Optimized buffer element

Abstract

The cushioning element includes a plurality of interconnected walls defining a hollow post. The interconnect wall includes a void. The shape, size, and location of the voids may reduce the overall density and weight of the cushioning element without sacrificing its cushioning characteristics. The cushioning elements may even be thinner than existing cushioning elements of conventional configurations while providing the same or optimized cushioning. In some embodiments, the cushioning elements may also include enlarged junctions or other reinforcement features between the interconnect walls. Methods of designing such buffer elements are also disclosed.

Description

[0001] Cross Reference to Related Applications

[0002] Pursuant to 35 U.S.C. § 119(e), priority is claimed from U.S. Provisional Patent Application No. 63 / 391,995, filed July 25, 2023, entitled “Optimized Cushioning Element” (“the ‘995 Provisional Application”). The entire disclosure of the ‘995 Provisional Application is hereby incorporated by reference. TECHNICAL FIELD

[0003] The present disclosure relates generally to cushioning elements comprising a plurality of interconnected walls defining a plurality of hollow columns, and more particularly to techniques for optimizing (e.g., reducing, etc.) the thickness, weight, and / or density of such cushioning elements while maintaining the cushioning properties of such cushioning elements. More particularly, a cushioning element comprising a plurality of interconnected walls defining a plurality of hollow columns can include one or more reinforcement features and / or one or more voids in the walls defining the hollow columns. Methods of designing a cushioning element having interconnected walls defining hollow columns are also disclosed to optimize (e.g., minimize, etc.) the thickness, weight, and / or density of such a cushioning element. SUMMARY

[0004] The cushioning elements of the present disclosure comprise a plurality of interconnected walls defining a plurality of hollow columns. The walls of the plurality of interconnected walls can be formed from an elastic material. The walls can be arranged in a manner defining a grid (e.g., a square grid, a rectangular grid, a triangular grid, a hexagonal grid, etc.), the hollow columns comprising the spaces defined by the grid. The hollow columns can be arranged in an array. The walls and / or hollow columns of such a cushioning element can include features that enable the cushioning element to have predetermined cushioning properties, thereby cushioning an object (e.g., a person, etc.) in a predetermined manner while optimizing (e.g., minimizing, etc.) one or more of the thickness, weight, and density of the cushioning element. In this regard, the walls and / or hollow columns of a cushioning element according to the present disclosure can have a configuration (e.g., reinforcement features, voids in the walls defining the hollow columns, etc.) that imparts predetermined stiffness and / or weight to the cushioning element.

[0005] The elastic material forming the plurality of interconnected walls can comprise any suitable material that readily deforms when subjected to a load and elastically rebounds when the load is removed. In various embodiments, the elastic material can comprise a gel. In one specific, but non-limiting, example, the gel can comprise a block copolymer that has been extended with a plasticizer. A non-limiting example of a block copolymer is a tri-block copolymer, such as a so-called A-B-A tri-block copolymer. A non-limiting example of a plasticizer is mineral oil. Other so-called “synthetic rubber” materials and other materials that can be used to form the walls include, but are not limited to, rubbers, foams (such as polyurethane foams, etc.), and other materials that deform when subjected to a load and elastically rebound (such as return to their original shape, etc.) when the load is removed.

[0006] In some embodiments, the cushioning element can include a reinforcement feature or reinforcement. The reinforcement feature or reinforcement can be defined by a material (e.g., an elastic material, etc.) that defines a plurality of interconnected walls. Without limitation, the reinforcement feature or reinforcement can include a hollow post of the cushioning element, or an enlarged junction between the interconnected walls at a corner of the cell. The enlarged junction can include one or more filleted (i.e., arcuate) interior corners (i.e., filleted junctions) or any other suitable enlarged shape (e.g., circular cross-sections, such as circles, ovals, ellipses, etc.; polygonal cross-sections, such as diamonds, squares, etc.; etc.) within the hollow post. Each dimension (e.g., in line with the interconnected walls, diagonal, etc.) of each end of such an enlarged junction can exceed the thickness of each wall of the walls that the enlarged junction connects.

[0007] The arrangement of the reinforcement features on the cushioning element can at least partially define one or more cushioning properties of the cushioning element at different locations on the cushioning surface of the cushioning element. For example, the reinforcement features can be uniformly arranged on the cushioning element to cause the cushioning element to have the same cushioning properties across or substantially across the cushioning surface (e.g., except possibly at the edges of the cushioning element, etc.). As another example, locations of the cushioning surface intended to be relatively firm can include a firm reinforcement feature arrangement (e.g., more reinforcement features, larger reinforcement features, etc.), while locations of the cushioning element intended to be relatively soft can include a soft reinforcement feature arrangement (e.g., fewer reinforcement features, smaller reinforcement features, etc.).

[0008] The hollow post can include an enlarged junction (e.g., a filleted junction, etc.) at one corner. Alternatively, the hollow post can include an enlarged junction (e.g., a filleted junction, etc.) at multiple corners (e.g., opposite corners of the hollow post, etc.). As another alternative, each corner of the hollow post can include an enlarged junction (e.g., a filleted junction, etc.) (i.e., all corners of the hollow post can include an enlarged junction).

[0009] All of the hollow posts of the cushioning element can include at least one reinforcement feature. Alternatively, only selected hollow posts of the cushioning element can include at least one reinforcement feature. For example, the hollow posts at the corners of the cushioning element, the hollow posts at the outer edges of the cushioning element, and the hollow posts at locations of the cushioning element expected to experience the greatest loads (e.g., between the head and foot of a mattress, etc.) can include at least one reinforcement feature.

[0010] Each hollow column of the cushioning element that includes at least one reinforcing feature (e.g., one or more enlarged junctions, etc.) can be reinforced in the same manner as every other hollow column that includes at least one reinforcing feature (e.g., it can have the same number of enlarged junctions, etc.). Alternatively, the manner and extent of reinforcement of each hollow column (e.g., the type, number, and arrangement of reinforcing features, such as enlarged junctions of the hollow column, etc.) can correspond to the location of the hollow column on the cushioning element. In some embodiments, incorporating reinforcing features into a cushioning element having interconnected walls that define a hollow column can facilitate reducing the thickness of the cushioning element.

[0011] In some embodiments, a cushioning element can include voids in at least one wall that defines at least one hollow column. Such voids can include features that reduce the amount of material from the plurality of interconnected walls. In some embodiments, the voids can include openings in the walls of the plurality of interconnected walls. Such openings can include notches in the edges of the walls. Such openings can include windows in the walls. In other embodiments, the voids can include recesses or thinned regions (e.g., dimples, etc.) in one or both surfaces of the walls.

[0012] Each void can have a size and shape that enables it to remove material from the walls, thereby reducing the weight of the walls and the cushioning element to which the walls belong, without reducing the cushioning characteristics of the cushioning element. In some embodiments, incorporating voids into the walls of a cushioning element having interconnected walls that define a hollow column can facilitate reducing the thickness of the cushioning element without sacrificing the cushioning characteristics of the cushioning element.

[0013] The arrangement of the voids in the walls of the cushioning element can at least partially define one or more cushioning characteristics of the cushioning element at different locations on the cushioning surface of the cushioning element. For example, the voids can be arranged uniformly across the cushioning element to cause the cushioning element to have the same cushioning characteristics across or substantially across the cushioning surface (e.g., possibly except for the edges of the cushioning element, etc.). As another example, locations of the cushioning surface that are intended to be relatively firm can include a firm arrangement of voids (e.g., more voids, larger voids, differently shaped voids, etc.), while locations of the cushioning element that are intended to be relatively soft can include a soft arrangement of voids (e.g., fewer voids, smaller voids, etc.).

[0014] A method for designing a cushioning element having a plurality of interconnected walls defining a hollow column can include determining one or more cushioning characteristics of the cushioning pad and optimizing (e.g., minimizing, etc.) one or more of the thickness, weight, and density of the cushioning element to achieve the one or more cushioning characteristics. Such a method can include incorporating features that optimize the weight and / or density of the cushioning element into the cushioning element. Such a method can include designing features that result in the cushioning element being thinner than a cushioning element design that does not include the features. For example, such a method can include designing reinforcing features (e.g., enlarged junctions between the walls of the plurality of interconnected walls, etc.) in the walls of the cushioning element. As another example, such a method can include designing the plurality of interconnected walls to include voids that reduce the amount of material needed to define the plurality of interconnected walls while having little or no impact on the cushioning characteristics (e.g., compression, rebound, etc.) of the cushioning element as compared to a cushioning element that lacks such voids (e.g., notches, windows, recessed areas, etc. in the interconnected walls of the cushioning element).

[0015] Other aspects of the disclosure, as well as features and advantages of various aspects of the disclosed subject matter, will become apparent to those of ordinary skill in the art through consideration of the following description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0016] In the drawings:

[0017] Figure 1 is a perspective view of a portion of an existing cushioning element;

[0018] Figure 2 is a perspective view of a cross-section of an embodiment of a cushioning element designed with an embodiment of a reinforcing feature to provide cushioning characteristics that are the same or substantially the same as a cross-section of an existing cushioning element shown in Figure 1 but that has a thickness, weight, and / or density that is less than a cross-section of an existing cushioning element shown in Figure 1 .

[0019] Figure 2 Embodiments of voids in the walls defining a hollow column that can be used to provide a cushioning element having cushioning characteristics that are the same or substantially the same as a cross-section of a cushioning element shown in Figure 1 but that has a weight and / or thickness that is less than a cross-section of an existing cushioning element shown in Figure 1 .

[0020] Figure 2A An enlarged view of an embodiment of a void in the walls defining a portion of a hollow column of a cushioning element in Figure 2 is provided.

[0021] Figure 3is a perspective view of a cross-section of another embodiment of a cushioning element having walls designed with voids and optional reinforcement features of other embodiments to provide cushioning properties that are the same or substantially the same as the cushioning properties of the cross-section cushioning element shown in Figure 1 but which has a weight and / or thickness that is less than the cross-section cushioning element shown in Figure 1 .

[0022] Figures 4-7 are front, left, top, and perspective views, respectively, showing the results of a topological study of a 3-column by 3-column square cross-section of a cushioning element of a conventional configuration showing areas of the cushioning element interconnecting walls that should be retained and areas of the interconnecting walls that can be removed without significantly affecting the cushioning properties of the cushioning element cross-section.

[0023] Figure 8 is a cross-section of the cushioning element shown in Figures 4-7 the topological study.

[0024] Figure 9 is a graph comparing the cushioning properties of a cushioning element according to the present disclosure with the cushioning properties of a cushioning element of a conventional configuration that is thicker and heavier.

[0025] Figure 10 and 11 show stresses at various locations of a 3-column by 3-column square cross-section of a cushioning element of a conventional configuration that lacks reinforcement features and voids in its walls and a 3-column by 3-column square cross-section of an embodiment of a cushioning element according to the present disclosure (i.e., an optimized cushioning element), respectively;

[0026] Figure 12 and 13 show deflections at various locations of a 3-column by 3-column square cross-section of a cushioning element of a conventional configuration that lacks reinforcement features and voids in its walls and a 3-column by 3-column square cross-section of an embodiment of a cushioning element according to the present disclosure (i.e., an optimized cushioning element), respectively;

[0027] Figures 14A-14E show various embodiments of a cushioning element having interconnecting walls that include voids that include recessed areas or dimples; and

[0028] Figure 15 is a perspective view showing the results of a topological study of an 8-column by 8-column square cross-section of a cushioning element of a conventional configuration showing areas of the cushioning element interconnecting walls that should be retained and areas of the interconnecting walls that can be removed without significantly affecting the cushioning properties of the cushioning element cross-section. DETAILED DESCRIPTION

[0029] Figure 2 An embodiment of the buffer element 10 is shown. The buffer element 10 includes a plurality of walls 20. The walls 20 are connected to each other at joints 22, and can therefore be referred to as “interconnecting walls”. The walls 20 are arranged in an array defining units or hollow columns 30. As shown, the walls 20 are arranged in a grid pattern and define hollow columns 30 having cross-sections that are cut transversely to the height of the hollow column 30 and are substantially square in shape (e.g., with rounded corners, etc.).

[0030] like Figure 2 As shown, the maximum thickness of each joint 22 between the interconnecting walls 20 relative to the wall 20 defining the joint 22 can be increased. More specifically, such joints 22 can define rounded (i.e., arc-shaped) interior angles inside the hollow column 30, thereby forming a "rounded joint". Each dimension of each end 23, 24 of such joints 22 (e.g., aligned with the interconnecting wall 20, diagonals, etc.) may exceed the thickness of each wall 22 extending to the joint 22. Optionally, the joint 22e can define an external rounded corner (i.e., a rounded protrusion) at the outer edge 10e and / or corner 10c of the buffer element 10.

[0031] also, Figure 2 An embodiment of a cushioning element 10 is shown, which includes a gap 28 in a wall 20 defining a portion of a hollow column 30. More specifically, the gap 28 includes a notch (e.g., trapezoidal, rectangular, triangular, arched, etc.) extending upward from the bottom 26 of the wall 22 to the top edge 27 of the wall 20. The gap 28 may extend any length upward from the bottom 26 on the wall 20 and may be located on every wall 20 or on selected walls 20. Figure 3 A shows the shape and size of a specific embodiment of the gap 28.

[0032] Interconnecting walls 20, including their junctions 22, can be formed of any of a variety of suitable cushioning materials that are readily compressible under load and exhibit the desired elasticity or resilience (e.g., elastic resilience, viscoelastic resilience, etc.). Non-limitingly, interconnecting walls 20 can be formed of elastic materials. Elastic materials can include gels and are therefore referred to as “elastic gels.” Some non-limiting examples of elastic gels that can be used to form interconnecting walls 20 may include extended block copolymers (e.g., plasticizer-extended block polymers, such as oil-extended block copolymers and / or resin-extended block copolymers, etc.). More specifically, ABA triblock copolymers can be used. Examples of extended ABA block copolymers are disclosed in U.S. Patents 6,413,458, 6,797,765, and 7,964,664, the entire disclosure of which is incorporated herein by reference.

[0033] When the cushioning element 10 is subjected to a load, the hollow column 30 can bend, as described in U.S. Patents 7,730,566 and 8,919,750, the entire disclosures of which are hereby incorporated herein, or can bulge, as described in U.S. Application Publication No. US 2019 / 0075884 Al, the entire disclosure of which is hereby incorporated herein.

[0034] Referring now to Figure 3 , another embodiment of a cushioning element 10' is shown. The cushioning element 10' includes walls 20'. The walls 20' are connected at joints 22'. The walls 20' define a hollow column 30'. A void 28' is defined in the walls 20'. The void 28' can include a lower void of a bottom 26' of the walls 20' and an upper void of a top edge 27' of the walls 20'. More specifically, the void 28' has a so-called "keyhole" shape that extends to either the bottom 26' or the top edge 27' of the walls 20'. In addition, selected joints 22' can be enlarged relative to the thickness of the walls 20' that define such joints 22'.

[0035] The interconnected walls 20', including the joints 22' thereof, can be formed of any of a variety of suitable cushioning materials that are susceptible to compression under a load and exhibit a desired elasticity or resilience (e.g., elastic resilience, viscoelastic resilience, etc.). Without limitation, the interconnected walls 20' can be formed of an elastic material. The elastic material can include a gel and thus can be referred to as an "elastic gel". Some non-limiting examples of elastic gels that can be used to form the interconnected walls 20' include extended block copolymers (e.g., plasticizer-extended block polymers, such as oil-extended block copolymers and / or resin-extended block copolymers, etc.). More specifically, A-B-A triblock copolymers can be used. U.S. Patents 6,413,458, 6,797,765, and 7,964,664 disclose examples of extended A-B-A block copolymers.

[0036] When the cushioning element 10' is subjected to a load, the hollow column 30 can bend, as described in U.S. Patents 7,730,566 and 8,919,750, or can bulge, as described in U.S. Application Publication No. US 2019 / 0075884 Al.

[0037] Figures 4-7 and 15 depict the results of a topology study that was conducted by fixing the position of the bottom 112 of a portion of an existing conventional configured cushioning element 110, 210 (also shown in Figure 1 U.S. Patents 7,730,566 and 8,919,750, and by applying a compressive force to the top 114 of the portion of the cushioning element 110, 210 (i.e., the top edge 127, 227 of the walls 120, 220). The topology study was conducted using a Newton tester and the ASTM F 1566 compression test parameters. InFigures 4-7 In one, a 3-column by 3-column square cross-section of a 2-inch (5.1 cm) thick cushioning element 110 was topologically investigated. In Figure 15 In one, an 8-column by 8-column square cross-section of a 2-inch (5.1 cm) thick cushioning element 210 was topologically investigated. The walls 120, 220 of each section of the cushioning elements 110, 210 were 0.12 inches (30 mm) thick and defined a hollow column 130, 230 having a cross-section that was substantially square, taken transverse to the length of the hollow column 130, 230. The junctions 122, 222 between the interconnecting walls 120, 220 were cylindrical, having a diameter of 0.26 inches (67 mm). The center of each junction 122, 222 was spaced 1.2 inches (2.9 cm) from an adjacent junction along the walls 120, 220 defining the junction 122, 222. Each section of the cushioning elements 110, 210 was made of a hyperelastic polymer 4.0 blend of Purple® containing an oil-extended A-B-A triblock copolymer.

[0038] Figure 8 is a plot of the displacement achieved at different loads in the topological investigation. Figures 4-7 The topological investigation results shown reveal that the regions 125s, 225s of the walls 120, 220 of the cushioning elements 110, 210 provide structural integrity to the cushioning elements 110, 210, the regions 125u, 225u of the walls 120, 220 appear to be unnecessary for the cushioning elements 110, 210 to perform their intended function (transparent regions, shown as holes in the walls 120, 220), and the regions 125o, 225o of the walls 110, 210 can provide some structural integrity but can not be necessary for the cushioning elements 110, 210 to perform their intended function.

[0039] To compare with existing, conventionally configured cushioning elements 110, 120, computer simulation topological investigations were performed on Figure 2 and Figure 2A Embodiments of the cushioning element 10 shown having a thickness of 1 3 / 4 inch (4.4 cm), hollow columns 30 having a 0.10 inch (2.5 mm) filleted internal corner, and voids 28 having dimensions as shown in Figure 2A . Figure 9 A comparison of the computer simulation topological investigations with the above topological investigations (referenced in Figures 4-7 ) is provided. As shown in Figure 9 , thinner, lighter cushioning elements according to the present disclosure can provide the same cushioning characteristics as conventionally configured cushioning elements. Subsequently, actual physical topological investigations of prototypes of the cushioning elements 10, 10' using the same parameters as the existing, conventionally configured cushioning elements 110 and 120 confirmed these results.

[0040] Figure 10 Stress in various locations of a cross-section of a traditionally configured buffer element 110 during a topology study is shown. Figure 11 An embodiment of a buffer element 110' is shown that includes a void 128' that includes a window in a selected wall 120' that can be formed of the same material as the walls 20, 20' of other embodiments of the buffer elements 10, 10' described herein. While the void is depicted as including a rectangular window, other shaped windows (e.g., windows having other polygonal shapes, windows having circular shapes, etc.) are within the scope of the present disclosure. Figure 11 An embodiment of a buffer element 110' is also shown that includes a void 128' in a selected wall 120' that is subjected to stress under the same conditions as the traditionally configured buffer element 110 shown. Figure 10 Computer modeling of stress experienced by the traditionally configured buffer element 110 shown under the same conditions is shown.

[0041] Figure 12 Deflection in various locations of a cross-section of a traditionally configured buffer element 110 during a topology study is shown. Figure 13 Computer modeling of deflection caused in various locations of a cross-section of an embodiment of a buffer element 110' is shown, where a void 128' is included in a selected wall 120' under the same conditions.

[0042] Turning now to Figures 14A-14E embodiments of buffer elements 310, 310', 310", 310"' having voids 328, 328', 328", 328"' that include a recess or dimple in a surface of a wall 320, 320', 320", 320"' that can be formed of the same material as the walls 20, 20' of other embodiments of the buffer elements 10, 10' described herein. Figure 14A and 14B An embodiment of a buffer element 310 is shown having a void 328 at a bottom 326 or a top edge 327 of a wall 320, where Figure 14B A cross-sectional view of a wall 320 is provided that shows a void 328 that includes a recess in an opposing surface of the wall 320. Figure 14C A cross-sectional view of a wall 320' of a buffer element 310' and a void 328' in the wall 320' is provided that includes only one recess on one surface of the wall 320'. Figure 14D An embodiment of a buffer element 310" is shown having a wall 320" that includes a void 328" that includes at least one recess at an intermediate location along a height of the wall 320" in one surface (see, e.g., Figure 14C ) or an opposing surface (see, e.g., Figure 14B ) of the wall 320". Figure 14EOne embodiment of a cushioning element 310" is shown having a wall 320"' that includes voids 328"' in the bottom 326"' and top edge 327"' of the wall 320"' in one surface (see, e.g. Figure 14C ) or the opposite surface (see, e.g. Figure 14B ) of the wall 320"'. Such voids 328, 328', 328", 328"' can be used without or without reinforcing features, such as the enlarged joints 22 described previously herein with reference to Figure 2

[0043] Cushioning elements that include combinations of different types of voids (e.g., openings, recesses, etc.) and / or voids at multiple different height locations on the interconnected walls of the cushioning element are within the scope of the present disclosure. Such embodiments can lack reinforcing elements or include reinforcing elements.

[0044] Referring back to Figure 15 , a topological study of an existing or conventional configuration of a cushioning element 210 can be utilized to identify locations of walls 220 where material can be omitted. This information can be helpful in determining locations where voids (e.g., openings (e.g., notches, windows, etc.), dimples, etc.) can be provided in the walls while designing a similar but less dense, lighter, and optionally thinner cushioning element to provide similar cushioning characteristics as the existing or conventional configuration of a cushioning element 210.

[0045] While this disclosure has provided many details, these should not be construed as limiting the scope of any claims that can be presented, but rather as describing many embodiments of elements and features that can form part of the disclosed subject matter. Other embodiments of the disclosed subject matter can be designed and can be used without departing from the spirit or scope of any claims. Features of different embodiments can be combined. Thus, the scope of each claim is to be determined solely by the language and legal equivalents of that language, and not by the descriptions herein.​

Claims

1. A cushioning element characterized by, including: a plurality of interconnected walls formed of an elastic material, the interconnected walls defining a plurality of hollow columns, each hollow column of the plurality of hollow columns including: at least one reinforcing feature; and at least one void in at least one wall of the plurality of interconnected walls. The at least one reinforcing feature includes an enlarged joint defining a corner of each hollow column at a location where walls of the plurality of interconnected walls join one another, each dimension of each end of the enlarged joint exceeding a thickness of each of the walls connected at the enlarged joint.

2. The cushioning element of claim 1, wherein, Each corner of each hollow column includes the enlarged joint.

3. The cushioning element of claim 2, wherein, The at least one reinforcing feature is defined by the elastic material.

4. The cushioning element of claim 1, wherein, The at least one void includes an opening in at least one wall of the plurality of interconnected walls.

5. The cushioning element of claim 1, wherein, The opening includes a notch in an edge of the at least one wall.

6. The cushioning element of claim 5, wherein, The opening includes a window in the at least one wall.

7. The cushioning element of claim 5, wherein, The elastic material includes a gel.

8. The cushioning element of claim 1, wherein, The gel includes a block copolymer and a plasticizer.

9. The cushioning element of claim 8, wherein, The block copolymer includes a tri-block copolymer.

10. The cushioning element of claim 9, wherein, The tri-block copolymer includes an A-B-A tri-block copolymer.

11. The cushioning element of claim 10, wherein, The plurality of hollow columns flex when at least a portion of the cushioning element is placed under load.

12. The cushioning element of claim 1, wherein, including:

13. A cushioning element characterized by, a plurality of interconnected walls formed of an elastic material, the interconnected walls defining a plurality of hollow columns, each hollow column of the plurality of hollow columns including at least one void in walls of the plurality of interconnected walls. The at least one void includes at least one notch formed in an edge of the wall.

14. The cushioning element of claim 13, wherein, The at least one notch is formed in a bottom edge of the wall.

15. The cushioning element of claim 14, wherein, The at least one void includes a window formed in the wall.

16. The cushioning element of claim 13, wherein, The at least one void is formed in a plurality of walls of the plurality of interconnected walls defining each hollow column.

17. The cushioning element of claim 13, wherein, including at least one void in each wall defining each hollow column.

18. The cushioning element of claim 17, wherein, further including:

19. The cushioning element of claim 13, wherein, at least one reinforcing feature. The at least one reinforcing feature includes an enlarged joint at a corner of each hollow column of the plurality of hollow columns, each dimension of each end of the enlarged joint exceeding a thickness of each of the plurality of interconnected walls connected at the enlarged joint.

20. The cushioning element of claim 19, wherein, The at least one reinforcing feature includes an enlarged joint at a plurality of corners of each hollow column of the plurality of hollow columns, each dimension of each end of the enlarged joint exceeding a thickness of each of the plurality of interconnected walls connected at the enlarged joint.

21. The cushioning element of claim 19, wherein, The at least one reinforcing feature includes an enlarged joint at each corner of each hollow column of the plurality of hollow columns, each dimension of each end of the enlarged joint exceeding a thickness of each of the plurality of interconnected walls connected at the enlarged joint.

22. The cushioning element of claim 19, wherein, The plurality of hollow columns flex when at least a portion of the cushioning element is placed under load.

23. The cushioning element of claim 13, wherein, including:

24. A method for designing a cushioning element having a plurality of interconnected walls defining an array of hollow columns, characterized by, reinforcing at least a portion of the plurality of interconnected walls to minimize a thickness of the cushioning element to provide predetermined compression and rebound characteristics; and / or designing the plurality of interconnected walls to include voids. ​ 25. The method of claim 24, wherein, Strengthening at least a portion of the plurality of interconnected walls includes designing enlarged junctions at corners of the hollow columns to strengthen the corners, each enlarged junction having each dimension of each end exceeding a thickness of each wall of the plurality of interconnected walls connected at the enlarged junction.

26. The method of claim 24, wherein, Designing the plurality of interconnected walls to include voids includes designing the plurality of interconnected walls to include notches in edges of the plurality of interconnected walls and / or windows in the plurality of interconnected walls.

27. The method of claim 24, wherein, Including strengthening at least a portion of the plurality of interconnected walls and designing the plurality of interconnected walls to include voids.

28. The method of claim 24, wherein, Also including: Designing the array of hollow columns to bend under load.

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