a "pocket") is configured to receive a main cushioning element 100.

[0030] The first panel 40 may carry or include a secondary cushioning element 50. The second panel 60 may also carry or include a secondary cushioning element 70. Each secondary cushioning element 50, 70 may include any suitable cushioning material. The secondary cushioning elements 50 and 70 may be relatively thin. In various embodiments, the secondary cushioning elements 50 and 70 may have a maximum thickness and a minimum thickness, where the maximum thickness may tend towards the centers 56, 76 ( Figure 3 ) of the secondary cushioning elements 50, 70, and the minimum thickness may tend towards the outer perimeters 58, 78 of the secondary cushioning elements 50, 70.

[0031] As a non-limiting example, each secondary cushioning element 50, 70 may include a compressible, resilient elastomeric material (e.g., materials described in U.S. Patents 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated herein by reference, etc.), the elastomeric material defining a plurality of thin interconnecting walls 52, 72, which in turn define an array of cells or columns 54, 74 (e.g., cushioning elements described in U.S. Patents 5,749,111 and 6,026,527, the entire disclosures of which are hereby incorporated herein). As Figure 3 and 3A shown, the cells or columns 54, 74 of each secondary cushioning element 50, 70 may be hexagonal in shape; however, any circular or polygonal shape (e.g., square, rhombus, triangle, etc.) is considered to be within the scope of the present disclosure. Secondary cushioning elements 50 and 70 having other shapes or configurations are also within the scope of the present disclosure (e.g., solid sheets; adhered multi-component structures; etc.). Other materials may also be used to define each secondary cushioning element 50, 70, including but not limited to other oil-filled block copolymers, foamed rubbers (e.g., natural latex, polyurethane, viscoelastic foam, etc.), etc.

[0032] In some embodiments, the main container 80 may be configured to enable a consumer to place the main buffer element 100 within the main container 80 and remove the main buffer element 100 from the main container 80. Such a main container 80 may be reached through the main opening 90 of the cover 20, enabling the main buffer element 100 to be inserted into the main container 80 and removed from the main container 80. In other embodiments, the main buffer element 100 may be permanently fixed within the main container 80.

[0033] As Figure 1A shown, in some embodiments, the cover 20 may include a pair of long edges 24 and 25 and a pair of short edges 26 and 27. As Figure 1B shown, the main opening 90 providing access to the main container 80 of the cover 20 may extend along the entire length of the short edge 26 of the cover 20. Alternatively, the main opening 80 may extend along the long edge 24 of the cover 20 or multiple edges (including corners), which may provide easy access to the main container 80 and thus enable the main buffer element 100 to be easily introduced into or removed from the main container 80 of the cover 20. In some embodiments, the main opening 90 may be as openable (e.g., by its elasticity and stretchability, etc.) as allowed by the material defining the main opening 90. A fastener 95 (e.g., a zipper, which may be visible or hidden under one or more material flaps; a button; a fastener, etc.) may be associated with the main opening 90 to enable the main opening 90 to be closed and reopened.

[0034] Continuing to refer to Figure 1 、 1A and 1B, when the main opening 90 of the cover 20 is closed (e.g., zipped up, fastened, folded, etc.), the main container 80 may be inaccessible or even hidden. The main container 80 may enable the secondary buffer elements 50 of the first panel 40 and the secondary buffer elements 70 of the second panel 60 to at least partially cover the respective surfaces of the main buffer element 100. In some embodiments, the secondary buffer elements 50 and 70 may extend over the entire length and width of the main buffer element 100, providing additional buffer layers on each surface 105 and 107 of the main buffer element 100, respectively.

[0035] The cover 20 may be rectangular, although any of a variety of suitable shapes (e.g., regular polygons, irregular polygons, stars, circles (e.g., circular, oval, elliptical, etc.), and other shapes) are also within the scope of the present disclosure. In embodiments where the cover 20 has a rectangular shape, the outer peripheral edges at three sides of the first panel 40 may be fixed to the outer peripheral edges at three sides of the corresponding second panel 60, while the outer peripheral edges at the fourth side of the first panel 40 and the fourth side of the corresponding second panel may define the main opening 90 ( Figure 1B)。The main opening 90 can remain continuously open and / or be selectively closed, for example, by fasteners (such as buttons, zippers, etc.) that make closing and reopening possible, and so on. The dimensions of the first panel 40 and the second panel 60 of such a cover 20 can vary, but can be approximately 20 inches (about 51 cm) by about 26 inches (about 66 nm), that is, approximately the same as the dimensions of a standard-sized pillowcase or pillow cover, with reasonable deviations. However, for larger pillows, namely, king-sized pillows (20 inches × 30 inches, or about 51 cm × about 76 cm), super king-sized pillows (20 inches × 36 inches, or about 51 cm × about 91 cm), European pillows (26 inches × 26 inches, or about 66 cm × 66 cm), and smaller pillows, other dimensions are considered and envisioned.

[0036] The main cushioning element 100 can include any suitable cushioning element. In embodiments where the pads 10 ( Figure 1 , 1A and 1B) include pillows, the main cushioning element 100 can include filling materials, pillow inserts, or standard pillows. In some embodiments, an individual can select the specific main cushioning element 100 that he or she wants to place within the main container 80 of the cover 20 to provide a customized pad 10 that achieves a specific or desired cushioning effect.

[0037] Figure 1 A specific embodiment of the main cushioning element 100 is depicted. The main cushioning element 100 can be formed of a compressible, resilient foam material. As a non-limiting example, the main cushioning element 100 can be formed of foam rubber, such as natural latex foam (such as Talalay latex foam, etc.), polyurethane foam, etc. An array of channels 102 can extend through the thickness of the main cushioning element 100. The channels 102 can facilitate the flow of air through the main cushioning element 100 and the pad 10, where the main cushioning element 100 is part of the pad 10. Alternatively, the main cushioning element 100 can include a compressible, resilient elastomeric material (such as the materials described in U.S. Patents 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are incorporated herein by reference, and so on). The elastomeric material can define a plurality of thin interconnected walls that in turn define an array of cells or columns (such as the cushioning elements described in U.S. Patents 5,749,111 and 6,026,527 and U.S. Patent Application Publication US2018 / 0305199A1, hereby incorporated herein, and so on).

[0038] In embodiments where the main cushioning element 100 includes a filling material, the filling material can include any material suitable for use as a cushion, such as a pillow (e.g., for cushioning a person's head, back, legs, etc.). The filling material can be directly introduced into the main container 80 to define the main cushioning element 100 of the cushion 10. Alternatively, the filling material can be contained in a separate cover that, together with the filling material, defines the main cushioning element 100 before the main cushioning element 100 (e.g., an existing pillow, etc.) is placed in the main container 80.

[0039] Turning now Figure 2 , a first panel 40 and a second panel 60 of a particular embodiment of the cover 20 are shown in more detail. The first panel 40 can include an outer layer 42 and an inner layer 46. The outer layer 42 and the inner layer 46 can each include a thin layer fixed to each other around their outer perimeters 44 and 48, respectively. As Figure 2 shown, the outer perimeters 44 and 48 of the outer layer 42 and the inner layer 46 can be directly fixed to each other (e.g., with stitches, adhesives, etc.). Alternatively, the outer perimeters 44 and 48 of the outer layer 42 and the inner layer 46 can be fixed to the respective edges of a lining ( Figure 2 not shown in the figure) that indirectly fixes the outer layer 42 and the inner layer 46 to each other.

[0040] The second panel 60 can similarly include an outer layer 62 and an inner layer 66. The outer layer 62 and the inner layer 66 can each include a thin layer fixed to each other around their outer perimeters 64 and 68, respectively. As Figure 2 shown, the outer perimeters 64 and 68 of the outer layer 62 and the inner layer 66 can be directly fixed to each other (e.g., with stitches, adhesives, etc.). Alternatively, the outer layer 62 and the inner layer 66 can be indirectly fixed to each other by fixing their outer perimeters 64 and 68 to the respective edges of a lining ( Figure 2 not shown in the figure).

[0041] In some embodiments, the outer layers 42 and 62 and the inner layers 46 and 66 can be breathable, or air can flow through them. The outer layers 42 and 62 and the inner layers 46 and 66 can be formed of a flexible material (e.g., a fabric). The fabric can stretch elastically (e.g., the fabric can include up to 10% spandex or elastane, etc.). The fabric can include a moisture-wicking material that can provide a cooling effect when a body part is placed against it. Non-limiting examples are that the outer layers 42 and 62 can be formed of stretchable nylon that can include visible perforations (i.e., nylon mesh) therethrough, while the inner layers 46 and 66 can be formed of a soft and slightly fluffy fabric (e.g., cotton or a cotton-polyester blend). Other examples of fabrics that can be used to define the outer layers 42 and 62 and the inner layers 46 and 66 include, but are not limited to (to name just a few), cotton fabrics, cotton blend fabrics, rayon, polyester, other synthetic fabrics, and bamboo fabrics.

[0042] In the first panel 40 of the cover 20, the secondary buffer element 50 may be located between the outer layer 42 and the inner layer 46. The second panel 60 of the cover 20 may similarly include a secondary buffer element 70 located between the outer layer 62 and the inner layer 66 of the second panel 60. Each of the secondary buffer elements 50, 70 may include a compressible and resilient elastomeric material that defines a plurality of thin interconnecting walls 52, 72 which in turn define an array of cells or columns 54, 74. The thin interconnecting walls 52 and the array of cells or columns 54 of the secondary buffer element 50 of the first panel 40 may be offset relative to the thin interconnecting walls 72 and the array of cells or columns 74 of the secondary buffer element 70 of the second panel 60.

[0043] As Figure 3 shown, each of the secondary buffer elements 50, 70 may include a larger profile center 56, 76 and a smaller profile outer perimeter 58, 78. The buffer elements 50, 70 may have longer or taller cells or columns 54, 74 at and around the center 56, 76 and shorter cells or columns 54, 74 at and adjacent to the outer perimeter 58, 78. In some embodiments, the outer surfaces 51, 71 of the secondary buffer elements 50, 70 may taper from their center 56, 76 or central portion 57, 77 down to their outer perimeter 58, 78. Such tapering may be linear or curved. In other words, the length or height of the cells or columns 54, 74 may form a gradient that decreases from the center 56, 76 towards the outer perimeter 58, 78 or increases from the outer perimeter 58, 78 towards the center 56, 76. U.S. Design Patent Application Nos. 29 / 694,846 and 29 / 694,851 illustrate embodiments of such pads, the entire disclosures of which are incorporated herein. This configuration may enable the center 56, 76 or central portion 57, 77 of the secondary buffer elements 50, 70 to provide greater support and cushioning than the outer edge locations and outer perimeter 58, 78 of the secondary buffer elements 50, 70. As a non-limiting example, the thickness of each of the secondary buffer elements 50, 70 at its center 56, 76 may be from about one-half inch (about 1 1 / 4 cm) to about two inches (about 5 cm), while the thickness of each of the secondary buffer elements 50, 70 at its outer perimeter 58, 78 may be from about one-sixteenth inch (about 1.5875 mm) to about one inch (about 2.54 cm). In a more specific embodiment, the thickness of each of the secondary buffer elements 50, 70 at its center 56, 76 may be about one inch (about 2.54 cm), while the thickness of each of the secondary buffer elements 50, 70 at its outer perimeter 58, 78 may be about one-eighth inch (about 3.175 mm), and such secondary buffer elements 50, 70 may be at any position from the outer perimeter 58, 78 towards the center 56, 76 of about 5 3tapering outwardly at a distance of 1 / 4 inch (about 14.6 cm); thus, the length of the central portions 57, 77 of the secondary cushioning elements 50, 70 having substantially uniform thickness can be greater than the width, which means that the maximum thickness region can have substantially the same shape as the secondary cushioning elements 50, 70. Even when using a standard-sized pillow of about 20 inches by 26 inches (about 51 cm by about 66 cm), the central portions 57, 77 having substantially uniform thickness include most of the regions of the secondary cushioning elements 50, 70.

[0044] Return reference Figure 2 , each secondary cushioning element 50, 70 can be fixed to the corresponding inner layers 46, 66 of its corresponding panel (i.e., the first panel 40 or the second panel 60, respectively). The secondary cushioning elements 50 and 70 can be manufactured simultaneously by placing overlapping layers of fabric or muslin between the two sides of a mold and then molding each secondary cushioning element 50, 70 onto the corresponding muslin. Once the secondary cushioning elements 50 and 70 are molded, each muslin can continue to adhere to its respective secondary cushioning element 50, 70, while each of the corresponding inner layers 46, 66 no longer adheres to each other and can thus serve as the inner layers 46, 66 of the panels (i.e., the first panel 40 and the second panel 60, respectively) of the cover 20. Alternatively, the secondary cushioning elements 50, 70 can be fixed to one or both of their respective outer layers 42, 62 and outer layers 46, 66 by any other suitable technique (e.g., heating and melting an elastomeric material, ultrasonic welding, gluing, stitching, etc.). Further, the first cushioning element 14 can be fixed to the top panel 18 in a similar manner. It should be understood that an open-knit or woven fabric can be used as the muslin or other parts of the fabric to allow breathability and air flow.

[0045] In some embodiments (e.g., Figure 2 the embodiment shown), the array of multiple interconnecting walls 52 and cells or columns 54 of the secondary cushioning element 50 can be laterally offset from the array of multiple interconnecting walls 72 and cells or columns 74 of the secondary cushioning element 70. Embodiments of such secondary cushioning elements are shown in U.S. Design Patent Applications 29 / 694,846 and 29 / 694,851.

[0046] Figure 4 depicts an embodiment of the cover 20′, which may include multiple or all of the same features and elements as Figure 2 the embodiment of the cover 20 shown. The main difference between the cover 20′ and the cover 20 is that the array of multiple interconnecting walls 52′ and cells or columns 54′ of the secondary cushioning element 50′ of the first panel 40′ of the cover 20′ is substantially aligned with the array of multiple interconnecting walls 72′ and cells or columns 74′ of the secondary cushioning element 70′ of the second panel 60′ of the cover 20′, respectively.

[0047] Figure 5 depicts an embodiment of the cover 20", wherein each sub-buffer element 50", 70" includes a first half 50a", 70a" and a second half 50b", 70b". The halves 50a" and 50b", 70a" and 70b" define opposing surfaces of the sub-buffer elements 50", 70". The first halves 50a", 70a" include a compressible, resilient elastomeric material that defines a plurality of thin interconnecting walls 52a", 72a", which in turn define an array of cells or columns 54a", 74a" and the second halves 50b", 70b". The second halves 50b", 70b" also include a compressible, resilient elastomeric material that defines another plurality of thin interconnecting walls 52b", 72b", which in turn define another array of cells or columns 54b", 74b". The first halves 50a", 70a" and the second halves 50b", 70b" have patterns that are offset relative to each other. More specifically, as Figure 5 , Figure 3A shown in, and U.S. Design Patent Applications 29 / 694,846 and 29 / 694,851, the plurality of thin interconnecting walls 52a", 72a" of the first halves 50a", 70a" can be laterally offset from the other plurality of thin interconnecting walls 52b", 72b" of the second halves 50b", 70b", and thus, the array of cells or columns 54a", 74a" of the first halves 50a", 70a" can be laterally offset from the array of cells or columns 54b", 74b" of the second halves 50b", 70b". Alternatively, the plurality of thin interconnecting walls 52a", 72a" and the array of cells or columns 54a", 74a" of the first halves 50a", 70a" can be aligned with the other plurality of thin interconnecting walls 52b", 72b" and the other array of cells or columns 54b", 74b" of the second halves 50b", 70b".

[0048] Figure 6 shows an example of the sub-buffer elements 50", 70" wherein the first halves 50a", 70a" have different thicknesses from their central positions 57a", 77a" to their outer peripheries 58a", 78a" (e.g., tapering as previously referenced Figure 3 described). The second halves 50b", 70b" of such sub-buffer elements 50", 70" can have a substantially uniform thickness over the entire area occupied by the second halves 50b", 70b".

[0049] Figure 7 shows another example of the sub-buffer elements 50", 70" wherein the first halves 50a", 70a" have different thicknesses from their central positions 57a", 77a" to their outer peripheries 58a", 78a" (e.g., tapering as previously referenced Figure 3The described tapering (becoming smaller). The second halves 50b” and 70b” of such secondary cushioning elements 50” and 70” can also have different thicknesses from their central positions 57b” and 77b” to their outer perimeters 58b” and 78b”. Thus, the two halves 50a” and 50b”, and 70a” and 70b” of each secondary cushioning element 50” and 70” of the cover 20” can be thicker at their centers than at their outer perimeters.

[0050] As Figure 5-7 shown, the secondary cushioning elements 50” and 70” with an offset arrangement can provide greater support than other embodiments of secondary cushioning elements while allowing air to flow through the secondary cushioning elements 50” and 70”. A fabric or scrim can be molded between the first halves 50a” and 70a” and the second halves 50b” and 70b” of each secondary cushioning element 50” and 70”, which can fix the halves 50a” and 50b”, and 70a” and 70b” to their respective scrims. The scrim can include a single, continuous fabric that extends through the thickness of the secondary cushioning elements 50” and 70” and spans the entire area occupied by the secondary cushioning elements 50” and 70”. The scrim can be perforated, cut, or modified to enhance the breathability, support, and / or stability of the secondary cushioning elements 50” and 70”. The scrim can also affect the cushioning characteristics of the secondary cushioning elements 50” and 70”; for example, the stretchability and resilience of the scrim may improve the feel of the entire outer surface of the secondary cushioning elements 50” and 70”.

[0051] In addition to the configuration of its secondary cushioning elements 50”' and 70”', Figure 8 the illustrated embodiment of the cover 20”' can include multiple or all of the same elements and features as the Figure 2 illustrated embodiment of the cover 20, Figure 4 the illustrated embodiment of the cover 20', and Figure 5 the illustrated embodiment of the cover 20”. Referring again to Figure 9 , each secondary cushioning element 50”' and 70”' of the cover 20”' can have a substantially uniform thickness across the entire area it occupies; that is, from its center 56”' and 76”', across the central positions 57”' and 77”', to its outer perimeter 58”' and 78”'.

[0052] Figure 10A cross-sectional view of another embodiment of the cover 120 for a mat according to the present disclosure is provided, wherein a first panel 140 including a secondary cushioning element 150 and a second panel 140 including a secondary cushioning element 170 are fixed to each other by a peripheral lining 130 but spaced apart from each other. The peripheral lining 130 may include an elongate flexible element (e.g., a strip of breathable material, a fabric strip, etc.) having a first edge 134 along the length of the peripheral lining 130 and a second edge 136 along the length of the peripheral lining 130. The first edge 134 and the second edge 136 may be opposite each other. The first edge 134 of the peripheral lining 130 may be fixed to the outer peripheral edge 141 of the first panel 140, and the second edge 136 of the peripheral lining 130 may be fixed to the outer peripheral edge 161 of the second panel 160.

[0053] The peripheral lining 30 may carry at least a portion of a fastener ( Figure 10 ) (not shown in the figure) to provide a selective passage to the main opening 90 ( Figure 1B ) of the cover 120.

[0054] Although Figure 4 , 5 , 8, and 10 respectively show embodiments of the covers 20', 20", 20"', and 120 having substantially the same or identical secondary cushioning elements 50' and 70', 50" and 70", 50"' and 70"', and 150 and 170, respectively, embodiments of the cover 20 including different combinations of the cushioning elements 50 and 70 are also within the scope of the present disclosure (as Figure 2 shown only to a limited extent). Using cushioning elements 50 and 70 that are different in softness, thickness, material, or other properties can provide an individual using the cover 20 on the main cushioning element 10 with the ability to experience different cushioning effects using the same mat 10 ( Figure 1 , 1A, and 1B).

[0055] Figure 11 An embodiment of an assembled mat 10 including any embodiment of the cover 20 according to the present disclosure is shown, wherein the secondary cushioning element 50 can be slightly seen through the cover 20.

[0056] Referring Figure 12 , another embodiment of the mat 210 is shown. The cover 220 of the mat includes a first panel 240 and a second panel 260, with a main container 280 therebetween. Only the first panel 240 of the cover 220 includes a secondary cushioning element 250. The first panel 240 and its secondary cushioning element can be configured in any suitable manner, including those previously described herein. The second panel 260 may include one or more layers of flexible material, such as fabric (e.g., breathable fabric, moisture-wicking fabric, etc.). The main container 280 may accommodate the main cushioning element 100.

[0057] While embodiments of the mats described herein include a main container that can removably house a main cushioning element, a closure system including a cover according to the present disclosure and a main cushioning element permanently fixed therein and thus lacking modularity is also considered to be within the scope of the present disclosure.

[0058] Although the foregoing description contains many details, these should not be construed as limiting the scope of the invention as claimed in any of the appended claims, but merely as providing information relevant to some specific embodiments that may fall within the scope of the appended claims. Features from different embodiments may be used in combination. Additionally, other embodiments may also fall within the scope of the appended claims. All additions, deletions, and modifications to the disclosed subject matter that fall within the scope of the claims are included in the claims.

Claims

1. A cover for a mat, comprising: A first panel, comprising: An outer layer; An inner layer; and A secondary cushioning element comprising a molded compressible and resilient elastomeric material adhered to the inner layer, the secondary cushioning element being located between the outer layer and the inner layer, wherein the inner layer comprises a scrim fabric, the secondary cushioning element is formed on the scrim fabric, and the molded compressible and resilient elastomeric material of the secondary cushioning element is adhered to the scrim fabric; A second panel, which is superimposed on the first panel, wherein the outer peripheral edge of the second panel is directly fixed to the corresponding outer peripheral edge of the first panel; and A main container that houses a main cushioning element between the first panel and the second panel.

2. The cover according to claim 1, wherein The molded compressible and resilient elastomeric material of the secondary cushioning element defines a plurality of interconnected walls that define an array of cells.

3. The cover according to claim 2, wherein, The central region of the cell array is higher than the outer peripheral edge of the cell array.

4. The cover according to claim 2, wherein at least some of the plurality of interconnected walls include buckling walls that define buckling cells.

5. The cover according to claim 2, wherein, The secondary cushioning element comprises: A first half that defines a first major surface of the secondary cushioning element, the first half comprising a first plurality of interconnected walls that define a first cell array; and A second half that defines a second major surface of the secondary cushioning element, the second half comprising a second plurality of interconnected walls that define a second cell array.

6. The cover according to claim 5, wherein, The second plurality of interconnected walls and the second cell array are laterally offset with respect to the first plurality of interconnected walls and the first cell array.

7. The cover according to claim 5, wherein, The second plurality of interconnected walls and the second cell array are aligned with the first plurality of interconnected walls and the first cell array.

8. The cover according to any one of claims 5 - 7, wherein, The secondary cushioning element further comprises a scrim located between the first half and the second half.

9. The cover according to any one of claims 1-8, wherein the second panel comprises: An inner layer; An outer layer; And Another secondary cushioning element comprising a molded compressible and resilient elastomeric material adhered to the inner layer, the another secondary cushioning element being located between the outer layer and the inner layer of the second panel, wherein the inner layer of the second panel comprises a scrim fabric, the another secondary cushioning element is formed on the scrim fabric, and the molded compressible and resilient elastomeric material of the another secondary cushioning element is adhered to the scrim fabric.

10. A method for forming a cushioning element in a single molding step, comprising: Placing overlapping fabric layers adjacent to each other between two sides of a mold; And Molding a cushioning element on opposite sides of the overlapping fabric layers through the two sides of the mold, the molding comprising molding a first cushioning element on a first fabric layer of the overlapping fabric layers and molding a second cushioning element on a second fabric layer of the overlapping fabric layers.

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